* TM 1-1500-204-23-1

TECHNICAL MANUAL
AVIATION UNIT MAINTENANCE (AVUM)
AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

* This manual together with TM 1-500-204-23-2 through TM 1-1500-204-23-10, dated 31 July 1992, supersedes
TM 55-1500-204-25/1, dated 6 April 1970, including all changes.

HEADQUARTERS, DEPARTMENT OF THE ARMY

31 JULY 1992
 TM 1-1500-204-23-1

An operating or maintenance procedure, practice, condition, statement, etc., which if not strictly
observed, could result in injury to or death of personnel.

An operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly
observed, could result in damage to, or destruction of, equipment or loss of mission effectiveness
or long term health hazards to personnel.

NOTE

An essential operating or maintenance procedure, condition, or statement, which must be high-

lighted.

PRECAUTIONARY DATA
Personnel performing instructions involving operations, procedures, and practices which are included or implied
in this technical manual shall observe the following instructions. Disregard of these warnings and precautionary
information can cause serious injury, death, or an aborted mission.

ELECTRICAL TESTS
Electrical power up to 500 volts is used in testing the equipment. Exercise extreme caution during these tests.
Ensure the equipment is grounded and operated in accordance with the operator’s manual. Never operate electrical
equipment during rain or while standing in water or wet areas. Use rubber mats to stand on.

ELECTRICAL EQUIPMENT
All switches and electrical equipment shall be of the enclosed explosion-proof type. All metal apparatus shall be
grounded to avoid the danger of igniting test fluid fumes or creating electrical shock.

USING SOLVENTS/PAINTS
Standard precautions such as fire prevention and adequate ventilation shall be exercised when using solvents or
applying primer and coating.
Wear gloves or gauntlets when handling solvents as solvents may cause skin disorders.
Cements and solvents used to repair life rafts are flammable and shall be treated as such. Never smoke or permit
any type of open flame near when using cements or solvents.
Deleted.

Change 8 a
TM 1-1500-204-23-1

HANDLING PLASTICS
Wear gloves to protect hands while handling hot plastic. Boiling water shall not be used for heating acrylate base
plastics.
Provide adequate ventilation when working with Furane Plastics, Epocast H-991-A, Furane hardener 941, or equiv-
alents as these materials are toxic.

LUBRICATING OIL
Lubricating oil MIL-L-7808 or MIL-L-23699, contains an additive which is poisonous and absorbed readily through
the skin. Do not allow oil to remain on skin. Wash with soap and water.

FUEL
When servicing aircraft or support equipment, clean up spilled fuel with cotton mops or cotton rags. Wash off any
fuel on hands, body, or clothing.

HANDLING ACID
Wear protective clothing when mixing acid with water. Always pour acid into water, never water into acid.

HANDLING PYROTECHNIC FLARES

Handle pyrotechnic flares with the same care as high explosives.

MAGNESIUM ALLOY FIRE

Do not use water or any standard liquid or foam-type fire extinguishers on a magnesium alloy fire, as they may cause
an explosion. Use dry sand or talcum powder, Federal Specification U-T-30.

AIRCRAFT ENGINE VALVES

Severe personal injury may result when sodium-filled valves are mutilated. The metallic sodium used in these valves,
when brought into contact with the skin (contacts moisture), gives off highly flammable hydrogen gas.

REMOVING CORROSION
Take precautions, such as wetting the area or exhausting debris, to prevent possible dust explosions when removing
corrosion from steel alloys. Use goggles or face shield when removing paint or corrosion with a wire brush or by the
grinding method.

b Change 5
 TM 1-1500-204-23-1

TIRES AND WHEELS

If it is necessary to approach a wheel with a hot brake, do so either from directly in front or directly behind the aircraft.
Use extreme caution when prying out foreign material imbedded in tire tread.
Do not use air bottles or booster pumps not designed for tire inflation.
Ensure the valve core is removed before removing wheel bolts or screws.
Tires shall be inflated outside a restraining device only to a pressure sufficient to force the tire bead onto the rim
ledge and create an airtight seal with the tire and bead. Use no more than 15 pounds pressure outside the restraining
device. If seal is not formed, check tire rim and bead and repeat procedure. Use soap type liquid on rim for ease of
movement.

OXYGEN SYSTEM
Do not allow petroleum base products to come in contact with oxygen system components, as an explosion or fire
may result.
Do not use masking tape to seal openings in oxygen regulators. Masking tape constitutes a safety hazard when use
on either serviceable or repairable oxygen equipment.

GROUND SUPPORT EQUIPMENT

Always operate all equipment in accordance with the operator’s manual.
Do not attempt to lift any load when the hydraulic axle jack is tilted.
To prevent accidental falls, appropriate maintenance platforms/safety stands illustrated in appropriate workstand
manuals or any other approved locally procured/manufactured safety stands/restraint equipment will be used when
working (above 4 feet) on aircraft in a non-tactical environment.
Install safety lock when an adjustable-height maintenance platform is in use.
Ensure the air hose used with compressed air is safe for the pressure being handled.
Release air pressure in air compressor tank before performing maintenance on air compressors.
Disconnect power before changing belts on electrically-driven compressors.
Disconnect electrical power before opening or disassembling any part of electrical equipment.

RADIOGRAPHIC EQUIPMENT
Exercise extreme caution when performing radiographic inspections to prevent personnel from coming in contact
with radiation. Radiation from X-ray units and radioisotope sources is extremely destructive to living tissue.

Change 10 c
TM 1-1500-204-23-1

FIRE EXTINGUISHERS
Halon type fire extinguishers, Monobromotrifluoromethane (CF3BR) are odorless gasses. When used in confined
areas, available oxygen for breathing may be depleted. Use supplied breathing air when using these gasses in
enclosed spaces.

HYDRAULIC FLUID
To avoid contamination, do not use previously opened cans of hydraulic fluid. A new, sealed can of fluid must be
opened and used. When opening can, clean top and use a clean, sharp, unplated instrument to prevent contami-
nation.
Acrylic monomer and polymer base adhesive, MIL-A-8576, contains a volatile liquid which may prove toxic when
vapors are inhaled over extended periods. Use only with adequate ventilation.
Observe fire precautions when using aliphatic naphtha, Federal Specification TT-N-95.

COMPRESSED AIR
Compressed air shall not be used for cleaning purposes except if reduced to less than 30 psi and then only with
effective chip-guarding and personal protective equipment.

NOISE HAZARD
Noise levels reached during ground runup of Army aircraft are of a level that may cause permanent hearing loss.
Maintenance personnel shall wear adequate hearing protection when working on aircraft with engines in operation.

TURBINE ENGINE OIL

To avoid contamination, do not use previously opened cans of engine oil, new sealed can of fluid must be opened
and used. When opening can, clean top and use a clean, sharp un-plated instrument to prevent contamination.

MERCURY
A very small amount of mercury may produce hazardous vapors. Refer to TB 385-4, Safety Precautions for Main-
tenance of Electrical/Electronic Equipment, for safety precautions to use when handling mercury and for methods
that are used to clean up mercury spillage.

CARTRIDGES
Electrically activated fire extinguisher cartridges, external stores release cartridges, external load cable cutter car-
tridges and cargo hook thruster cartridges shall be protectively wrapped in aluminum foil or electrically shunted
whenever removed from the aircraft installation to preclude "stray" electrical voltage activation and resulting per-
sonal injury.

d Change 8
 TM 1-1500-204-23-1

PROPER USE OF PLATED TOOLS

Use only chrome plated steel or unplated steel tools for disassembly or reassembly procedures described in this
manual. Use of cadmium or zinc plated tools is not permitted since these platings are prone to chipping and flaking.
Should these chips or flakes become embedded in aircraft parts, galvanic corrosion will result. Should these chips
or flakes enter fuel or oil wetted components, they may eventually clog the filter or produce intergranular attack of
nickel or titanium base alloys at elevated temperature. All tools regardless of type plating should be serviceable and
free of chipping.

SPECIAL INSTRUCTIONS
All equipment must be operated in accordance with the manufacturer’s operating instructions. If unavailable, instruc-
tions for the use and care will be developed. Standard Operating Procedures (SOPs) will be prepared and used for
all shop operations (refer to AR 385-95). The supporting Safety Office will use their expertise to provide assistance.
Guidance for industrial hazards can be found in the Code of Federal Regulations, Code of Federal Regulations 29
CFR 1910.

DEGREASING SOLVENTS
Degreasing Solvent, MIL-PRF-680, is combustible and toxic to eyes, skin, and respiratory tract. Wear protective
gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in well ventilated areas (or use
approved respirator as determined by local safety/industrial hygiene personnel). Keep away from open flames,
sparks, or other sources of ignition.

ALIPHATIC NAPTHA
Aliphatic Naphtha, TT-N-95, is extremely flammable and toxic to eyes, skin, and respiratory tract. Wear protective
gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in well ventilated areas (or use
approved respirator as determined by local safety/industrial hygiene personnel). Keep away from open flames,
sparks, or other sources of ignition.

CLEANING SOLVENT
Cleaning Solvent, HFE-71DE, is toxic to eyes, skin, and respiratory tract, and decomposes into other hazardous
products when exposed to extreme heat. Wear chemical protective gloves and goggles/face shield. Avoid repeated
or prolonged contact. Use only in well ventilated areas. If ventilation is not adequate, use approved respirator as
determined by local safety/industrial hygiene personnel. Keep away from open flames, welding, or other sources of
extreme heat.

CLEANING COMPOUND
Cleaning Compound, MIL-PRF-87937, Type II, can irritate eyes, skin, and respiratory tract. Wear protective gloves
and goggles. Avoid repeated or prolonged contact.

Change 5 e
TM 1-1500-204-23-1

CLEANING COMPOUND
Cleaning Compound, MIL-PRF-85570, Type II, can irritate eyes, skin, and respiratory tract. Wear protective gloves
and goggles. Avoid repeated or prolonged contact. Use in well ventilated areas.

ISOPROPYL ALCOHOL
Isopropyl Alcohol, TT-I735, is flammable and toxic to eyes, skin, and respiratory tract. Wear protective gloves and
goggles/face shield. Avoid repeated or prolonged contact. Use only in well ventilated areas (or use approved res-
pirator as determined by local safety/industrial hygiene personnel). Keep away from open flames, sparks, or other
sources of ignition.

f Change 5
 TM 1-1500-204-23-1
C10

ROUTINE
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 10 WASHINGTON, DC., 3 August 2016

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1
HAZARDOUS MATERIAL INFORMATION
This document has been reviewed for the presence of HAZARDOUS CHEMICALS AND TOXIC SUBSTANCES as defined by the
EPCRA 302 and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of base document through change 07, dated 22
December 2010, all references to Hazardous Chemicals and Toxic Substances have been removed from this document by substi-
tution with non-hazardous or less hazardous materials where possible EXCEPT Bromotrifluoromethane (CF3BR); Fire Extinguisher
Agent (Halon 1301).

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-2-1, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

c and d c and d
A through C/(D blank) A through E/(F blank)
11-1 and 11-2 11-1 and 11-2
11-17 and 11-18 11-17 and 11-18
12-1 and 12-2 12-1 and 12-2

2. Retain this sheet in front of manual for references purposes.

By Order of the Secretary of the Army:

MARK A. MILLEY
General, United States Army
Official: Chief of Staff

GERALD B. O’KEEFE
Administrative Assistant to the
Secretary of the Army
1617604

Distribution:
Initially published in electronic media only. If at a later date this publication is printed, it will be distributed in
accordance with the initial distribution number (IDN) 313302, requirements for TM 1-1500-204-23-1.
 TM 1-1500-204-23-1
C9

ROUTINE
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 9 WASHINGTON, DC., 10 March 2015

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1
HAZARDOUS MATERIAL INFORMATION
This document has been reviewed for the presence of HAZARDOUS CHEMICALS AND TOXIC SUBSTANCES as defined by the
EPCRA 302 and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of base document through change 07, dated 22
December 2010, all references to Hazardous Chemicals and Toxic Substances have been removed from this document by substi-
tution with non-hazardous or less hazardous materials where possible EXCEPT Bromotrifluoromethane (CF3BR); Fire Extinguisher
Agent (Halon 1301).

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-2-1, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

A through C/(D blank) A through C/(D blank)

i and ii i and ii
2-9 and 2-10 2-9 and 2-10
3-5 and 3-6 3-5 and 3-6
9-27 and 9-28 9-27 and 9-28
11-1 through 11-12 11-1 through 11-12
11-19 through 11-22 11-19 through 11-22
11-27 through 11-34 11-27 through 11-34
A-1 and A-2 A-1 through A-10

2. Retain this sheet in front of manual for references purposes.

Distribution:
Initially published in eelctronic media only. If at a later date this publication is printed, it will be distributed
in accordance with nitial distribution number (IDN) 313302, requirements for TM 1-1500-204-23-1.
 TM 1-1500-204-23-1
C8

ROUTINE
CHANGE HEADQUARTERSDEPARTMENT OF THE ARMY
WASHINGTON, DC., 28 December 2012
NO. 8

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1
HAZARDOUS MATERIAL INFORMATION
This document has been reviewed for the presence of HAZARDOUS CHEMICALS AND TOXIC SUBSTANCES as defined by the
EPCRA 302 and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of base document through change 07, dated 22
December 2010, all references to Hazardous Chemicals and Toxic Substances have been removed from this document by substi-
tution with non-hazardous or less hazardous materials where possible EXCEPT Bromotrifluoromethane (CF3BR); Fire Extinguisher
Agent (Halon 1301).

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-2-1, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

a through d a through d
A and B A through C/(D blank)
i and ii i and ii
2-5 through 2-8 2-5 through 2-8
3-5 and 3-6 3-5 and 3-6
9-41 and 9-42 9-41 and 9-42
11-3 and 11-4 11-3 and 11-4
11-7 and 11-8 11-7 and 11-8
11-13 and 11-14 11-13 and 11-14
11-17 and 11-18 11-17 and 11-18
11-29 and 11-30 11-29 and 11-30
A-1 and A-2 A-1 and A-2

2. Retain this sheet in front of manual for references purposes.

Distribution:

To be distributed in accordance with the initial distribution number (IDN) 313302, requirements for TM 1-1500-204-23-1.
 TM 1-1500-204-23-1
C7

CHANGE
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 7 WASHINGTON, DC., 22 December 2010

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1
HAZARDOUS MATERIAL INFORMATION
This document has been reviewed for the presence of HAZARDOUS CHEMICALS AND TOXIC SUBSTANCES as defined by the
EPCRA 302 and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of base document through change 07, dated 22
December 2010, all references to Hazardous Chemicals and Toxic Substances have been removed from this document by substi-
tution with non-hazardous or less hazardous materials where possible EXCEPT Bromotrifluoromethane (CF3BR); Fire Extinguisher
Agent (Halon 1301).

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-2-1, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

A and B A and B
3-5 and 3-6 3-5 and 3-6
6-1 and 6-2 6-1 and 6-2
9-29 and 9-30 9-29 and 9-30
9-37 and 9-38 9-37 and 9-38
11-21 and 11-22 11-21 and 11-22
13-1 and 13-2 13-1 and 13-2

2. Retain this sheet in front of manual for references purposes.

TM 1-1500-204-23-1
C7

Distribution:
To be distributed in accordance with the initial distribution number (IDN) 313302, requirements for TM
1-1500-204-23-1.
 TM 1-1500-204-23-1
C6

CHANGE
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 6 WASHINGTON, DC., 18 December 2009

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1
This document has been reviewed for the presence of SOLVENTS containing hazardous materials as defined by the EPCRA 302
and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of the base through C03, dated 13 January 2003, all ref-
erences to Solvents containing hazardous materials have been removed from this document by substitution with non-hazardous or
less hazardous materials where possible.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-2-1, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

A and B A and B
2-9 and 2-10 2-9 and 2-10
3-5 through 3-8 3-5 through 3-8
9-29 and 9-30 9-29 and 9-30
11-13 and 11-14 11-13 and 11-14
13-1 and 13-2 13-1 and 13-2

2. Retain this sheet in front of manual for references purposes.

TM 1-1500-204-23-1
C6

Distribution:
To be distributed in accordance with the initial distribution number (IDN) 313302, requirements for TM
1-1500-204-23-1.
 TM 1-1500-204-23-1
C5

CHANGE
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 5 WASHINGTON, DC., 31 May 2006

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1
This document has been reviewed for the presence of HAZARDOUS CHEMCIALS AND TOXIC SUBSTANCES as defined by the
EPCRA 302 and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of base document through change 07, dated 22
December 2010, all references to Hazardous Chemicals and Toxic Substances have been removed from this document by substi-
tution with non-hazardous or less hazardous materials where possible EXCEPT Bromotrifluoromethane (CF3BR); Fire Extinguisher
Agent (Halon 1301).

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-2-1, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

a through d a through f
A and B A and B
i through iv i through iv
2-3 and 2-6 2-3 and 2-6
6-1 through 6-6 6-1 through 6-6
7-19 through 7-24 7-19 through 7-24
7-29 through 7-30 7-29 through 7-30
7-37 through 7-38 7-37 through 7-38
8-17 through 8-20 8-17 through 8-20
9-7 through 9-10 9-7 through 9-10
9-29 and 9-32 9-29 and 9-32
9-43 and 9-44 9-43 and 9-44
TM 1-1500-204-23-1
C5

Remove Pages Insert Pages

9-49 through 9-58 9-49 through 9-58

13-1 through 13-2 13-1 through 13-2
Index 79 and Index 80 Index 79 and Index 80
Index 89 and Index 90 Index 89 and Index 90

2. Retain this sheet in front of manual for references purposes.

Distribution:
To be distributed in accordance with the initial distribution number (IDN) 313302, requirements for TM
1-1500-204-23-1.
 TM 1-1500-204-23-1
C4

CHANGE
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 4 WASHINGTON, DC., 10 June 2005

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-2-1, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

A /(B blank) A and B

3-5 and 3-6 3-5 and 3-6
3-9 through 3-10 3-9 through 3-10
3-15 through 3-16 3-15 through 3-16
4-1 through 4-2 4-1 through 4-2
11-15 through 11-16 11-15 through 11-16
Index 63 and Index 64 Index 63 and Index 64

2. Retain this sheet in front of manual for references purposes.

Distribution:
To be distributed in accordance with the initial distribution number (IDN) 313302, requirements for TM
1-1500-204-23-1.
 TM 1-1500-204-23-1
C3

CHANGE
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 3 WASHINGTON, DC., 13 January 2003

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-2-1, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

A/(B blank) A and B

i and ii i and ii
2-9 and 2-10 2-9 and 2-10
8-1 and 8-2 8-1 and 8-2
11-1 and 11-2 11-1 and 11-2
11-17 and 11-18 11-17 and 11-18
13-3/(13-4 blank) 13-3/(13-4 blank)
TM 1-1500-204-23-1
C3

2. Retain this sheet in front of manual for references purposes.

Distribution:
To be distributed in accordance with the initial distribution number (IDN) 313302, requirements for TM
1-1500-204-23-1.
 TM 1-1500-204-23-1
C2

CHANGE
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 2 WASHINGTON, DC., 1 March 2000

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-2-1, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

i and ii i and ii
v and vi v and vi
3-9 and 3-10 3-9 and 3-10
3-19/(3-20/blank) 3-19/(3-20/blank)
6-1 and 6-2 6-1 and 6-2
9-43 and 9-44 9-43 and 9-44
11-1 and 11-2 11-1 and 11-2
11-5 through 11-10 11-5 through 11-10
11-13 through 11-18 11-13 through 11-18
11-33 through 11-38 11-33 through 11-38
13-1 and 13-2 13-1 and 13-2
A-1 and A-2 A-1 and A-2
Index 9 and Index 10 Index 9 and Index 10

2. Retain this sheet in front of manual for references purposes.

TM 1-1500-204-23-1
C2

Distribution:
To be distributed in accordance with the initial distribution number (IDN) 313302, requirements for TM
1-1500-204-23-1.
 TM 1-1500-204-23-1
C1

CHANGE
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 1 WASHINGTON, DC., 29 October 1993

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-2-1, Dated 31 July 1992, is changes as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.

Remove Pages Insert Pages

c and d c and d
i and ii i and ii
3-5 and 3-6 3-5 and 3-6
3-9 through 3-12 3-9 through 3-12
11-13 through 11-16 11-13 through 11-16
11-25 through 11-28 11-25 through 11-28
12-1 and 12-2 12-1 and 12-2
A-1 and A-2 A-1 and A-2

2. Retain this sheet in front of manual for references purposes.

TM 1-1500-204-23-1
C1

Distribution:
To be distributed in accordance with the initial distribution number (IDN) 313302, requirements for TM
1-1500-204-23-1.
 TM 1-1500-204-23-1

LIST OF EFFECTIVE PAGES

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . . . . . . . 31 July 1992 Change 6 . . . . . . . . . . . . . . . . . . . 18 December 2009

Change 1 . . . . . . . . . . . . . . . . . . . . . 29 October 1993 Change 7 . . . . . . . . . . . . . . . . . . . 22 December 2010
Change 2 . . . . . . . . . . . . . . . . . . . . . . . . 1 March 2000 Change 8 . . . . . . . . . . . . . . . . . . . 28 December 2012
Change 3 . . . . . . . . . . . . . . . . . . . . . 13 January 2003 Change 9 . . . . . . . . . . . . . . . . . . . . . . 10 March 2015
Change 4 . . . . . . . . . . . . . . . . . . . . . . . . 10 June 2005 Change 10 . . . . . . . . . . . . . . . . . . . . . . 3 August 2016
Change 5 . . . . . . . . . . . . . . . . . . . . . . . . 31 May 2006

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 305, CONSISTING OF THE FOLLOWING:

Page No. *Change No. Page No. *Change No.

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
a ......................................... 8 3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
b ......................................... 5 3-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
d ......................................... 8 3-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
e ......................................... 5 3-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
f ......................................... 5 3-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3-20 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
i.......................................... 8 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5-2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
v ......................................... 2 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1-2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-12 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 7-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 7-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

*Zero in this column indicates an original page.

Change 10 A
TM 1-1500-204-23-1

LIST OF EFFECTIVE PAGES (Cont)

Page No. *Change No. Page No. *Change No.

7-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7-48 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 9-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
8-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8-22 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 9-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
*Zero in this column indicates an original page.
B Change 10
 TM 1-1500-204-23-1

LIST OF EFFECTIVE PAGES (Cont)

Page No. *Change No. Page No. *Change No.

9-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 11-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9-59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 11-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
9-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 11-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 11-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 11-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
9-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 11-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 11-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
9-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 11-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
9-66 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 12-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 12-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 13-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 13-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 13-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 13-4 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 A-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 A-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 A-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 A-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Glossary-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Glossary-2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Index-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Index-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Index-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Index-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Index-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Index-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Index-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Index-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Index-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Index-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Index-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Index-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Index-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
11-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Index-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
*Zero in this column indicates an original page.
Change 10 C
TM 1-1500-204-23-1

LIST OF EFFECTIVE PAGES (Cont)

Page No. *Change No. Page No. *Change No.

Index-28 .................................. 0 Index-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

Index-29 .................................. 0 Index-82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-30 .................................. 0 Index-83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-31 .................................. 0 Index-84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-32 .................................. 0 Index-85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-33 .................................. 0 Index-86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-34 .................................. 0 Index-87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-35 .................................. 0 Index-88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-36 .................................. 0 Index-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-37 .................................. 0 Index-90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-38 .................................. 0 Index-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-39 .................................. 0 Index-92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-40 .................................. 0 Index-93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-41 .................................. 0 Index-94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-42 .................................. 0 Index-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-43 .................................. 0 Index-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-44 .................................. 0 Index-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-45 .................................. 0 Index-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-46 .................................. 0 Index-99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-47 .................................. 0 Index-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-48 .................................. 0 Index-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-49 .................................. 0 Index-102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-50 .................................. 0 Index-103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-51 .................................. 0 Index-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-52 .................................. 0 Index-105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-53 .................................. 0 Index-106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-54 .................................. 0 Index-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-55 .................................. 0 Index-108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-56 .................................. 0 Index-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-57 .................................. 0 Index-110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-58 .................................. 0 Index-111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-59 .................................. 0 Index-112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-60 .................................. 0 Index-113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-61 .................................. 0 Index-114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-62 .................................. 0 Index-115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-63 .................................. 0 Index-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-64 .................................. 0 Index-117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-65 .................................. 0 Index-118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-66 .................................. 0 Index-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-67 .................................. 0 Index-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-68 .................................. 0 Index-121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-69 .................................. 0 Index-122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-70 .................................. 0 Index-123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-71 .................................. 0 Index-124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-72 .................................. 0 Index-125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-73 .................................. 0 Index-126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-74 .................................. 0 Index-127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-75 .................................. 0 Index-128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-76 .................................. 0 Index-129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-77 .................................. 0 Index-130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-78 .................................. 0 Index-131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-79 .................................. 0 Index-132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Index-80 .................................. 0 Index-133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
*Zero in this column indicates an original page.
D Change 10
 TM 1-1500-204-23-1

LIST OF EFFECTIVE PAGES (Cont)

Page No. *Change No. Page No. *Change No.

Index-134 ................................. 0 Index-151 ................................. 0

Index-135 ................................. 0 Index-152 ................................. 0
Index-136 ................................. 0 Index-153 ................................. 0
Index-137 ................................. 0 Index-154 ................................. 0
Index-138 ................................. 0 Index-155 ................................. 0
Index-139 ................................. 0 Index-156 ................................. 0
Index-140 ................................. 0 Index-157 ................................. 0
Index-141 ................................. 0 Index-158 ................................. 0
Index-142 ................................. 0 Index-159 ................................. 0
Index-143 ................................. 0 Index-160 ................................. 0
Index-144 ................................. 0 Index-161 ................................. 0
Index-145 ................................. 0 Index-162 ................................. 0
Index-146 ................................. 0 Index-163 ................................. 0
Index-147 ................................. 0 Index-164 ................................. 0
Index-148 ................................. 0 Index-165 ................................. 0
Index-149 ................................. 0 Index-166 ................................. 0
Index-150 ................................. 0

*Zero in this column indicates an original page.

Change 10 E/(F blank)
 * TM 1-1500-204-23-1

TECHNICAL MANUAL U.S. ARMY AVIATION

AND MISSILE COMMAND
No. 1-1500-204-23-1 31 July 1992
AVIATION UNIT MAINTENANCE (AVUM)
AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(GENERAL MAINTENANCE AND PRACTICES)
VOLUME 1

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can improve this manual. If you find mistakes, or if you know of a way to improve these
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U.S. Army Aviation and Missile Command, ATTN: AMSAM-MSS-LP, Redstone Arsenal, AL
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HAZARDOUS MATERIAL INFORMATION

This document has been reviewed for the presence of HAZARDOUS CHEMICALS AND TOXIC SUBSTANCES as defined by
the EPCRA 302 and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of base document through change
07, dated 22 December 2010, all references to Hazardous Chemicals and Toxic Substances have been removed from this
document by substitution with non-hazardous or less hazardous materials where possible EXCEPT Bromotrifluoromethane
(CF3BR); Fire Extinguisher Agent (Halon 1301)."

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TABLE OF CONTENTS
Page

CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

CHAPTER 2 HANGAR AND SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 FLIGHTLINE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 AIRCRAFT STORAGE AND SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5 MARKING OF AERONAUTICAL ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHAPTER 6 APPLICATION AND REMOVAL OF DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHAPTER 7 GENERAL RECIPROCATING ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
CHAPTER 8 GENERAL TURBINE ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CHAPTER 9 GENERAL AIRFRAME MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
CHAPTER 10 ARCTIC, DESERT, AND TROPIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
CHAPTER 11 AVIATION LIFE SUPPORT EQUIPMENT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
CHAPTER 12 PYROTECHNICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
CHAPTER 13 AIRCRAFT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX ............................................................................ Index-1

* This manual together with TM 1-500-204-23-2 through TM 1-1500-204-23-10, dated 31 July 1992, supersedes TM 55-1500-204-25/1,
dated 6 April 1970, including all changes.
Change 8 i
TM 1-1500-204-23-1

Volume 2
Page
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 PNEUDRAULICS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 HYDRAULIC SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 HYDRAULIC MAINTENANCE PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Volume 3
Page
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 FUEL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Deleted
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

ii Change 9
 TM 1-1500-204-23-1

Volume 4
Page
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 ELECTRICAL SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 ELECTRICAL MAINTENANCE PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 INSTRUMENT SHOP PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Volume 5
Page
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 PROPELLER MAINTENANCE PRACTICES AND PROCEDURES . . . . . . . . . . 2-1
CHAPTER 3 ROTOR MAINTENANCE PRACTICES AND PROCEDURES . . . . . . . . . . . . . . . 3-1
CHAPTER 4 POWERTRAIN MAINTENANCE PRACTICES AND PROCEDURES . . . . . . . . . 4-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Volume 6
Page
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 RUBBER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 METALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5 PHENOLIC AND PLASTIC MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHAPTER 6 ADHESIVES, SEALANTS, AND CEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHAPTER 7 CONSUMABLE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Change 5 iii
TM 1-1500-204-23-1

Volume 7
Page
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 PENETRANT INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 MAGNETIC PARTICLE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5 RADIOGRAPHY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHAPTER 6 ULTRASONIC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHAPTER 7 ELECTROMAGNETIC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Volume 8
Page
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 MACHINE SHOP PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 WELDING SHOP PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Volume 9
Page
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 TOOL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

iv
 TM 1-1500-204-23-1

Page
CHAPTER 3 MEASURING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 GENERAL MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5 PNEUMATIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHAPTER 6 ELECTRIC POWER TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHAPTER 7 SPECIAL AIRCRAFT TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
CHAPTER 8 TORQUE TOOLS AND TORQUING PRINCIPLES AND PROCEDURES . . . . . . 8-1
CHAPTER 9 GROUND SUPPORT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Volume 10
Page
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 SHEET METAL SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 SHOP EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 AIRCRAFT STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5 STRUCTURAL METALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHAPTER 6 FORMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Change 2 v
TM 1-1500-204-23-1

Page
CHAPTER 7 RIVETS AND RIVETING TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
CHAPTER 8 AIRFRAME SHEET METAL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CHAPTER 9 SANDWICH CONSTRUCTION REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
CHAPTER 10 AIRCRAFT PLASTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
CHAPTER 11 REBALANCING MOVABLE SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
CHAPTER 12 SPOT WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B BLAND RIVET CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

vi
 TM 1-1500-204-23-1

CHAPTER 1
INTRODUCTION

1-1. PURPOSE. This volume provides general 1-2. SCOPE. General information to guide aircraft
information pertaining to general maintenance and maintenance personnel is covered in this volume; how-
practices. Specific aircraft application, usage, and sub- ever, no attempt has been made to include special parts
stitution is found in the individual aircraft maintenance or equipment which are applicable only to individual
manual. This volume is of maximum benefit to the me- or special aircraft. Chapters 1, 2, and 3 cover the
chanic who desires general information about general introduction, hangar and shop operations and flightline
maintenance and practices. This volume furnishes the operations. Chapters 4, 5, and 6 explain aircraft storage
mechanic a source of information about how to perform and shipment, marking of aeronautical items, and ap-
various maintenance practices used on all aircraft. This plication and removal of decals. General maintenance
volume is not a requisitioning authority, and applicable practices for reciprocating engines, turbine engines,
repair parts and special tools list should be consulted and airframes are described in Chapters 7, 8, and 9.
to obtain the unit of issue and National Stock Number Arctic, desert, and tropic maintenance procedures are
of the items required for maintenance. However, this covered in Chapter 10. Life support maintenance pro-
manual may be used as authority to obtain necessary cedures are covered in Chapter 11. Finally, Chapters
assistance and safety related material. 12 and 13 explain pyrotechnics and aircraft cleaning.

1-3. CONSUMABLE MATERIALS. Refer to TM

1-1500-204-23-6 for consumable materials in this vol-
ume.

1-1/(1-2 blank)
 TM 1-1500-204-23-1

CHAPTER 2
HANGAR AND SHOP OPERATIONS

2-1. GENERAL. The maintenance instructions and h. Noise Levels. Noise levels from machinery in
procedures contained in this chapter are general and permanent shops are high. Personnel working in these
applicable to hangar and shop operations. Maintenance shops shall wear adequate hearing protection.
instructions that are specific to a particular aircraft are
contained in the applicable maintenance manuals and i. Dust and Dirt Control. Use the following pro-
will be used in conjunction with general information con- cedures for dust and dirt control in permanent shops:
tained in this chapter.
(1) Sweep the floors daily with an ordinary push
2-2. PERMANENT SHOP INSTALLATIONS. The fol- broom.
lowing paragraphs describe permanent shop installa-
tions, operations, and equipment. NOTE

a. Typical Layout. Permanent shop layout varies Carefully clean areas where dust producing op-
depending on shop purpose and the facility being used. erations have taken place.
Care should be taken to provide proper spacing between
equipment so as not to prevent emergency access. (2) Clean shop equipment in accordance with
the applicable maintenance manuals.
b. Shop Size. The size of each permanent shop
shall be adequate to allow shop personnel to accomplish (3) Clean walls and tables periodically with a
all normal shop operations. cloth dampened with a mild detergent.

c. Shop Equipment Required. Permanent shops j. Spray Painting. All painting shall be accom-
shall be equipped with all required equipment as speci- plished in the paint shop in accordance with proper pro-
fied by Army command. cedures as set forth by the facility supervisor.

d. Shop Equipment Arrangement. Shop equip- k. Adhesive Operations. Adhesives join objects
ment is arranged to best meet the needs of the particular over a broad area, instead of localizing stresses at one
shop operation. All equipment must be arranged with ut- or more points, as with spot welding or metal fastening.
most care to prevent danger to personnel. Adhesives simplify construction by eliminating bracing,
sTIFFeners, local reinforcements, or framing. Adhesive
e. Overhead Chain Hoist. Overhead chain hoists use is a reliable, efficient assembly method.
shall be inspected daily for the following:
l. Balancing Equipment. The equipment used
• Excessive wear or stretch for balancing measurements consists of a set of knife
edges, weights, weighing scale, and a steel tape mea-
• Bent or twisted links sure.
• Defective welds m. Environmental Control. The permanent shop
environment is controlled by environmental control units
• Nicks and gouges installed throughout the shop.
f. Compressed Air and Water Outlets. Perma- n. Lighting Requirements. Adequate lighting
nent shops are equipped with compressed air and water shall be provided for all shop operations. Light fixtures
outlets. Care should be taken to allow clear access to
each outlet.

g. Electrical Utilities. Electrical power is dis-

tributed throughout the permanent shop. Care should
be taken to allow clear access to each outlet.

2-1
TM 1-1500-204-23-1

should be inspected regularly for damage and worn • Do not store cylinders near salt or corrosive
components. chemicals or fumes of any kind as the cylin-
ders will become rusty and the valve caps
o. Storage of Shop Stocks, Repair Parts, and will stick.
Consumable Materials. Storage of all shop items
shall be in accordance with the applicable maintenance • Keep valves closed on all cylinders after
manuals. Utmost care shall be taken to ensure the safe usage.
storage of all items.
• Do not store cylinders near radiators or
p. Storage of Compressed Gases. The following other sources of heat.
precautions will be taken when storing compressed gas
cylinders. • Cylinders of one kind of gas should not
be stored near cylinders of other kinds of
• Cylinders must be protected against exces- gas. A fire-resistant partition should sep-
sive rise or fall of temperature. arate flammable and nonflammable gases
unless the cylinders are otherwise widely
NOTE separated. Oxygen, in particular, will be
separated from flammable gases or sup-
Cylinders will be stored inside wherever possi-
plies.
ble, and, if not, they may be stored in the open
but must be protected from extreme weather • Storage rooms must be well ventilated to
conditions and also from the ground to prevent prevent possible accumulation of explosive
rusting. Cylinders stored in the open must be or harmful concentration of gas.
protected from accumulation of ice and snow.
In the summer, cylinders stored in this manner
q. Storage of High-Value Items. High value
will be protected or screened against direct rays
items shall be stored in areas that can be secured to
of the sun. Ventilation will be provided to keep
prevent theft. Care shall be taken to store high-value
temperatures below 125°F (52.6°C) and carry
items in such a manner as to prevent inadvertent dam-
off leakage of inflammable gases.
age.
• Cylinders must never be stored near highly
flammable substances such as oil, gaso- r. Open Storage for Repaired Equipment and
line, waste, etc. A minimum distance of 50 Consumable Material. Avoid storing repaired equip-
feet will be maintained between cylinders ment and consumable materials in open storage areas
and flammable items. where they can be easily damaged.
2-3. TEMPORARY SHOP INSTALLATIONS. The
• Care will be taken to protect cylinders from following paragraphs describe temporary shop installa-
any object which might cut or damage their tions, operations and equipment.
surfaces. Cylinders will not be stored at
a place where heavy moving objects may a. Typical Shop Layout. A typical shop layout is
strike or fall on them. shown in figure 2-1. Layout of equipment varies depend-
• Cylinders will not be stored in an area which ing on the temporary shop purpose.
is continually damp. Neither should they
be stored near live electric wires or rails of b. Shop Size. The exterior dimensions for a de-
electrical equipment. ployed temporary shop are as follows:

• Valve protection caps will always be in-

stalled. If they become frozen, they should • Width 22 ft. 3 in. (6.78
be thawed out in a warm room. Do not use meters)
a steam hose to thaw them out as fusible
safety plugs may melt and allow discharge • Height 7 ft. 11 in. (2.41
of the cylinder. meters)
• Length 13 ft. 4 in. (4.06
• Keep empty cylinders separated from full
meters)
cylinders.

2-2
 TM 1-1500-204-23-1

Figure 2-1. Temporary Shop Layout

c. Equipment Mounted in Mobile Shelters. f. Compressed Air Panels. The compressed air
Equipment shall be mounted in accordance with the panel connector installed through the wall of the S-280
specific shop requirements. shops may be replaced by removing the two bolts se-
curing it to the mounting plate. Apply sealant to the re-
d. Shop Equipment Arrangement. Shop equip- placement connector and reinstall mounting bolts.
ment is arranged to best meet the needs of the particular
shop operation. All equipment must be arranged with ut- g. Electrical Utilities. Electrical power is trans-
most care to prevent danger to personnel. mitted from 60Hz mobile electric generators through the
power distribution panels to the shops by heavy-duty
e. Chain Hoists. Chain hoists for temporary power cables.
shops shall be inspected daily for the following:
h. Noise Levels. Noise levels in temporary shops
• Excessive wear or stretch are high. Personnel working in these shops shall wear
adequate hearing protection.
• Bent or twisted links
i. Dust and Dirt Control. Use the following pro-
• Defective welds cedures for dust and dirt control:
• Nicks and gouges
(1) Sweep the floor each morning with an ordi-
nary push broom.

2-3
TM 1-1500-204-23-1

(2) Once a week, clean the interior walls with a r. Open Storage Areas. Open storage areas will
cloth dampened with a mild detergent solution and wipe be arranged be each shop facility as needed. Supplies
dry. shall be organized to provide easy access, removal, and
use.
(3) Once a week, clean the exterior of the shel-
ter, using the same detergent as in step (2). Apply with 2-4. MAINTENANCE OF SHOP EQUIPMENT. The
a soft bristle brush or sponge, scrubbing off all dirt and maintenance of machinery and shop equipment shall
grime. Rinse with clean water. Dry with a soft cloth. be divided into operator maintenance, major repair, and
painting.
j. Spray Painting. Spray painting can be used to a. Operator Maintenance. Operator mainte-
repaint any spots in need of refinishing. The following nance consists of cleaning, lubrication, and minor
procedures explain spray painting of temporary shops: adjustment of belts, guards, gibs, etc. It also includes
periodic visual inspection to preclude possible damage,
(1) Remove all loose or flaked paint. failure, or breakdown due to loose or excessively worn
parts, defective wiring connections, insulation, safety
(2) Smooth with No. O sandpaper, feather edg- appliances, etc.
ing all sanded spots to ensure a smooth surface for the
b. Major Repair. Major repair consists of all repair
new paint.
work not performed by operators. Major repair within
(3) Apply paint with a 2-inch spray pattern. the scope of facilities shall be accomplished locally. Re-
pairs not within the scope of local facilities shall be ac-
NOTE complished through a work order to direct support or a
commercial contractor.
Thin paint if necessary with an acceptable thin-
ner conforming to TT-T-291. c. Painting. Painting consists of any refinishing of
equipment, from touchup to complete repainting of the
(4) Allow 4 to 8 hours to dry.
item.
k. Adhesive Operations. Adhesives join objects
over a broad area, instead of localizing stresses at one NOTE
or more points, as with spot welding or metal fastening.
Adhesives simplify construction by eliminating bracing, All color shades shall be in accordance with
sTIFFeners, local reinforcements, or framing. Adhesive Federal Specification FED-STD-595.
use is a reliable, efficient assembly method. (1) Equipment repainting. When complete re-
l. Balancing Equipment. The equipment used painting is necessary, the original painted surface shall
for balancing measurements consists of a set of knife be refinished with synthetic gloss enamel, Federal Spec-
edges, weights, a small accurate weighing scale, and ification TT-E-489. The color shall be green, color shade
a steel tape measure. 14260.
m. Temperature and Humidity Control. Tem- (2) Work areas and critical parts. Work areas
perature and humidity is controlled in temporary shop and critical parts will be highlighted by painting with Fed-
structures by environmental control units attached to eral Specification TT-E-489. The color shade shall be
the structure. 13655 yellow enamel. To ensure maximum color pattern
n. Flammable Materials. All flammables shall be uniformity on like items of equipment, painting and high-
stored in accordance with existing command policies. lighting shall be accomplished in accordance with the
general pattern shown in figure 2-2. Equipment other
o. Lighting. Light fixtures should be inspected for than the type illustrated, shall be painted in accordance
broken lamp contacts or other damage. The lamp and with these general instructions. The painted finish on
protector may be replaced by removing the screws hold- this equipment may be touched up. The commanding
ing the retaining straps to the light fixture. officer or his designated representative shall determine
p. Repair Parts Van. The repair parts van shall the extent of the touchup allowed without complete re-
be fully stocked with repair parts for the specific shop. painting.
The van shall be located as to provide easy access by (3) Natural wood pieces. Wood pieces or
maintenance personnel. equipment finished in colors other than those listed in
q. Protected Storage Areas. Each command paragraph c may be touched up with colors to match
shall provide protected storage areas for flammable or existing finish, provided touchup does not involve re-
hazardous materials. Care should be taken to provide finishing a total area equal to more than 10 percent of
security and proper handling of items in these areas. painted surface area. When more than 10 percent of
painted surface area must be touched up, item shall be
repainted with colors as specified.

2-4 Change 5
 TM 1-1500-204-23-1

NOTE mine the use of this color and furnish instructions. Paint-
Instrument repair benches or other special ing of machined parts, such as face plates, chucks, spin-
purpose benches, parts, and equipment hav- dels, etc, is not authorized.
ing natural wood finish may be refinished in (7) Preparation for painting. Prepare sur-
natural wood or white enamel, Federal Specifi- faces to be repainted using the following procedures:
cation TT-E-489, color shade 17875. Working
surfaces of bench tops covered with metal or (a) Surface should be clean, dry, and free
composition need not be repaired. from dust, grease, oil, rust, and dirt. Glossy surfaces
should be sanded to dull the gloss to ensure adhesion.
(4) Start buttons. Start buttons shall be Remove all rust and scale by scraping or wire brushing.
painted with Federal Specification TT-E-489, green
synthetic gloss enamel, color shade 14260.

Under no circumstances shall flammable mate-

rial be used near an open flame. Otherwise in-
jury or death may result to personnel.
(b) Remove oil and grease deposits from ma-
chinery to be repainted with degreasing solvent, MIL-
PRF-680.

Degreasing Solvent, MIL-PRF-680, is com-

bustible and toxic to eyes, skin, and respiratory
tract. Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged con-
tact. Use only in well ventilated areas (or use
approved respirator as determined by local
safety/industrial hygiene personnel). Keep
away from open flames or other sources of
ignition.

Aliphatic Naphtha is extremely flammable and

toxic to eyes, skin, and respiratory tract. Wear
protective gloves and goggles/face shield.
Avoid repeated or prolonged contact. Use only
in well ventilated areas (or use approved res-
pirator as determined by local safety/industrial
Figure 2-2. Painting of Shop Equipment to hygiene personnel). Keep away from open
Highlight Operator Position flames, sparks, or other sources of ignition.

(5) Stop buttons. Stop buttons for electrical (c) Wipe surface with a clean cloth moist-
switches used for emergency stopping of machinery ened with a grease-free solvent, such as Degreasing
shall be painted with red synthetic gloss enamel, Fed- Solvent, MIL-PRF-680, or Aliphatic Naphtha, TT-N-95.
eral Specification TT-E-489, color shade 11105. Repeat this procedure until machinery surfaces are
completely clean.
(6) Hazardous areas. On some equipment, ex-
tremely hazardous conditions may exist, such as open (d) Bare spots resulting from scraping or
flywheels, gears, or other moving parts which cannot be chipping should be sanded to a feather edge and spot
guarded or which might be impractical to guard. These primed with lacquer proof primer, Federal Specifica-
parts may be painted with Federal Specification TT-E- tion TT-P-664. Allow priming coats to dry thoroughly
489, orange synthetic gloss enamel, color shade 12197. and apply two coats of enamel, Federal Specification
Overuse of orange color will defeat the intended pur- TT-E-489, in prescribed colors.
pose, therefore, the local safety engineer shall deter-

Change 8 2-5
TM 1-1500-204-23-1

Allow first coat to dry thoroughly before applying second generated, or which require electrical cir-
coat. cuits of a hazardous nature.

NOTE • All switches and electrical equipment shall

be of the enclosed explosion-proof type.
Machines shall not be operated during painting
operation. • All metal apparatus shall be grounded to
avoid the danger of igniting test fluid fumes
d. Equipment Maintenance Form. The equip- or creating electrical shock.
ment maintenance form is explained in the following
paragraph. b. Machine Tool Safety. Machine Tool safety pre-
DD Form 314. This form, properly initiated, shall be cautions are explained in the following paragraphs.
attached to each piece of equipment. The preventive
maintenance requirements shall be accomplished and (1) Face shields and safety glasses. Person-
noted by operator by placing his initials in the appropri- nel operating machinery shall wear eye protection as
ate block. prescribed. A protective face shield or safety glasses
shall be worn when operating a grinder regardless of
2-5. HANGAR AND SHOP SAFETY. All supervisory whether grinder is equipped with attached shields.
personnel in Army hangars and shops are responsible
for a continuing and effective shop safety program. To (2) Drilling, grinding, or sawing precautions.
implement and maintain this program, shop supervisors The following safety precautions shall be observed
will utilize bulletin boards, signs, and any other effective when drilling, grinding, or sawing:
method. Shop personnel will cooperate in the shop
safety program by making helpful recommendations, • Clamp work securely so that work will
and continually exercising care and caution in the oper- not move.
ation of all shop equipment. The following paragraphs
describe electrical, machine tool, and fire safety pre- • Stop machine prior to attempting to ad-
cautions. just work that has become jammed.

a. Electrical Safety. The following electrical • Cutting tools must be kept sharp.
safety precautions shall be observed in Army hangars
and shops: • Allow chuck to come to a stop on its own
accord. Do not use hand pressure to
• Ensure that all unauthorized personnel are stop a spinning chuck.
clear of area before opening valves or ener-
gizing electrical circuits for starting machin- • Do not set tools while power is on. Ex-
ery. amine tools and chucks for cracks and
defects prior to use.
• Electrical tools must be connected to a low
resistance ground. • Stand to one side of grinding wheel
when it is first started to avoid injury in
• Electrical cables and air hoses to portable case wheel fractures.
units will be laid out so there is no danger
of tripping. • Wear suitable gloves in addition to gog-
gles when buffing.
• Whenever possible, aircraft batteries will
be disconnected when undergoing mainte- c. Fire Safety. Unsafe equipment and fire haz-
nance performed in the hangar. ards are the main factors to be observed while plan-
ning safety procedures for hangars and shops. Unsafe
• Substantial low resistance conductors equipment shall be reported immediately. A constant
shall be used to ground all stationary and vigilance must be maintained to seek out fire hazards.
portable machines, equipment, or other Fire hazards are constantly present in the shop where
devices in which static charges may be sparks, friction, or careless handling can cause

2-6
 TM 1-1500-204-23-1

an explosion that may destroy equipment or buildings,

and injure or kill personnel. Refer to AR 385-10, Army (d) Replace with new cylinder immediately.
Safety Program and The Occupation Safety and Health
Act of 1971. (4) Inspection requirements for fire extin-
guishers. Inspect fire extinguishers in accordance
(1) Classifications of fires. Fires are classified with the manufacturer inspection procedures.
as follows:
(5) Identifying fire extinguishers. Since fire
• Class A fire (wood, paper, trash, etc). extinguishers can be exchanged readily among aircraft,
Use water or soda-acid fire extinguisher. a means is required to identify and assure control of in-
spection cycle. To accomplish this, all portable, hand-
• Class B fire (oil, paint, fuel, grease, etc). operated fire extinguishers intended for use in Army air-
Use bromotrifluoromethaneor carbon craft will be tagged as follows:
dioxide fire extinguisher.
• Class C fire (electrical equipment). Use • All serviceable fire extinguishers in-
bromotrifluoromethane or carbon diox- stalled in aircraft will have a DD Form
ide fire extinguisher. 1574 (Serviceable Tag Materiel) at-
tached. The DD Form 1574 will show
• Class D fire (combustible metals) mag- next inspection due, as stated in DA
nesium, titanium, zirconium, sodium, PAM 738-751.
lithium, and potassium. Use dry powder
type fire extinguisher. • Fire extinguishers are considered un-
serviceable if the gross weight stamped
(2) Types of fire extinguishers. Types of fire on data ring, as shown in figure 2-3, is
extinguishers are listed below: not legible or the data ring is missing.

• Soda-acid (class A fires) • Fire extinguishers determined unser-

viceable or requiring a scheduled in-
• Bromotrifluoromethane - Halon 1301 spection will be replaced with a service-
(class B and C fires) able fire extinguisher, tagged with a DD
Form 1574.
• Carbon dioxide (class B and C fires)
• Fire extinguishers received through sup-
• Dry powder (class D fires) ply channels that are in original manu-
facturer’s packaging and show no evi-
• Potassium Bicarbonate (class B and C
dence of damage shall be considered
fires)
serviceable and will be tagged accord-
ingly; prior to installation in aircraft.
(3) Use of fire extinguishers. Operate fire ex-
tinguisher as follows: • Fire extinguisher cylinders have a ser-
vice life of 12 years. Check the manu-
(a) Pull ring pin. facture date stamped on top of the cylin-
der to ensure the cylinder service life will
(b) Point horn close to fire. not expire before the next 6 month in-
spection.
(c) Depress trigger for discharge, and keep
base of flames covered. (6) Location of fire extinguishers. Fire extin-
guishers shall be located throughout the shop in readily
accessible areas.

Do not remove cylinder head until extinguisher (7) Marking of fire lanes. Fire lanes shall be
has been fully discharged. Injury to personnel marked and kept clear for emergency personnel should
may otherwise result. fire occur.

Change 8 2-7
TM 1-1500-204-23-1

Figure 2-3. Fire Extinguisher Nameplates

2-8
 TM 1-1500-204-23-1

(8) Fire fighting equipment requirements. • Aircraft shall be static-grounded from ba-
Fire fighting equipment requirements are listed as fol- sic structure of aircraft to a low resistance
lows: ground.

• Personnel shall be trained in the use, • After parking aircraft, chock securely and
knowledge, and location of shop fire release parking brake.
fighting equipment.
c. Parking of Aircraft with Fuel Tanks Less Than
• Each shop shall be equipped with fire Full. Aircraft shall have all fuel cells fully serviced
extinguishers suited for type fire most prior to being parked or stored in a hangar. All fuel
likely to occur. cells should be full in order to minimize the presence
of flammable vapors within the fuel cell (for safety pur-
• Oily waste, rags, and similar com- poses) and additionally to minimize water condensation
bustible trash shall be discarded in and subsequent microbiological growth which results in
self-closing metal containers which shall contamination of the fuel.
be emptied daily.
NOTE
• Flammable supplies shall not be stored
in the shop. This procedure should be adhered to at all
times, except when impending mission require-
• Use correct fire extinguisher for class of ments shall necessitate a reduced fuel load or
fire. when an aircraft shall require maintenance to
the fuel system.
2-6. PARKING OF AIRCRAFT AND EQUIPMENT
IN HANGARS. The following paragraphs explain the d. Usage of Drip Pans. Drip pans shall be placed
parking of aircraft and equipment in hangars. under aircraft engines to collect oil. Drip pans shall be
emptied daily.
a. Safety Lanes. Safety Lanes should be clearly
marked and kept clear of parked aircraft and equipment. e. Location of Static Ground Points. Static
The width of fire lanes between parked aircraft should be ground points are located throughout the hangar for
slightly greater than the wing span of parked aircraft in static grounding of aircraft. The grounding point is
order to facilitate removal of any one aircraft from park- marked by a yellow circle 18 inches in diameter, with
ing area and also to permit ease of movement for mobile a 2 inch black border surrounding it. The words
fire fighting equipment within the area. STATIC GROUND CONNECTION and a numeric or
alphanumeric identification of the grounding rod shall
b. Parking of Aircraft in Hangars. Aircraft be stenciled in black on the yellow circle.
parked in hangars shall be spaced a sufficient distance
apart to provide adequate clearance for maintenance, f. Testing of Static Ground Points. The electri-
servicing, and fire lanes. Observe the following parking cal resistance of each grounding system should be as
precautions: low as possible but not greater than 10,000 ohms. A
log must be kept for permanent or semi-permanent air-
NOTE fields to show the identification of each rod, the date
tested, and the reading in ohms. If the measured re-
Aircraft shall be secured in accordance with the sistance of a rod is greater than 10,000 ohms, the rod
existing mooring instructions contained in the should immediately be marked DEFECTIVE DO NOT
applicable aircraft maintenance manuals. USE and it should be removed or replaced as soon as
possible. A log is not required at temporary refueling
• The direction in which the aircraft are to points. Each ground rod must be inspected when it is
be parked shall be determined by ease of installed. Ground wires are inspected monthly. The
maintenance and servicing. grounding system must be inspected and tested
• Parking arrangement shall vary to utilize lo-
cal space facilities to the maximum. Dou-
ble row lateral parking, with first and sec-
ond rows of aircraft placed tail to tail, shall
be accomplished where possible.

2-9
TM 1-1500-204-23-1

every five years or when there is a possibility of mechan- NOTE

ical damage. If any damage is found, it must be repaired Place tail stands under all aircraft equipped with
immediately. tricycle landing gear. Secure a ground-sup-
ported weight to tail of conventional gear air-
g. Static Grounding of Aircraft. All aircraft craft. When tail wheel is to remain in contact
parked in a hangar must be grounded (earthed) at all with ground, lock it after aircraft reaches desired
times. height. Leave tail wheel free to roll fore and aft
during jacking and lowering operations.
h. Static Grounding of Ground Support Equip-
ment. Ground support equipment in a hangar must (6) Operate all jacks simultaneously, both up
be grounded (cable or power cord) at all times when in and down, to prevent binding of aircraft struts. Binding
contact with the aircraft being worked on. may be corrected by tapping strut with a rawhide mallet
or kicking tire.
i. Emergency Evacuation of Aircraft from
Hangar. A plan for the emergency evacuation of (7) Ensure that there is sufficient clearance
aircraft from a hangar must be established and imple- above aircraft to complete desired operation.
mented by the maintenance officer using the expertise
of the aviation safety officer and other applicable
elements. Care must be taken to ensure the safe evac-
uation of as many aircraft as possible in an emergency.
Aircraft on jacks shall be so labeled, and access
2-7. JACKING AND HOISTING. General instructions restricted to prevent injury to personnel.
for jacking and hoisting are explained in the following
paragraphs. For specific instructions on a particular air-
craft, refer to the applicable maintenance manual.

a. Jacking. Use the following procedures for in Unauthorized persons will not be in, on or un-
and out of hangar jacking: der aircraft supported by jacks. Areas shall be
restricted by proper warning signs and barriers
(1) Do not stand, sit, or lie inside or on aircraft to preclude entry into the area.
during raising or lowering operations.
NOTE
(2) Ensure that all stress panels are installed on
The use of auxiliary supports is recommended,
aircraft.
but not required, as standard jacks are designed
to withstand all vertical loads. When several
(3) Disengage aircraft brakes and remove people are to be working on the aircraft, aux-
chocks. iliary supports are highly recommended.
(4) Place all jacks on a level surface so that an (8) Do not jack aircraft when wind velocity is
imaginary line drawn through any 2 feet of jack will be greater than maximum amount specified in applicable
parallel to fuselage or load to be jacked. Jack only at maintenance manual. When applicable maintenance
specified jack points. manual does not list a maximum wind velocity, a velocity
of 15 miles per hour will be considered maximum.
(5) Position auxiliary supports as necessary to
adequately prevent accidental injury to personnel or
damage to aircraft.

2-10 Change 9
 TM 1-1500-204-23-1

(9) Head aircraft into prevailing wind when wind

velocity does not exceed velocity given in step (8). (1) Remove all excess items such as baggage,
etc., from aircraft. Do not allow personnel in or on air-
(10) After jacks are extended, make no attempt craft during hoisting operations.
to lock hydraulic ram in place by use of a clamp. Jacks
with threaded collar locks or locking pins will not permit (2) Apply ballast as required by applicable
load to lower, but may require additional lift to disengage maintenance manual.
collar lock or remove pin.
(3) Attach hoist sling at hoist location specified
(11) Prior to lowering aircraft, make a careful in- in applicable maintenance manual.
spection to ensure that retractable gear (when applica-
ble) are in down-and-locked position, ground locking de- (4) Ensure that there is sufficient clearance
vices are installed, and that there are no maintenance above aircraft to complete desired operation.
stands, support equipment, or other objects under air-
craft. (5) Fasten ropes to mooring points of aircraft
and use ropes to steady and guide aircraft during hoist-
(12) After aircraft no longer rests on jacks, re- ing operation.
move jacks from under aircraft as quickly as possible.
(6) Hoist aircraft cautiously and smoothly,
b. Hoisting. Use the following procedures for in avoiding sudden starts, stops and drops.
and out of hangar hoisting:
(7) Ensure that retractable gear down-lock pins
are installed prior to lowering aircraft.

(8) Ensure that all maintenance and support

Hoist aircraft out-of-hangar only when wind is equipment which could injure personnel or damage
calm. Otherwise damage to aircraft may result. aircraft is removed from under aircraft.

2-11/(2-12 blank)
 TM 1-1500-204-23-1

CHAPTER 3
FLIGHTLINE OPERATIONS

3-1. GENERAL. General flightline operations used • After work has been accomplished, inspect
on all aircraft are described in the following paragraphs. to ensure that all accessories and attaching
parts are secure and that work areas are
3-2. FLIGHTLINE SAFETY. To avoid injury to per- cleared of foreign objects prior to engine
sonnel or damage to aircraft, the procedures and gen- operation.
eral safety rules will be followed when servicing, oper-
ating, mooring, maintaining, or moving aircraft on the • Provide properly marked receptacles in all
ground. work areas into which trash, ferrous and
non-ferrous scrap, safety wire, etc, may be
a. Hearing Protection. Noise levels reached dur- placed.
ing ground runup of Army aircraft are of a level that may • Adhere to applicable gas turbine-powered
cause permanent hearing loss. Maintenance personnel aircraft taxiing and parking procedures as
shall wear adequate hearing protection when working outlined in applicable technical bulletins.
on aircraft with engines in operation. This minimizes damage due to material
being thrown by the exhaust blast into the
b. Foreign Object Damage. To prevent Foreign intake of other aircraft.
Object Damage (FOD), the following precautions shall
be observed during maintenance of turbine engines: • Ensure that gas turbine-powered aircraft
takeoff and landing procedures are such
• Regularly police parking areas, runways, as to avoid the intake of foreign objects
taxiways, and runup and exhaust areas to blasted from runways and runway shoul-
ensure against the presence of foreign ob- ders by preceding aircraft.
jects which could enter the engine. Spe-
cial attention shall be given to cleaning of • Use inlet duct runup screens during all
cracks and expansion seams in hard sur- ground operations, including taxiing to and
faced areas where engines will be oper- from takeoff position.
ated. Tests have indicated that these are
the main source of foreign objects which are • Inlet duct runup screens are not required on
ingested. aircraft using centrifugal flow engines.

• Periodically instruct personnel concerned • When necessary to properly evaluate en-

with aircraft maintenance of foreign object gine performance or when icing conditions
hazards to ensure that maximum preven- exist, inlet duct runup screens should be
tive measures are taken. removed. Runup with screens removed
shall be made in a designated, thoroughly
• Ensure that air inlet and tailpipe dust ex- cleaned area.
cluders are installed at all times when en-
gines are not being operated, except when
it is known the engine will again be operated
immediately following shutdown. Inlet duct runup screens shall not be installed
and removed with engines operating above idle
• Prior to each engine start, thoroughly in- rpm. Loose items of clothing shall not be worn.
spect and clean inlet ducting. Remove all Objects which might be drawn into the intake
loose nuts, bolts, tools, or other objects ducts shall not be carried when installing or re-
which would cause engine damage and moving screens. Damage to equipment may
possible subsequent failure. otherwise result.

3-1
TM 1-1500-204-23-1

• Inlet duct runup screens may be left off

during taxiing to and from takeoff position d. Parking and Mooring. The following instruc-
when requirements or existing conditions tions are general in nature, and are applicable to Army
make the use of screens impractical. Since aircraft. For specific instructions on parking and mooring
specific conditions warranting removal of particular aircraft, refer to the applicable maintenance
screens as specified above cannot be pre- manual. The following are general precautions for all
determined, specific conditions may be de- aircraft:
termined by each command as necessary
to conduct their operations. Approval of • Do not park or moor aircraft closer than
screen removal should include any addi- wing or rotor span, except by authority of
tional precautions necessary to assure safe the commanding officer or his designated
operation of engines. representative.

• Use only nonmetallic-head hammers when NOTE

required to install parts on engine.
When aircraft are to be parked in rows, position
c. Safety Around Aircraft. The following safety aircraft in adjacent rows to most effectively re-
precautions shall be employed to ensure safety around duce propeller wash during engine operation.
helicopters on the flightline:
• When possible, park aircraft in such a loca-
• Stand clear of plane-of-rotation of engine tion that transparent enclosures are not in
cooling fan during operation. direct rays of sun.

• Stand clear of tail rotor plane-of-rotation • Install gear locking devices (when applica-
during operation. ble).

• Main rotor blades tend to droop at de- • Attach mooring ropes to aircraft and ground
creased speeds; approach with caution, fittings at an angle of approximately 45 de-
especially blades with a low plane-of-rota- grees. Attach mooring ropes and install
tion. mooring devices as specified in applicable
maintenance manual.

NOTE

Personnel shall exercise extreme caution when Allow sufficient slack in the mooring rope to pre-
hand-pulling a propeller to keep their bodies as vent stress on ground fittings, rope, mooring de-
clear of the plane-of-propeller-rotation as con- vices, or aircraft structure due to tire or strut in-
ditions permit. Ground crewmembers should flation/deflation, or wet rope shrinkage.
be conscious of the fact that an accidental start
may occur at any time, and should therefore be • Place fully charged, 50 pound carbon diox-
alert to jump clear in such an event. A suitable ide type fire extinguishers in readily acces-
length of canvas strap or similar material, with- sible areas where aircraft are parked.
out metal fittings, may be placed around pro-
peller blades to facilitate hand-pulling. Be es- • When aircraft are to be moored for storage,
pecially certain that the ignition switch is in the they shall not be parked less than 750 feet
OFF position before turning propeller by hand. from center of nearest taxiway. Provide ad-
Death or injury may otherwise result. equate clearance for maintenance, servic-
ing, fire lanes and taxiways.

• All aircraft parked inside enclosures will be

grounded at all times.

3-2
 TM 1-1500-204-23-1

• Place chocks fore and aft of main landing

gear wheels. Do not use parking brakes as • Refer to the applicable aircraft maintenance
substitutes for chocks. Use steel chocks for manual for the use of spoilers if severe wind
snow or ice operating only. Use sandbags is expected.
on steel matting. Use wooden chocks for all
other operations. Set brakes only after they • Ensure aircraft is chocked and tied down
have cooled. in accordance with applicable maintenance
manual storm procedures.
NOTE
• In case of emergency, tie down aircraft us-
Do not set brakes of aircraft in a hangar or out- ing trees or arctic-type (dead-man) mooring
side during subzero temperature. anchor.

• Service aircraft systems as required by f. Flightline Equipment. All flightline equipment

applicable maintenance manual. Exercise should be inspected and functionally checked to ensure
care during servicing to prevent moisture safety prior to use.
from entering systems being serviced.
(1) General inspection. The following para-
• Avoid parking aircraft in wet or slushy areas graphs describe inspection requirements for flightline
saturated with fuel or oil. equipment.
• Install pitot tube covers and wheel covers. (a) Cleanliness. Inspect equipment inter-
nally and externally for cleanliness. Equipment will be
• Move controls to neutral position and lock
dry and free of mud or other debris.
by either internal or external means.

• When parking helicopters overnight for stor- (b) Serviceability. Perform serviceability in-
age, or during adverse weather, set ground spection of all new equipment.
handling wheels (when applicable) in re-
tracted position. (c) Lubrication. Lubrication will conform to
the applicable maintenance manual.
• Rotate or fold main rotor blades (when
applicable) in accordance with instructions (d) Oil seals. Inspect oil seals for leakage.
contained in applicable maintenance man- Oil seals that are wet and show only a slight drip, after
ual. operation or standing, are considered as seeping and
are acceptable. Seals that show definite leakage will be
e. Preparation of Aircraft for Storms. The fol- replaced.
lowing general precautions are to be observed when
storms are anticipated: (e) Performance. Ensure that ground sup-
port equipment is in such condition that its performance
• Install all protective covers and shields to will approximately equal new equipment and meet all
protect aircraft from accumulation of snow, general safety requirements.
frost, or ice.
(2) Functional check. The following proce-
NOTE dures explain functional checks for flightline equipment.
If wings are wet or a freezing rain is expected, (a) Check all levers, switches, valves, shut-
cover aircraft with a coat of anticing and deicing- ters, etc., to ensure proper operation.
defrosting fluid, MIL-A-8243, before installing
fabric covers.
(b) Check all meters and gauges for proper
operation and adjustment.

3-3
TM 1-1500-204-23-1

(c) Check powered ground support equip- on smooth surface and jerk the paper liner off to half
ment for operation at peak, rated output, and capacity the length of strip. Fold loosened paper liner.
for which it was designed.
(d) Position tape on equipment and adhere
(d) Check nonpowered ground support one edge with finger. Hold unapplied portion slightly
equipment for performance capabilities within the pur- away from surface to prevent premature adhesion.
pose for which it was designed. Wipe tape to surface with firm pressure, using a plastic
squeegee. Remove remaining liner and apply remain-
(e) Check equipment for unusual noises dur- der of tape. Any air bubbles should be pricked with
ing operation. An unusual noise is any sound that in- pinpoint and air worked out with squeegee.
dicates malfunction or improper operation of a compo-
nent. NOTE

Apply only when equipment surface tempera-

g. Reflectorizing of Equipment. All non-tactical
ture is above 60°F (16°C). Activate adhesive
ground support equipment (which is normally painted
lightly with a solvent activator as recommended
yellow) will be outlined with reflective tape to ensure high
by the reflective tape manufacturer.
visibility during low light level operations.
(e) Apply clear edge sealer, as recom-
(1) Outlining. Equipment shall be marked in a
mended by reflective tape manufacturer, to edges of
manner to outline the entire piece of equipment, so that
tape to prolong life of marking.
during periods of low visibility the entire outline of the
equipment will be obvious. Outline using the following
procedures: (f) Repair to damaged reflective areas can be
made without stripping of original material. Abrade any
rough edges, clean damaged area thoroughly and apply
(a) Outline the equipment with 4-inch wide
a new piece of reflective tape over damaged area.
silver-white tape conforming to Federal Specification
L-S-300, NSN 9390-00-949-8047. NOTE
(b) Compound surfaces (corners, large bolts, The reflective tape cannot be subjected to paint
rivets, etc.) may be left unmarked. oven baking process.

NOTE (3) Use of flags. All support equipment

which cannot be taped (i.e., tactical vehicles, trac-
If area to be striped can not accommodate tors, sweepers, occasional use vehicles, etc.) will
4-inch wide tape, use the widest width possible. display a white-orange checkered flag conforming to
MIL-F-40047, NSN 8345-00-027-3704. The flag will
(2) Application of reflectorizing sheeting. be flown while on the flight line or any area in which
The following procedures shall be used to apply reflec- aircraft may be present. The flag shall be mounted to
torizing sheeting, Federal Specification L-S-300: facilitate easy removal when departing airfield area or
when entering into a tactical condition.
(a) Clean surfaces of all loose scale and dirt
by brushing or applying cleaning compound, Federal 3-3. GROUND HANDLING. Aircraft shall not be
Specification P-C-437. Remove deposits of cleaning moved where, or in such a manner that, injury to per-
compound by washing with clear water. Dry surfaces sonnel or damage to the aircraft or property could result.
with high-pressure compressed air. Ensure tow tug drivers are trained to tow all types of
aircraft prior to towing and exercise supervision when
(b) Measure reflectorizing sheeting and cut necessary. For specific instructions on a particular
to desired lengths. aircraft, refer to the applicable maintenance manual.
Aircraft shall not be moved where, or in such a manner
(c) Start removal of protective paper liner that injury to personnel or damage to the aircraft or
from adhesive by holding the tape reflective side in and property could result. The following paragraphs contain
flick one corner sharply in toward reflective face. When general procedures for ground movements, towing,
corner is loosened lay the reflective side of tape down pushing, and standard visual signals.

3-4
 TM 1-1500-204-23-1

a. General Procedures. The following proce- (3) Use caution when towing aircraft in ex-
dures are for all ground movements: tremely low temperatures to prevent damage to hy-
draulic seals which would result in strut leakage.
(1) Disconnect and move clear all ground sup-
port, ground servicing, and maintenance equipment not c. Pushing. Push aircraft by hand in accordance
essential to movement of the aircraft. with the applicable maintenance manual. The following
procedures are for general hand moving of all aircraft:
(2) Assign an authorized ground crewmember
to operate aircraft brakes, as required, from the time
chocks are removed until they are reinstalled.

(3) Assign a ground crewmember to stand near Keep clear of skids, aircraft wheels, and/or
tip of each wing to act as a guide during ground move- ground handling wheels.
ments.
(1) Position ground handling wheels (when ap-
(4) Stand clear of aircraft immediately prior to plicable) in down-and-locked position.
and during movement.
(2) Apply physical pressure for pushing, lifting,
(5) Assign a qualified ground crewmember to di- and turning only at authorized pressure points as desig-
rect departure from, or approach to, a parking position. nated in applicable maintenance manual.
Only approved standard signals will be used. Use a
flashlight or luminescent wand to signal instructions at (3) Push by hand at proper pressure points.
night.
(4) Senior person will brief duties and dangers
(6) Do not stand, sit, or lie on any external por- of ground handling aircraft.
tion of an aircraft while it is in motion. Do not jump from
or board a moving aircraft. d. Standard Visual Signals. Visual signals for
movement of Army aircraft are contained in FM 21-60.
(7) When moving aircraft, avoid sudden stops
and starts. 3-4. STATIC GROUNDING OF AIRCRAFT. Standard
grounding of aircraft is explained in the following para-
(8) No person, vehicle, or aircraft shall ap- graphs.
proach close to an oncoming taxiing aircraft, pass closer
than 200 feet to the rear of an operating turbine-pow- a. Grounding Requirements. Positive require-
ered aircraft, or pass closer than 100 feet to the rear of ments for grounding or bonding of aircraft are as follows:
other operating aircraft.
NOTE
(9) Do not taxi or tow aircraft, or start or runup Grounding of aircraft during refueling is no
engines within 50 feet of any fuel, oil, or water-alcohol longer required by NFPA standards 77 and 407.
servicing operation, or within 50 feet of any spill until the Grounding will not prevent sparking at the fuel
spill has been removed and the area rendered safe. surface. (See Chapter 2, Section III for more
information).
b. Towing. Tow aircraft in accordance with the ap-
plicable maintenance manual. The following procedures • All aircraft parked outside will be grounded
are for general towing of all aircraft. and bonded, in accordance with TC
3-04.75, to the aerospace ground equip-
(1) Prior to towing aircraft, ensure that towing ment while servicing (i.e., fueling or defu-
attachments, lines, and bars are of adequate capacity, eling, arming ammunition or explosives,
serviceable, and secured firmly to designated tow fit- oxygen, hydraulic fluids, or any flammable
tings of aircraft and tow vehicle. liquids). Grounding is not necessary for
aircraft parked outside unless one of the
(2) Do not exceed the walking speed of the above is being accomplished.
slowest team member, with a maximum speed of 5
mph. Tow with extreme care over ice, snow, rough, • Gounding of aircraft is required when exter-
rocky or muddy ground and in congested areas. nal power is applied to the aircraft.

Change 9 3-5
TM 1-1500-204-23-1

• All aircraft parked in a hangar must be are inspected monthly. The grounding system must be
grounded at all times. inspected and tested every five years or when there is
a possibility of mechanical damage. If any damage is
• Deleted found, it must be repaired immediately.

b. Earth Grounds. An earth ground (electrode) is (2) Method of testing. Ground rods are tested
a conductive pipe or rod made of galvanized iron, galva- with a multimeter (Multimeter: TS-352B/U, LIN M81372,
nized steel, or copperweld steel. The rod regularly used NSN 6625-00-553-0142). Refer to FM 10-67-1 for spe-
for grounding is Rod, Ground: MX-148G Line Item Num- cific procedures when testing ground rods.
ber (LIN) S08698, National/NATO Stock Number (NSN)
5975-00-224-5260. This ground rod is ¾ inch in diam- d. Fabrication of Ground Cable. Fabricate static
eter and 6 feet long, and it is made of galvanized steel. grounding cable assembly, as shown in figure 3-1, using
It has one pointed end to be driven into the earth and a the following procedures:
bolt and nut at the other end for connecting a grounding
cable. (1) Cut wire rope (figure 3-1, 1) to length
needed.
(1) Use of earth grounds. The rod is driven
into the earth far enough to reach below the permanent (2) If coated wire rope (1) is used; remove ¾
ground-moisture level. On the apron or ramp of a fixed inch of coating from each end.
airfield, the top of the rod should be level with the sur-
rounding surface; at other types of facilities, the top of (3) Loosen set screws (4) in clip (5).
the rod should be either low enough or high enough so
that people will not trip over it. If the top of the rod is (4) Insert wire rope (1) into handle of clip (5) and
level with the surrounding surface, an area around the tighten set screws (4).
top of the rod must be dished out so ground cable clips
can be attached to the rod.
(5) Insert unattached end of wire rope (1)
through cap (2). Rope will extend past end of cap.
(2) Marking of earth grounds. A yellow circle
18 inches in diameter, with a 2-inch black border sur-
(6) Screw cap (2) into plug (3).
rounding it, should encircle each rod that is installed in a
hard surface. These circles should be painted on. The
words STATIC GROUND CONNECTION and a numeric (7) If desired, clips (5) may be attached to both
or alphanumeric identification of the rod should be sten- ends of wire rope (1) with a plug (3) attached to handle
ciled in black on the yellow circle. The number and spac- of one of the clips as follows:
ing of fixed rods should be determined by the require-
ments of the local situation. Markings of this type are (a) Cut short length of wire rope to attach plug
not required for temporary ground rods. to clip.

c. Earth Ground Testing. The electrical resis- (b) Assemble items for alternate configura-
tance of each grounding system should be as low tion as in (2) through (6) above. See detail A for view
as possible but not greater than 10,000 ohms. A log of alternate cable assembly.
must be kept for airfields to show the identification of
each rod, the date tested, and the reading in ohms. NOTE
If the measured resistance of a rod is greater than
10,000 ohms, the rod should immediately be marked Never fasten electrical clip to a painted surface.
DEFECTIVE-DO NOT USE and it should be removed
or replaced as soon as possible. A log is not required (8) Insert plug into receptacle on aircraft. Attach
at temporary refueling points. clip to grounding stake.

(1) Frequency of testing. Each ground rod (9) Attach warning streamers, NAS 1756-12 or
must be inspected when it is installed. Ground wires MS 51700-12, to coated wire rope.

3-6 Change 7
 TM 1-1500-204-23-1

KEY TO FIGURE
1. 4010-00-286-2681 ROPE, WIRE (COATED)
(ALT.) 4010-01-145-8455 ROPE, WIRE (NON-COATED)
5935-00-572-5174 PLUG-TIP,
CONSISTING OF:
2. CAP
3. PLUG
4. SET SCREW
5. 5999-00-134-5844 CLIP ELECTRICAL

Figure 3-1. Fabrication of Static Grounding Cable Assembly

Change 6 3-7
TM 1-1500-204-23-1

(10) Attach yellow reflective tape, 9390-00-040- inches (1066.80 mm) and not less than 12
6102, to non-coated wire rope. inches (304.80 mm) from the filler opening.

(a) Wrap tape around handles of clip and • Receptacle can be grounded by mounting
around the wire at three-foot intervals. or bonding to aircraft structure.

(b) Do not apply tape to those parts of plug • Receptacle shall be used with ground-
and clip that complete electrical circuit. ing plug conforming to MIL-C-83413/MIL-
C83410.
(11) Test ground cable for resistance to ground.
• Dissimilar metals as defined by MIL-STD-
889 be used in intimate contact with each
e. Ground Receptacle Criteria. Aircraft ground- other.
ing receptacles, as shown in figure 3-2, shall conform to
the following criteria: • Place a fully charged fire extinguisher (50 lb
CO2 or 22 lb Halon 1211) in readily acces-
• For internal and external tanks, the recep- sible area where aircraft are parked.
tacle shall be installed at not more than 42

NOTES:
DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
METRIC EQUIVALENTS (TO THE NEAREST .01 MM) ARE GIVEN FOR GENERAL INFORMATION ONLY AND
ARE BASED UPON 1 INCH - 25.4 MM.

Figure 3-2. Aircraft Grounding Receptacle Installation

3-8
 TM 1-1500-204-23-1

NOTE (4) When a satisfactory measured resistance

has been reached, touch-up paint as required per TM
Precautions should be taken to ensure that 55-1500-345-23.
these parking area extinguishers are period-
ically inspected and adequately marked to 3-5. AIRCRAFT REFUELING. Servicing aircraft with
ensure high visibility (for ease of location in fuel and defueling aircraft requires the utmost precaution
the event of an emergency and to prevent ac- due to the highly flammable characteristics of fuel. Per-
cidents during aircraft movement). Due to the sonnel performing fueling and defueling operations must
smaller size of the Halon 1211 portable-type be thoroughly familiar with FM 10-67-1, Concepts and
extinguishers, these bottles should be secured Equipment of Petroleum Operations. Personnel must
in a permanent location to facilitate recognition also be completely familiar with the aircraft being ser-
and prevent damage to the extinguisher. viced.

f. Ground Receptacle Testing. Test ground re- NOTE

ceptacle using the following procedures: Aircraft shall have all fuel cells fully serviced
prior to being parked or stored in a hangar. All
(1) Using an ohmmeter, check resistance from fuel cells should be full in order to minimize
the receptacle to a point on the aircraft skin adjacent to the presence of flammable vapors within fuel
the receptacle. Contact point used must be free of paint cell (for safety purposes) and additionally to
and corrosion and cleaned for good electrical contact. minimize water condensation and subsequent
An ordinary ohmmeter set on R x 1 scale, will read a microbiological growth which results in con-
direct short or not more than 1 ohm. tamination of the fuel.Aircraft shall have all
fuel cells fully serviced prior to being parked or
(2) If resistance reading exceeds requirement of stored in a hangar. All fuel cells should be full
paragraph (1), receptacle must be removed and aircraft in order to minimize the presence of flammable
skin around it must be cleaned of paint corrosion and vapors within fuel cell (for safety purposes) and
treated per TM 55-1500-345-23. Reinstall the recepta- additionally to minimize water condensation
cle in accordance with MIL-C-83413/MIL-C-8349. Nut and subsequent microbiological growth which
must be tight. results in contamination of the fuel.

(3) Recheck ohmmeter reading as in step (1). If This procedure should be adhered to at all
it does not meet requirement, repeat procedures times; except when impending mission require-
ments shall necessitate a reduced fuel load
(4) Retouch paint as required per or when an aircraft shall require maintenance
TM 55-1500-345-23. to the fuel system.This procedure should be
adhered to at all times; except when impending
g. Aircraft Fuel Port Testing. Test aircraft fuel mission requirements shall necessitate a re-
port ground using the following procedures. duced fuel load or when an aircraft shall require
maintenance to the fuel system.
(1) Use multimeter, TS352B/U, to check the re-
sistance of aircraft fuel port to the skin adjacent to the a. Open-Port Refueling. Open-port refueling is
fuel port. The contact on the fuel port and aircraft skin refueling by inserting an automotive-type nozzle into a
should be free of paint and corrosion for a good electri- fill port of larger diameter. Most of the Army fueling noz-
cal contact. zles are designed for open-port refueling and must be
used until enough FARE systems are deployed to make
(2) Set the multimeter on the RX1 scale. If the open-port aircraft refueling an obsolete practice. Be-
measured resistance is greater than 1 ohm, the aircraft cause the port is larger than the nozzle, fuel vapors can
fuel port must be removed. The aircraft skin around the escape through the fill port during open-port refueling
fuel port must be cleaned of paint, corrosion and then operations. Airborne dust and dirt, as well as rain, snow,
treated in accordance with TM 55-1500-345-23. Re- and ice can get into the fill port during refueling, thus low-
install fuel port in accordance with the applicable TM ering the quality of the fuel in the tanks and endangering
55-1500-345-23 aircraft maintenance manual. the aircraft. Spills from overflowing tanks are possible
in open-port refueling. Spills can also be caused by the
sudden pressure surge that comes when pumping from
(3) Recheck OHM reading as stated in para-
another nozzle in the system is completed, throwing the
graph 3-4g(1). If it does not meet requirement, repeat
whole pressure of the pump to the operating nozzle. Be-
procedure.
cause of these dangers, hot refueling by the open-port
method is restricted to combat or vital training or testing
use. Refer to FM 10-67-1.

Change 4 3-9
TM 1-1500-204-23-1

b. Open-Port Hot Refueling. In combat op- (2) General operation. After the aircraft parks
erations, the open-port method of hot refueling may and its engine or engines are shut down, the rotor blades
be used for helicopters when, in the judgment of the are secured, and armaments are set on SAFE, the se-
aviation commander, the requirements of the tactical quence of the refueling operation can start. The follow-
mission and the benefits of reducing ground time out- ing procedures are for all aircraft:
weigh the inherent risks of this method of refueling. In
noncombat situations, helicopters may be refueled by (a) Check the interior of the aircraft. No one
this method only when there are compelling reasons to should be aboard during refueling unless the pilot or
do so. For example, aviation commanders may decide copilot are on board to monitor the quantity of fuel to
that hot refueling must be done for purposes of training, be loaded. When the D-1 nozzle is used, the only way
or for field testing or combat testing for development. of knowing when to stop flow is for the pilot or copilot to
When the FARE system is used for hot refueling in watch the fuel gauges in the aircraft.
a training situation, a firewall should be built around
500-gallon drums whenever it is possible. Refer to FM (b) Drive the tank vehicle into position in front
10-67-1. of the aircraft. Use the sort of approach route shown in
figure 3-3. Do not drive the refueler directly at the aircraft
NOTE because brake failure could cause a serious accident.
Nozzles of the open-port type must be held
open by hand throughout use. If any automatic (c) Keep a distance of at least 10 feet be-
device has been added to the nozzle to hold it tween the refueler and the aircraft. There must be at
open, the device must be removed; if notches least 10 feet between the refueler and rotor blades of a
have been made to hold open, they must be helicopter. Keep a distance of at least 20 feet between
filed off. No exceptions to this rule are allowed the exhaust pipe of the pump engine (or truck engine)
in aircraft refueling. and the aircraft fill port and tank vent as shown in figure
3-4.
c. Rapid Hot Refueling. Aircraft may be rapid
(hot) refueled (with engines running), electrical power (d) Park the refueler so that it has a clear and
on, radios on, weapons system on with safety cov- open path to drive away from the aircraft in an emer-
ers/guards/switches in safe position, and with any gency. Do not detach a tank semitrailer from its tractor
computer systems operating that would require repro- when refueling an aircraft; the tractor must be ready to
gramming if shut down. See the applicable aircraft pull the trailer away from the aircraft if the need arises.
operator’s manuals (-10 and -CL) for detailed instruc-
tions. If rapid (hot) refueling is required (prescribed NOTE
in FM 10-67-1), ground the aircraft properly. It is also
recommended that the aircraft be in a revetment type If the refueler can be driven into position without
shelter or separated from fuel storage by a fire wall. backing, do so. If it must be backed toward the
aircraft, bring the truck to a full stop when it is
20 to 25 feet away from the aircraft or its rotor
blades. Have another person act as a ground
guide. Follow signals to guide the final backing
Only emergency radio transmissions should approach until signaled to stop at the proper
be made during rapid (hot) refueling. Radio distance from the aircraft and its fill port and
switches may electrically arc when being keyed. vent, as shown in figure 3-5.

d. Fuel Truck Operations. Fuel truck operations (e) Stop the refueler engine (unless it powers
are covered in the following paragraphs. the pump) and set the brake. Chock the tires of the
refueler and of the aircraft if appropriate.
(1) Fuel truck types. The M49A2C tank truck
with a 1,200 gallon stainless steel tank, the M559 tank (f) Check the fuel in the tank to make sure it
truck with a 2,500 gallon stainless steel tank, and the is the right type for the aircraft. Check the sight glass
M857 semitrailer with a 5,000 gallon tank are used to of the filter/separator to make sure all water has been
fuel Army aircraft. drained out.

3-10 Change 4
 TM 1-1500-204-23-1

Figure 3-3. Fuel Truck Approach Route

Figure 3-4. Fuel Truck Required Spacing

3-11
TM 1-1500-204-23-1

Figure 3-5. Fuel Truck Backing Approach

(g) Place the truck fire extinguisher by the (i) Ground the aircraft by attaching one end
pump. Place a fire extinguisher provided at the refueling of a ground cable to the ground rod (either the rod that
point by the aircraft fill port. grounds the refueler or a separate ground rod) and the
other end to a bare metal part of the aircraft.
NOTE
NOTE
Have members of the ground crew or the air
crew man these two fire extinguishers. If there Use the axle of the landing gear or some other
are no people available to man the fire extin- unpainted metal part, but do not clip the ground
guishers, place the extinguishers near the pump cable to the propeller or the radio antenna. At-
and nozzle operators, but position them so that taching this clip grounds the aircraft and bonds
they will not be in the operators way and where the refueler to the aircraft. If the refueler does
they are not likely to be engulfed if a fire should not have a Y-cable that will ground both the re-
start at either the pump or the nozzle. fueler and the aircraft to one ground rod, a sep-
arate ground cable is required to ground the
(h) Unreel the ground cable and attach its aircraft. A wire, such as building wire (type
ground-rod clip to the nearest ground rod. If refuel- TW, number 14 AWG or larger, solid copper) or
ing where no ground rod is installed, drive the refueler any other solid copper wire, size number 14 or
ground rod into the earth to the required depth and at- larger, may be used.
tach the clip to the rod.

3-12 Change 1
 TM 1-1500-204-23-1

(j) Bond the nozzle to the aircraft before tak- NOTE

ing the dust cap off the nozzle and the cap off the fill port.
If the aircraft has a receiver for the bond plug, use the Personnel who refuel aircraft may not carry
plug; if not, clip the alligator clip to a bare metal part of lighters or matches on their persons and must
the aircraft. not allow anyone else to carry a lighter or
matches within 50 feet of an aircraft that is
(k) Open the aircraft fill port and remove the being refueled. Use of exposed-flame heaters,
nozzle dust cap. welding or cutting torches, and flare pots is
forbidden within 50 feet of refueling operations.
NOTE
When using an open-port nozzle or the CCR • Do not allow electrically powered tools
nozzle adapter, put the nozzle well down into to be used in the refueling area.
the port. Do not open the nozzle until it is inside
the fill port. When using the CCR nozzle, mate • Do not allow any metalworking tools to
the nozzle into the fill port. If they will not latch be used within 50 feet of an aircraft be-
together, look for dirt in the fill port or on the noz- ing refueled.
zle. Wipe the fill port out and clean the nozzle,
then mate the two together. • Do not use flashlights within 50 feet of
the refueling operation unless the lights
are of the approved explosion-proof
(l) Refuel using procedures outlined in FM
type.
10-68.
• Do not allow flashbulbs or electronic
(m) Replace the cap on the fill port and then flash devices to be used within 10 feet
replace the nozzle dust cap before disconnecting the of refueling equipment or the fill port or
nozzle bond. fuel tank vents of aircraft.
(n) Remove the nozzle bond plug or undo the • Do not remove any piece of clothing
alligator clip. Reel up the hose and nozzle. Do not drag while within 50 feet of a refueling oper-
the nozzle across the ground. ation or in an area where a flammable
vapor-air mixture may exist.
(o) Undo the clip that grounds the aircraft.
Replace the fire extinguisher used at the nozzle. NOTE

(p) Release the clip on the ground rod and If fuel gets on clothing, leave the refueling area
reel up the grounding cable. Do not drag the cable clips as soon as refueling is completed. Wet the
across the ground. If the refueling operation is over and clothes with water before taking them off. If
the refueler ground rod was used, pull the rod up and there is not enough water at the site to wet the
stow it in the refueler. Replace the fire extinguisher in clothes thoroughly, ground yourself to a piece
the refueler. of grounded equipment by taking hold of it with
both hands before taking off the fuel-soaked
(3) Safety requirements. The following safety clothes. A skin irritation from fuel is not fatal;
requirements must be followed when refueling Army air- the fire that may follow a static discharge from
craft: clothes may be.

• Do not allow any open flame, open- • Do not enter a flammable atmosphere
flame device, or lighted smoking materi- right after removing a garment. Wait
als within 50 feet of an aircraft refueling at least 10 minutes before carrying the
operation. garment into such an atmosphere.

3-13
TM 1-1500-204-23-1

NOTE NOTE

Before opening an aircraft fuel port or doing any- Restrict vehicle access to the refueling area; al-
thing else that would let fuel vapors escape into low only those vehicles actually involved in ser-
the air, bond yourself to the container by taking vicing aircraft to come within 50 feet of the refu-
hold of it. If it is an aircraft or piece of metal eling operation. Vehicles used in and around re-
equipment, take hold of a bare metal part with fueling areas must be maintained to a high stan-
both hands for a few seconds. Although this dard of performance to prevent the fire hazards
bonding will not completely discharge the static of backfires and sparks. The electrical circuits
electricity, it will equalize the charge with the of vehicles used in refueling operations must be
charge on the piece of equipment. maintained in top condition to prevent short cir-
cuits around defects.
• Do not refuel an aircraft until its engines
are shut down, except as provided in hot (4) Fuel contamination. Care shall be taken
refueling. when refueling to prevent fuel contamination. Sedi-
ment, water, microbiological growth, and mixed fuels
• Do not allow any work to be done on can cause fuel contamination and danger for aircraft
an aircraft’s batteries while the aircraft is operations.
being refueled.
(5) Protective clothing. To date, no regular
NOTE Army uniform (suitable for everyday field wear) has
been developed for personnel who handle aviation
The batteries should not be raised or lowered, fuels. Therefore, wear the standard combat uniform.
and battery chargers should not be connected, Air crewmembers should wear the nylon fire-retardant
used, or disconnected during refueling. uniform but should know that it loses its protective
properties if it is saturated with a petroleum product.
• Stop refueling operations when there Because combat uniforms and flight suits are not
are lightning discharges in the immedi- impervious to petroleum, use great care in refueling
ate area. operations to avoid spilling fuel on your clothing.
• Do not fuel an aircraft or store aviation
3-6. OIL SERVICING. Oil servicing precautionary
fuel within 100 feet of the antenna of an
measures are required due to the flammable nature of
airfield surface-detection radar.
oil. General precautions for oil servicing are the same
• Do not fuel an aircraft or store aviation as for fuel servicing. Additional safety precautions for
fuel within 300 feet of the antenna of oil servicing and draining are contained in the following
an airfield approach and traffic control procedures:
radar.

• Airborne surveillance units must be shut

down before the aircraft approaches
To avoid contamination, do not use previously
within 300 feet of a refueling or fuel
opened cans of engine oil, new sealed can of
storage area.
fluid must be opened and used. When opening
• A weather-mapping radar unit mounted can, clean top and use a clean, sharp un-plated
in an aircraft must be shut down before instrument to prevent contamination.
and during refueling of the aircraft.
a. Install drip pans where practicable.
• Radio transmission from the aircraft be-
ing refueled is not allowed because of
the danger of arcing.

3-14
 TM 1-1500-204-23-1

NOTE
Never use flammable solvents to remove oil
spillage. Oxygen equipment shall be kept clean at all
times. No organic matter or flammable sub-
b. Exercise caution to prevent overfilling or stance of any nature shall be allowed to con-
spilling. tact oxygen. Ensure that all components of the
systems are free of moisture, oil and grease
NOTE at all times. Oxygen is a nonflammable gas;
When oil has been spilled, immediate action however, it supports combustion and lowers the
shall be taken to remove spillage from aircraft flash ignition point of all combustible materials.
and adjacent area. Clean rags may be used to Oxygen shall be handled as a flammable gas.
remove oil spillage from the aircraft. Sand, dirt,
sawdust, or commercial products may be used When an aircraft is being serviced with oxygen
to remove oil spillage from adjacent ground. within 50 feet of an area where smoking is per-
mitted, NO SMOKING signs shall be placed at
3-7. OXYGEN SERVICING. Oxygen servicing re- a 50-foot radius around the servicing area. A
quires the utmost precautionary measures due to the spark in the servicing area could cause an ex-
highly explosive and flammable capabilities of oxygen. plosion and damage to equipment.
Prior to servicing an aircraft oxygen system, personnel
shall familiarize themselves with the system, precau- (1) To prevent overfilling of tanks, personnel
tions, and instructions for handling gaseous oxygen, shall observe aircraft oxygen system gauges at all times
operation of servicing equipment, and potential hazards during servicing operation.
involved.
(2) Personnel shall be stationed at the oxygen
servicing unit at all times during servicing operation to
shut off unit valves immediately upon receiving a com-
Only qualified personnel shall be authorized to mand from personnel watching aircraft system gauge.
operate equipment for servicing of an aircraft
oxygen system. Damage to system may oth- (3) Service aircraft from cylinders clearly la-
erwise result. beled DRY or AVIATOR’S BREATHING OXYGEN.
Other oxygen may have moisture which could cause
a. Safety Precautions. Aircraft shall not be ser- flow stoppage at temperatures below freezing.
viced with oxygen when any of the following conditions
prevail: (4) Always use a pressure-reducing device
when servicing low-pressure oxygen system from
• Aircraft electrical switches are on. high-pressure bottles.
• Ground powered equipment is operating
(5) Fill oxygen system slowly to prevent explo-
within 50 feet of the servicing area.
sion resulting from heat generated by filling too fast.
• Aircraft is being serviced with fuel, oil, or
anti-icing fluids. (6) An aircraft oxygen system not equipped
with shutoff devices at cylinders shall be completely dis-
• Any combustible items, such as fluid, etc., charged of all pressure prior to removing components.
are evident around oxygen servicing equip- All electrical power shall be turned off during oxygen
ment. discharge operations.

b. Servicing. General servicing procedures for (7) Refer to the applicable aircraft maintenance
oxygen systems are explained in the following para- manual for additional information and maintenance pro-
graphs. cedures.

3-15
TM 1-1500-204-23-1

3-8. HYDRAULIC FLUID SERVICING. Hydraulic Safety procedures and general operating procedures
fluid servicing precautions are explained in the following for reciprocating and turbine engines are contained in
paragraphs. the following paragraphs.

a. Safety Procedures. Safety procedures prior to

starting, during starting, during engine operation, and af-
ter operating engines are covered in the following para-
To avoid contamination, do not use previously graphs.
opened cans of hydraulic fluid. Cans of hy-
draulic fluid cannot be resealed. Immediately
(1) Safety procedures prior to starting. The
transfer unused hydraulic fluid to an approved
following safety procedures should be accomplished
airtight, pressure venting, stainless steel stor-
prior to starting:
age reservoir, an approved hydraulic servicing
unit or a hydraulic test stand containing the
same hydraulic fluid. When opening can, clean (a) Head aircraft so that exhaust blast is di-
top and use a clean sharp, unplated instru- rected to least inhabited areas.
ment to prevent contamination. Can openers
attached to the aircraft must be cleaned before (b) Place approved chocks fore and aft of
using. main landing gear wheels.

a. Do not overfill reservoir or spill fluid in surround- (c) Clear aircraft and surrounding areas of
ing areas. When fluid is spilled, absorb with clean rags. covers, tools, rags, work stands etc., and remove moor-
ing ropes.
b. When filling reservoirs, extreme care shall be
taken to ensure that no dirt or foreign matter enters the (d) Secure access doors by closing or re-
system. moving prior to ground testing turbine-powered aircraft
engines.
c. Refer to applicable aircraft maintenance man-
ual for additional servicing and maintenance instruc- (e) Do not allow personnel on any external
tions. Use only specified hydraulic fluid. portion of an aircraft during engine start or operation.

3-9. PNEUMATIC SYSTEM SERVICING. Safety (f) Station ground crew member, equipped
precautions for servicing pneumatic reservoirs are con- with a carbon dioxide or equivalent fire extinguisher
tained in the following paragraphs. to one side and forward of engine being started. This
crew member will observe for fire and fire hazards,
a. Never use pressure oxygen to inflate gear such as fuel from overflow lines, fuel/oil leakage, chock
shock struts, pressure accumulators, etc. slippage, and other irregular conditions.

b. Use only clearly labeled compressed air cylin-

ders or compressed air hoses of known origin.
If aircraft utility fire extinguisher is utilized for
c. Ensure that locking mechanism on aircraft an engine start, another fire extinguisher, rated
valve stem is engaged prior to installing hose to valve capacity of 10-B or more, will be located within
stem. Always engage locking mechanism after servic- 50 feet of all fixed or rotary wing Army aircraft.
ing. Fire fighting capability must be maintained.

d. Fill system slowly to reduce heat generated by NOTE

filling too rapidly.
If ground crewmember does not have radio
e. Exercise care not to overcharge the system. communication, he must stand in view of air-
craft operator.
f. Completely discharge pressure prior to remov-
ing a component from the system. (g) When appropriate, station a responsible
ground crewmember off to one side, away from danger
3-10. ENGINE OPERATION. For operation and spe- areas, and aft of operating turbine powered aircraft, to
cific instructions on a particular fixed or rotary wing Army warn approaching traffic. Use a danger flag when nec-
aircraft, refer to the applicable maintenance manual. essary.

3-16 Change 4
 TM 1-1500-204-23-1

(2) Safety procedures during starting. The (4) Safety procedures after operating en-
following safety procedures should be accomplished gines. The following safety procedures should be
during starting: accomplished after engine operation:

(a) Employ hand signals for directing activity (a) Place ignition switch in OFF position. It
when engine operating noise will not permit voice com- is imperative that the ignition switch of an aircraft en-
munication. gine be in OFF position when engine is not operating.
Master battery switch shall be turned off when no longer
(b) Avoid excessive fuel pressure when start- required.
ing turbine engines.
(b) Turn off all tank selector and emergency
(c) When fire occurs during engine start, fuel system valves.
or while operating, the operator shall take necessary
action, as outlined in applicable maintenance manual, (c) When practicable, make adjustment to
to extinguish flame. Should this action fail, the fire engine and rotors with engine stopped.
guards shall take immediate action with approved fire
extinguishing agent provided. Should fire get beyond b. Turbine Engines. Turbine engine starting,
control of operator and fire guard, all available approved ground checks, and shutdown are covered in the fol-
means of extinguishing an aircraft or engine fire shall lowing paragraphs.
be used.
(1) Starting. Start engines using the following
(d) During start, and while engines are oper- general procedures:
ating, personnel shall stand well clear of propellers and
of areas affected by turbine air intake flow and exhaust (a) Remove ice or frost from engine cowling
blast. and inlet section prior to starting.

(e) All personnel will remain clear of engines (b) Connect an authorized auxiliary power
necessitating close inspections or adjustment, as di- unit.
rected by the specific equipment manual, until operating
engine speed (rpm) has been obtained. (c) When specified minimum starting rpm
cannot be obtained with available auxiliary power unit,
(f) Do not use a quick, excessive throttle start preheat accessory section and oil reservoir to reduce
on rotary aircraft. This kind of start could swing the tail starting loads. Aircraft battery may be used as a boost
rapidly, with the possibility of injury to personnel or dam- to obtain required rpm.
age to equipment from the tail rotor. Keep personnel and
equipment clear of aircraft at a distance at least equal to NOTE
its length.
In normal temperatures, starting attempts below
(3) Safety procedures during engine oper- recommended starting rpm increases the possi-
ation. The following safety procedures should be bility of engine damage due to hot starts.
accomplished during engine operation:
(d) Accomplish engine starts according to
(a) Do not operate engines in hangars. procedures outlined in the applicable maintenance
manual, using specified jet fuel or required alternate.
(b) Do not operate aircraft engine where pro-
peller or turbine blast would cause injury to personnel or (e) When there is no oil pressure after suffi-
damage to aircraft and property. cient runup time, or if oil pressure drops below operat-
ing range after a few minutes of ground operation, shut
(c) Nonrated personnel cannot run up rotary down engine and determine cause.
wing aircraft under any conditions.

3-17
TM 1-1500-204-23-1

NOTE 3-11. RUNUP AND TAXIING. Nonrated personnel

who start, run, warmup test, taxi or otherwise operate
• Starting oil pressure may exceed standard oil aircraft on the ground will be fully qualified, demonstrate
pressure gauge limits. This condition is not con- satisfactory ability, and be authorized to perform such
sidered dangerous unless the pressure remains duties, in accordance with AR 95-1. Nonrated personnel
high. Takeoff should be delayed until oil pres- cannot run up rotary wing aircraft under any condition.
sure drops with range, as specified in applica- General safety procedures, taxiing, and postflight and
ble maintenance manual. parking are covered in the following paragraphs.
• A hot start occurs when the engine starts, a. Safety Procedures. General safety proce-
but the exhaust gas temperature exceeds spec- dures for runup and taxiing are provided in the following
ified limits. This is usually caused by an exces- steps:
sively rich fuel air mixture entering the combus-
tion chamber. The fuel to the engine should be (1) Chock aircraft securely before attempting an
shut off immediately. engine runup.
• False or hung starts occur when the engine
(2) Check runup area carefully to prevent pro-
starts normally but the rpm remains at some low
peller or jet blast from throwing ice and snow on other
value rather than increasing to the normal start-
aircraft.
ing rpm. This is often the result of insufficient
power to the starter, or the starter cutting off be- NOTE
fore the engine starts self-accelerating. In this
case, the engine should be shut down. Some instruments will give erroneous readings
due to cold. These readings can be compen-
(2) Ground checks. To ensure proper opera- sated for or corrective action may be taken. For
tion, perform the following procedures before taxiing or specific instruments and their characteristics,
takeoff: consult applicable maintenance manual.
(a) Inspect all aircraft systems and surfaces, (3) Position ground crew to ensure adequate
with emphasis on systems and surfaces directly affected guidance when aircraft is maneuvered close to other
by low temperatures. aircraft, buildings, or obstructions, or in gusty or high
winds.
(b) Inspect controls and trim tabs for freedom
of movement. (4) Check that brakes are not frozen, and that
aircraft will roll before attempting to taxi from parking
space.

Do not apply heat directly or too rapidly against (5) Free tires that have become frozen to sur-
windshield and windows as there is danger of face by application of heat or overinflation. Do not allow
cracking, crazing, and discoloration. heat to exceed 160°F (71°C).

(c) Inspect cabin heat, defrosting, and anti- NOTE

icing systems.
Immediate freeing action cannot be expected
from tires that have been overinflated. A time
(d) Inspect hydraulically-operated equip- period of one-half to one hour may be necessary
ment. Cycle system several times if sluggish operation for tires to become free.
is evident.

(3) Shutdown. Shut down turbine engines in

accordance with the applicable maintenance manual.

3-18
 TM 1-1500-204-23-1

(6) Avoid snow and slush blown by preceding (2) Inspect oil and fuel drains and crankcase
aircraft by increasing distance between aircraft when breathers for ice or frost. Remove any existing frost or
taxiing. ice.

(7) Reduce taxi speeds to ensure safe stopping. (3) Inspect battery for charge at least once a
week. If layovers are to be over 4 hours and temper-
(8) Exercise care when pulling out or turning ature is below -20°F (-29°C), remove battery and store
from parking line to ensure that other aircraft will not be in a warm place.
damaged or covered by snow and ice from propeller
blast. (4) Drain oil system when there is no provision
available for preheating oil and a long layover period is
(9) Avoid taxiing into deep snow or snow drifts, anticipated.
as steering could become difficult, brakes could freeze,
and damage to propellers could result. (5) When temperature rises above freezing dur-
ing a long layover, drain fuel and oil tank sumps of water
(10) Unless aircraft is equipped with an auxiliary before temperature drops.
power unit, use only essential electrical equipment to
preserve battery life while taxiing at low engine speeds. 3-12. TEST FLIGHTS AND MAINTENANCE OPER-
ATIONAL CHECKS. Maintenance test flights are cat-
b. Taxiing. The following are general procedures egorized as general test flights and limited test flights.
for taxiing: Specific and mandatory requirements for accomplish-
ment of aircraft test flights and maintenance operational
(1) Only personnel authorized to taxi as speci- checks are found in Section III, TM 55-1500-328-23.
fied in AR 95-1 may taxi Army aircraft.
a. Test Flight Safety. Maintenance test flights
(2) Do not taxi aircraft on any taxiway which will be accomplished with assistance as necessary from
runs within 100 feet of active runways unless necessi- the most proficient flight crew available; i.e., copilot,
tated by terrain or directed to do so by proper authority. technical inspectors, and observers. Aviators who are
not graduates of The Aircraft Maintenance Test Flight
(3) Upon approved signal from flight compart- course may be designated as Maintenance Test Pilots
ment, approach and remove wheel chocks. Exercise upon successful completion of an evaluation admin-
caution and consideration for operating propellers, tur- istered in accordance with FM 1-544. Minimum crew
bine inlet, and exhaust areas. possible will be aboard aircraft during test flight.

(4) Use only sufficient engine power to gain b. Maintenance Operational Checks. Mainte-
rolling momentum when taxiing aircraft from a row of nance operational checks (MOCs) are accomplished
parked aircraft. When it is necessary to turn aircraft, on the ground through engine runup, aircraft taxiing or
gain required momentum in straight movement to permit use of auxiliary power or testing equipment, in such
making turn with reduced power. a manner as to simulate conditions under which the
system is to operate. The purpose of an MOC is to
(5) Under normal operations, wing guides will assure that aircraft systems or components which have
not be mandatory. However, when an aircraft is maneu- been disturbed during an inspection or maintenance
vered in proximity of other aircraft, buildings, or obstruc- action have been repaired, reassembled or adjusted
tions, or in gusty or high wind conditions, there shall be satisfactorily.
wing guides to ensure adequate guidance.
c. Carbon Monoxide Detection. Determine the
c. Postflight and Parking. The following proce- carbon monoxide concentration in aircraft after every
dures are listed to prevent abortive flights following the major overhaul. Follow the procedures and limits in the
last flight of the day, and to protect parked aircraft: instructions packed with the carbon monoxide detector.

(1) Drain oil tank sump and main oil drain before
condensation freezes.

Change 2 3-19/(3-20 blank)

 TM 1-1500-204-23-1

CHAPTER 4
AIRCRAFT STORAGE AND SHIPMENT
4-1. GENERAL. The following paragraphs provide in- Aviation Unit Maintenance (AVUM) technical manuals.
formation on the preparation of Army aircraft for ship- Authorization to take deviation from published proce-
ment and storage. dures will be obtained, in writing, from Commander,
4-2. CATEGORIES OF STORAGE. The length of U.S. Army Aviation & Missile Command, ATTN: AM-
time that the aircraft will be inactive will determine which SAM-MMC-MM-DP, Packaging & Stock Readiness
of the following categories of storage will be used. Branch, Redstone Arsenal, AL 35898
a. Flyable Storage. Flyable storage is the pre- 4-5. INSPECTION OF STORED AIRCRAFT. All air-
scribed procedure to maintain a stored aircraft in oper- craft placed in storage shall be carefully inspected at
able condition. Next to daily use, this category of stor- regular intervals of 60 days or less, depending on local
age keeps the aircraft in the best possible condition. All conditions. Stored aircraft shall be corrosion-treated if
scheduled preventative maintenance will be performed this precaution is found necessary when conducting in-
on aircraft in flyable storage, and periodic operation of spection for corrosion. Particular attention shall be given
the aircraft and all systems is required. There is no time to those areas where moisture deposits will not evapo-
limit on flyable storage. rate rapidly. Normally, corrosion will not be as prevalent
b. Short Term Storage. Short term storage is on painted surfaces as on unpainted surfaces. The com-
used to store an aircraft for a period not to exceed 45 manding officer of the storage facilities shall be respon-
days. Aircraft in short term storage require extensive sible for establishing a program of periodic inspections
preservation but very little periodic attention. of stored aircraft in addition to the prescribed inspections
c. Intermediate Storage. Intermediate storage is listed below:
used to store aircraft for a period of 46 to 180 days. a. Ensure proper preservation and ventilation of
Aircraft in intermediate storage require very extensive aircraft and take immediate action to correct all unsatis-
preservation but minimal periodic attention. factory conditions.
d. Long Term Storage. Procedures for long term b. Ensure drainage holes on underside of fuse-
storage are not available for the storage of Army air- lage, wing, center section, and control surfaces remain
craft. If storage beyond 180 days is required, the aircraft unobstructed.
will be depreserved, returned to flyable status, operated, c. When canvas covers are used for protection,
and represerved in accordance with this chapter. they shall have drainage holes installed at locations
e. Preservation of Aircraft Undergoing Mainte- where water would tend to accumulate.
nance. Aircraft undergoing AVUM/AVIM maintenance d. During hot weather, spot checks shall be made
in a hangared environment shall not be considered to among each type and model of stored aircraft to de-
be in storage. Tasks applicable to short term storage termine maximum interior temperatures encountered.
shall be performed as necessary to prevent deteriora- This shall be accomplished by hanging a standard
tion of the aircraft. Selection of the required tasks is thermometer in the interior of aircraft, and recording
at the discretion of the maintenance officer based on readings during the hottest parts of day. When temper-
local conditions. Aircraft undergoing maintenance in an ature exceeds 160°F (71°C), action shall be taken to
outside environment and aircraft stored in an outside ventilate aircraft.
environment awaiting parts shall be preserved for the
appropriate storage category as described above. e. To aid ventilation on aircraft employing as-
trodomes, astrodome may be removed and replaced
with a covered flue.
4-3. RESPONSIBILITY. The Commanding Officer
shall be responsible for initiating action to place aircraft f. Forced ventilation may be employed when
in storage in accordance with this chapter. The type of other methods of ventilation are not adequate to prevent
storage used shall be selected based on the length of sweating in interior of aircraft and resulting accumula-
time the aircraft will be inactive. tion of condensation and mildew.
g. Exterior locks, ground wires, chocks, mooring
4-4. PREPARATION OF AIRCRAFT FOR STOR- ropes, rods, and eyes shall be inspected every 30 days
AGE. When the decision is made to place aircraft in and immediately after aircraft has been subjected to high
flyable, short term, or intermediate storage, the aircraft velocity winds (exceeding 40 mph). Pulled rods or
will be prepared in accordance with the applicable

Change 4 4-1
TM 1-1500-204-23-1

deteriorated locks, ground wires, chocks, mooring d. Operational Check. Perform Maintenance
ropes, and rods shall be replaced. Operational Check (MOC) and/or Maintenance Test
Flight (MTF) as required in accordance with TM
NOTE 1-1500-328-23.
Under some conditions, corrosion may attack 4-9. SHIPMENT OF AIRCRAFT. Step by step pro-
the metal through the paint. In such cases, the cedures for the preparation, loading, tiedown, and un-
affected areas will be indicated by blisters or a loading of Army aircraft for shipment by vessel, truck,
scaly appearance of the paint. and cargo aircraft are provided in the Preparation for
Shipment Manual applicable to the aircraft. Authority
4-6. MAINTENANCE OF STORED AIRCRAFT. to take deviation from the procedures in the applicable
Precautions shall be taken to ensure that adequate Preparation for Shipment Manual must be obtained, in
maintenance will be accomplished to maintain the writing, from Commander, U.S. Army Aviation & Missile
aircraft in the proper state of preservation in accor- Command, ATTN: AMSAM-MMC-MM-DP, Packaging &
dance with applicable aircraft maintenance manual. Stock Readiness Branch, Redstone Arsenal, AL 35898
For aircraft in flyable storage, calender and dual criteria
inspections will be completed as they become due. 4-10. PRESERVATION AND PACKAGING OF AIR-
CRAFT COMPONENTS. General information on the
4-7. ENTRIES IN AIRCRAFT FORMS. When an air- preservation and packaging of Army materiel is provided
craft is placed in storage, process DA Form 2408 series by TM 746-10, Marking, Packaging and Shipment of
forms in accordance with DA PAM 738-751. Include an Supplies and Equipment: General Packaging Instruc-
entry indicating the type of storage, the date placed in tions for Field Units. Detailed information is provided by
storage, and the date represervation is due. TM 38-230-1 and TM 38-230-2, Preservation of Materiel
Preservation, Volumes I and II, respectively.
4-8. REMOVAL OF AIRCRAFT FROM STORAGE.
a. Special Reusable Containers. Preservation
When an aircraft is removed from storage, the inspec- and packaging instructions for major aircraft com-
tion and maintenance performed will be dependent on ponents that have special reusable containers are
the type of storage the aircraft has been in. contained in the applicable Aviation Unit Maintenance
a. Depreservation. Depreserve aircraft in accor- (AVUM) Technical Manual.
dance with applicable AVUM technical manuals.
b. Packaging Procedures. Aircraft components
b. Inspection. Perform preventative mainte- will normally be shipped in the same packaging the re-
nance daily inspection and all calendar and dual criteria placement component was received in. When this is
inspections that are due. not possible and assistance is required in determining
c. Maintenance. Correct aircraft deficiencies as the preservation and packaging of a specific compo-
required. nent, contact Commander, U.S. Army Aviation & Missile
Command, ATTN: AMSAM-MMC-MM-DP, Packaging &
Stock Readiness Branch, Redstone Arsenal, AL 35898.

4-2 Change 4
 TM 1-1500-204-23-1

CHAPTER 5
MARKING OF AERONAUTICAL ITEMS

5-1. GENERAL. The marking system specified in the • Unserviceable (Repairable) Tag-Materiel (DD
following paragraphs provides the means for accurately Form 1577-2) and Unserviceable (Reparable)
identifying and indicating the condition of aeronautical Label-Materiel (DD Form1577-3).
items.
• Unserviceable (Condemned) Tag-Materiel (DD
5-2. MARKING REQUIREMENTS. A single materiel Form 1577) and Unserviceable (Condemned)
condition tag shall be used to identify each aeronauti- Label-Materiel (DD Form 1577-1).
cal component, assembly, kit, or set which is assigned
a Federal Stock Number and is stocked, stored, and is- • Suspended Tag-Materiel (DD Form 1575) and
sued as a single line item of supply. However, individual Suspended Label-Materiel (DD Form 1575-1).
parts of components, assemblies, kits, or sets which are
identified and listed as single line items of supply shall • Test/Modification Tag-Materiel (DD Form 1576)
be individually tagged when physically separated from and Test/Modification Label Materiel (DD Form
the component, assembly, kit, or set. 1576-1).

5-3. MATERIEL MARKING. The following are the 5-4. METHOD OF ACCOMPLISHING ENTRIES.
only materiel condition tags and labels authorized for When initiating materiel condition tags or labels, entries
use on Army aeronautical items. These tags and la- will be made in the appropriate blocks as prescribed by
bels are in addition to applicable maintenance forms, DA PAM 738-751.
records, or tags required by DA PAM 738-751.

• Serviceable Tag-Materiel (DD Form 1574) and

Serviceable Label Materiel (DD Form 1584-1).

5-1/(5-2 blank)
 TM 1-1500-204-23-1

CHAPTER 6
APPLICATION AND REMOVAL OF DECALS
6-1. GENERAL. Decals are suitable for exterior and NOTE
interior surface application as governed by MIL-D-8634
and MIL-D-8635 respectively. Prior to application of Apply pressure lightly to permit easy removal of
decals, the following instructions shall apply to assure backing; reimmerse decals from which backing
proper adhesion: is not easily removed.

(c) Perform minor alignment with fingers,

then remove water by gently blotting decal and adjacent
Aliphatic Naphtha, TT-N-95, is extremely area with a soft, absorbent cloth. Remove air or water
flammable and toxic to eyes, skin, and res- bubbles trapped under decal by wiping carefully toward
piratory tract. Wear protective gloves and nearest edge of decal with cloth. Allow decal to dry.
goggles/face shield. Avoid repeated or pro-
longed contact. Use only in well-ventilated ar- (d) Paint area surrounding decal and outer
eas (or use approved respirator as determined perimeter of decal with a coat of oil-type varnish, TT-V-
by local safety/industrial hygiene personnel). 109. Apply varnish in a ¼- to ½-inch wide stripe to pre-
Keep away from open flames, sparks, or other vent peeling.
sources of ignition.
(2) Removal. Remove paper decals by rubbing
a. Clean all surfaces thoroughly with a clean cloth decal with a cloth dampened with Aliphatic Naphtha,
dampened with aliphatic naphtha, Federal Specification TT-N-95.
TT-N-95, to remove grease, oil, wax, or other foreign
matter. b. Vinyl Film Decals. Application and removal
procedures are explained in the following paragraphs.
b. Wipe area with a clean, dry cloth to remove
dampness and residue, then seal porous surfaces and (1) Application. Apply vinyl film decals in ac-
sand rough surfaces. cordance with the following procedures:

c. Remove excess paper and film from decals (a) Separate paper backing from plastic film.
which have trim lines.
NOTE
6-2. DECAL TYPES. Decals approved for use on
Army aircraft are of three types: paper (lacquer), vinyl Remove paper backing adhering to the adhe-
film and metal. Application and removal of decals are sive by rubbing the area gently with a clean cloth
explained in the following paragraphs. saturated with water; remove small piece of re-
maining paper with masking tape.
a. Paper Decals. Application and removal proce-
dures are explained in the following paragraphs. (b) Place vinyl film, adhesive side up, on a
clean porous surface such as wood or blotter paper.
(1) Application. Apply paper decals in accor-
dance with the following procedures:

(a) Immerse paper decals in clean water for

one to three minutes. Acetone is extremely flammable and toxic to
eyes, skin and respiratory tract. Wear protective
NOTE gloves and goggle/face shield. Avoid repeated
or prolonged contact. Use only in well venti-
Allowing decals to soak longer than three min- lated areas (or use approved respirator as de-
utes will cause the backing to separate from the termined by local safety/industrial hygiene per-
decal while immersed; allowing decals to soak sonnel). Keep away from open flames, sparks,
less than one minute will result in the backing hot surfaces or other sources of ignition.
not separating from decal.
(c) Apply acetone, in firm, even strokes, to
(b) Place one edge of decal on prepared re- adhesive side of decal.
ceiving surface and press lightly, then slide paper back-
ing from beneath decal.

Change 7 6-1
TM 1-1500-204-23-1

NOTE (a) Application. Apply metal decals with cel-

lophane-backing adhesive in accordance with the fol-
Reactivate adhesives which have dried with lowing procedures:
actetone, or equivalent, prior to installation.
Adhesive may be reactivated as many as three 1 Immerse decal in clean, warm water
times without damage to adhesive capability. for one to three minutes.
Adhesives which are reactivated will be allowed
to air-dry thoroughly before application. 2 Remove from water and dry carefully
with a clean cloth.
(d) Position decal in proper location, while
adhesive is still tacky, with only one edge contacting pre- 3 Remove cellophane backing, but do
pared surface. not touch adhesive,
NOTE
(e) Work roller across decal with overlapping
strokes until all air bubbles are removed. Apply a few drops of Aliphatic Naphtha, Federal
Specification TT-N-95, to the adhesive when
room temperature is below 72°F (22°C).

4 Position one edge of decal onto pre-

Degreasing Solvent, MIL-PRF-680, is com- pared receiving surface. On large
bustible and toxic to eyes, skin, and respiratory foil sheet, place center onto receiving
tract. Wear protective gloves and goggles/face surface and work outward from cen-
shield. Avoid repeated or prolonged con- ter to edges.
tact. Use only in well-ventilated areas (or use
approved respirator as determined by local 5 Remove all air pockets by rolling
safety/industrial hygiene personnel). Keep firmly with a rubber roller, and press
away from open flames or other sources of all edges tightly against receiving
ignition. surface to ensure good adhesion.

(b) Removal. Remove metal decals by

moistening edge of foil with aliphatic naphtha, Federal
Specification TT-N-95, and peeling decal from adhering
Aliphatic Naphtha, TT-N-95, is extremely surface.
flammable and toxic to eyes, skin, and res-
piratory tract. Wear protective gloves and (2) Paper-backing adhesive type. Application
goggles/face shield. Avoid repeated or pro- and removal of paper-backing adhesive are explained in
longed contact. Use only in well-ventilated ar- the following paragraphs.
eas (or use approved respirator as determined
by local safety/industrial hygiene personnel).
(a) Application. Apply metal decals with pa-
Keep away from open flames, sparks, or other
per backing adhesive in accordance with the following
sources of ignition.
procedures:
(2) Removal. Remove vinyl film decals by plac- 1 Remove paper backing from decal.
ing, a cloth saturated with Aliphatic Naphtha, TT-N-95,
on decal and scraping film with a micarta scraper. Re- 2 Apply very light coat of acetone, or
move remaining adhesive by wiping with a cloth damp- equivalent, to adhesive.
ened with degreasing solvent, MIL-PRF- 680.
3 Position decal in proper location while
c. Metal Decals. Metal decals come in three adhesive is still tacky with only one
types: cellophane-backing adhesive type, paperback- edge contacting prepared surface.
ing adhesive type, and no adhesive type. Application
and removal procedures for each type are explained in 4 Work roller across decal with overlap-
the following paragraphs. ping strokes until all air bubbles are
removed.
(1) Cellophane-backing adhesive type. Ap-
plication and removal of cellophane-backing adhesives (b) Removal. Remove metal decals by
are explained in the following paragraphs. moistening edge of foil with Aliphatic Naphtha, Federal
Specification TT-N-95, and peeling decal from adhering
surface.

6-2 Change 7
 TM 1-1500-204-23-1

(3) No adhesive type. Application and re- additional words or abbreviations printed on a second
moval of no adhesive are explained in the following tape adjacent to first tape or, alternatively, interposed
paragraphs. between words descriptive of main function.
(a) Application. Apply decals with no adhe- (3) Systems not referenced. A white tape with
sive in accordance with the following procedures: black lettering will be used for coding lines of systems
such as the vacuum system not referenced in figure 6-1.
1 Apply one coat of cement, Federal
Specification MMM-A-1617, to decal Table 6-1. Colors and Codes.
and prepared receiving surface.
Code
2 Allow cement to dry until both sur-
Color Specification No.
faces are tacky.
Light blue ANA Bulletin 166 501
3 Apply decal and roll down to remove
Light green ANA Bulletin 166 503
air pockets.
Light yellow ANA Bulletin 166 505
International ANA Bulletin 166 508
orange
Aliphatic Naphtha, TT-N-95, is extremely
flammable and toxic to eyes, skin, and res- Insignia red ANA Bulletin 166 509
piratory tract. Wear protective gloves and Maroon ANA Bulletin 166 510
goggles/face shield. Avoid repeated or pro-
longed contact. Use only in well-ventilated ar- Insignia ANA Bulletin 166 511
eas (or use approved respirator as determined white
by local safety/industrial hygiene personnel).
Keep away from open flames, sparks, or other Aircraft gray ANA Bulletin 166 512
sources of ignition. Gloss black ANA Bulletin 166 515

4 Remove excess adhesive with a cloth Brown Federal Standard 595 10049
dampened with aliphatic naphtha, (4) Type of tape. Aircraft tubing identification
Federal Specification TT-N-95. marker tape (non-corrosive, heat, cold and solvent re-
(b) Removal. Remove metal decals by sistant), MIL-T-9906 conforming to MS87033, shall be
moistening edge of foil with aliphatic naphtha, Federal used.
Specification TT-N-95, and peeling decal from adhering b. Solid Color Band System. This alternate sys-
surface. tem consists of the use of one, two, or three bands of
6-3. APPLICATION AND INSTALLATION OF IDEN- ½-inch wide solid colored tape wrapped on various lines
TIFICATION TAPES. The Army uses two types of iden- for identification. This system is shown in figure 6-2.
tification systems to code the plumbing lines and elec- (1) Tape colors. Colors for tapes used in this
trical conduits of aircraft. The two systems used are the system shall conform to color codes in ANA Bulletin 166
printed-symbolized tape system (the preferred method), and FED-STD-595 (refer to table 6-1).
and the solid color band, (the alternate method). Identi-
fication tapes will be applied to plumbing lines and elec- (2) Tape spacing. When more than one color
trical conduits of all Army aircraft. of tape is required, tapes shall be placed approximately
1/16 inch apart. When one color is used but more than
a. Printed-Symbolized System. This latest and one tape is required, tapes shall be placed approxi-
preferred system utilizes printed colored tape (one inch mately 1/8 inch apart.
wide) with geometrical symbols. The main function of
the line is printed on the tape. Printing will be in accor- (3) Type of tape. Type II pressure-sensitive
dance with MIL-STD-1247. Colors will be in accordance tape, A-A-113, shall be used for this system.
with ANA Bulletin 166 and FED-STD-595 (refer to table c. Application of Identification Tapes. The ap-
6-1). plication and use of both identification systems are the
(1) Colored tapes. Colored tapes as shown in same, and the following paragraphs are applicable to
figure 6-1 shall be used to identify aircraft system lines. both systems.
(2) Line content. Identification of system line
content or subsidiary functions may be indicated by

Change 5 6-3
TM 1-1500-204-23-1

THE ABOVE COLOR CODES REPRESENT DESIGNATION FOR SYSTEMS ONLY FOR CODING LINES WHICH DO NOT FALL INTO ONE OF THESE
SYSTEMS,THE CONTENTS SHALL BE DESIGNATED BY BLACK LETTERING ON A WHITE TAPE.
SUBSIDIARY FUNCTIONS OR IDENTIFICATION OF LINE CONTENT MAY BE INDICATED BY THE USE OF ADDITIONAL WORDS OR ABBREVIATIONS
WHICH SHALL BE CARRIED ON A SECOND TAPE ADJACENT TO THE FIRST OR ALTERNATIVELY INTERPOSED BETWEEN THE WORDS
DESCRIPTIVE OF THE MAIN FUNCTION.
WARNING SYMBOL TAPES. 3/8 INCH WIDE. SHALL BE APPLIED TO THOSE LINES WITH CONTENTS CONSIDERED TO BE DANGEROUS TO
MAINTENANCE PERSONNEL WARNING TAPES ARE TO BE PLACED ADJACENT TO SYSTEM IDENTIFICATION TAPES ONE BAND SHALL BE LOCATED
ON EACH TUBE SEGMENT, 24 INCHES OR SHORTER.
ONE BAND SHALL BE LOCATED AT EACH END OF EACH TUBE SEGMENT LONGER THAN 24 INCHES ADDITIONAL BANDS SHALL BE APPLIED
WHEN THE TUBE SEGMENT PASSES THROUGH MORE THAN ONE COMPARTMENT OR BULKHEAD AT LEAST ONE BAND SHALL BE VISIBLE
IN EACH COMPARTMENT OR ON EACH SIDE OF THE BULKHEAD.
PRESSURE TRANSMITTER LINES SHALL BE IDENTIFIED BY THE SAME COLORS AS THE LINES FROM WHICH THE PRESSURE IS BEING
TRANSMITTED.
FILLER LINES, VENT LINES,AND DRAIN LINES OF A SYSTEM SHALL BE IDENTIFIED BY THE SAME COLORS AS THE RELATED SYSTEM.
TAPES SHALL NOT BE USED ON FLUID LINES IN THE ENGINE COMPARTMENT WHERE THERE IS A POSSIBILITY OF THE TAPE BEING DRAWN
INTO THE ENGINE INTAKE FOR SUCH LOCATIONS, SUITABLE PAINTS, CONFORMING TO THIS COLOR CODE AHD WHICH HAVE NO DELETERIOUS
EFFECT ON THE MATERIAL USED FOR THE LINES, SHALL BE USED FOR IDENTIFICATION PURPOSES IN THESE CASES, THE GEOMETRICAL
SYMBOLS WAY BE OMITTED
AV 001903

Figure 6-1. Color-Coded Tapes

6-4
 TM 1-1500-204-23-1

Figure 6-2. Solid Color Band System

6-5
TM 1-1500-204-23-1

(1) Secondary lines. Filler, vent, and drain

lines will be identified by colors of the plumbing system
for which they function. Aliphatic Naphtha, TT-N-95, is extremely
(2) Location of bands. One band will be lo- flammable and toxic to eyes, skin, and res-
cated on each tube segment of 24 inches or less when piratory tract. Wear protective gloves and
both ends of the segment are within the same compart- goggles/face shield. Avoid repeated or pro-
ment. One band shall be located at each end of tube longed contact. Use only in well-ventilated ar-
segments longer than 24 inches. When the tube seg- eas (or use approved respirator as determined
ment passes through more than one compartment or by local safety/industrial hygiene personnel).
bulkhead, additional bands will be applied to the tube Keep away from open flames, sparks, or other
so that a minimum of one band is visible in each com- sources of ignition.
partment or on each side of the bulkhead.
(3) Tapes in engine compartment. Tapes
shall not be used on fluid lines in the engine compart- The low flash point of solvents make them a
ment where there is a possibility of the tape being drawn fire hazard, therefore, employ utmost care when
into the engine intake. When tape cannot be employed, using them. Damage may otherwise result.
suitable paints conforming to the color codes in table
6-1, and having no injurious effect on the metal used (1) Clean areas to be banded with aliphatic
for the lines, shall be used for identification purposes. naphtha, Federal Specification TT-N-95.
When paints are used, the geometrical symbols may (2) Coat exterior surfaces of metal tubing when
be omitted. necessary, with epoxy primer, MIL-P-23377, prior to ap-
(4) Warning symbol. Warning symbol tapes, plication of tape.
as shown in figure 6-1, shall be applied adjacent to (3) Install tape not having clear acetate covering
the identification tape on those lines containing fluids by tightly wrapping 1 ¼ turns of tape around the part be-
considered to be dangerous to maintenance personnel. ing banded and press firmly to ensure adhesion. Apply
Warning tapes shall be used when applicable on both one coat of clear lacquer, Federal Specification TT-L-32,
identifying systems. Warning tape shall be 3/8 inch over band and extend ¼ inch beyond tape edges.
wide.
(4) Install tape having clear acetate covering by
d. Installation of Identification Tapes. Installa- tightly wrapping 1 ¼ turns of tape around the part being
tion of identification tape consists of the following proce- marked and press firmly to ensure adhesion.
dures:

6-6 Change 5
 TM 1-1500-204-23-1

CHAPTER 7
GENERAL RECIPROCATING ENGINE MAINTENANCE

7-1. GENERAL. The maintenance instructions and b. Designation Examples. An example of radial
procedures contained in this chapter are general and engine designation is R-1820-103. The R denotes a ra-
applicable to reciprocating engines used on Army air- dial arrangement of the cylinders, 1820 denotes a to-
craft. Maintenance instructions that are specific and pe- tal of 1820 cubic inches displacement, and 103 denotes
culiar to particular engines are contained in the applica- a particular modification or characteristic of the engine.
ble maintenance manuals and will be used in conjunc- For opposed engine designations, such as IGSO-480-
tion with general information contained in this chapter. A1A6, the I denotes injected, G denotes geared output
drive, S denotes supercharged, the O denotes opposed
7-2. ENGINE TYPES AND DESIGNATIONS. arrangement of the cylinders, 480 denotes a total or 480
Reciprocating engine types and designations are ex- cubic inches displacement, and the A1A6 denotes a par-
plained in the following paragraphs. ticular modification of characteristic of the engine.

a. Types. Types of aircraft reciprocating engines 7-3. RECIPROCATING ENGINE THEORY. A recip-
used by the Department of the Army are the radial type rocating (internal-combustion) engine is a device for
and the opposed type. Radial-type engines have the converting heat energy into mechanical energy. Gaso-
crankcase in the form of a circle, as shown in figure line is vaporized and mixed with air, forced or drawn into
7-1. The cylinders extend out from the housing in the a cylinder, compressed by a piston, and then ignited by
same manner as the spokes of a wheel. Cylinders are an electric spark. The conversion of the resultant heat
arranged evenly in the same circular plane and all pis- energy into mechanical energy and then into work is
tons are connected to a 360-degree crankshaft. Op- accomplished in the cylinder. The operating cycle of
posed-type engines have cylinder banks arranged in two an internal combustion reciprocating engine, as shown
rows directly opposite each other with a crankshaft in the in figure 7-3, includes the series of events required to
center as shown in figure 7-2. Pistons are connected to induct, compress, ignite, burn, and expand the fuel-air
the single crankshaft. This type engine may be mounted charge in the cylinder, and to scavenge or exhaust
with cylinders vertical or horizontal. the by products of the combustion process. When the
compressed mixture is ignited, the resultant gases of
combustion expand very rapidly and force the piston
to move away from the cylinder head. This downward
motion of the piston, acting on the crankshaft through
the connecting rod, is converted to a circular or rotary
motion by the crankshaft.

7-4. MAJOR ENGINE COMPONENTS. Major engine

component types and maintenance are described in the
following paragraphs.

a. Crankcases. The crankcase encloses the

various mechanisms surrounding the crankshaft. The
crankcase provides a tight enclosure for the lubricating
oil and supports various external and internal mecha-
nisms. It contains the bearings in which the crankshaft
revolves and provides support for attachment of cylin-
der assemblies. Finally, it provides mountings for
Figure 7-1. Radial-Type Engine attachment to the aircraft, and by reason of its strength
and rigidity, it prevents misalignment of the crankshaft
and its bearings. The following paragraphs describe
crankcase types and general maintenance.

7-1
TM 1-1500-204-23-1

Figure 7-2. Opposed-Type Engine

(1) Types. Opposed-type and radial-type en-

gine crankcases are described in the following para-
graphs.

(a) Opposed-type crankcases. The

crankcases used on engines opposed vary in form but
in general they are approximately cylindrical. One or
more sides are surfaced to serve as a base to which the
cylinders are attached by means of capscrews, bolts, or
studs. The crankshaft is carried in a position parallel to
the longitudinal axis of the crankcase and is generally
supported by a main bearing between each throw. See
figure 7-4.

(b) Radial-type crankcases. Radial-type

engine crankcases, as shown in figure 7-5, vary in size
and number of sections. Four common sections are
described by the following paragraphs.

1 Nose section. The nose section is usu-

ally made of an aluminum alloy and is fastened to the
power section by studs and nuts or caps and screws.
Most nose sections support the propeller thrust bearing,
propeller governor drive shaft, and the propeller reduc-
tion gear assembly. Various other engine accessories
Figure 7-3. Reciprocating Engine Operating Cycle are sometimes attached.
(Four-Stroke)

7-2
 TM 1-1500-204-23-1

2 Power section. The power or main sec- crankcase web section are crankshaft bearing supports.
tion may be of one-piece or two-piece construction and Cylinder mounting pads are located radially around the
usually consists of one, two, or possibly three pieces of outside circumference of the power section. The cylin-
high-strength heat-treated aluminum-alloy or steel forg- ders are fastened to the pads by means of studs and
ing, bolted together if there is more than one piece. The nuts or cap screws. Oil seals are located between the
cam-operating mechanism is usually housed and sup- nose section and the power section. Similar seals are in-
ported by the power section. At the center of each main stalled between the power section and the supercharger
section.

3 Supercharger section. The super-

charger section is normally located immediately behind
the main power section and may be of either one-piece
or two-piece construction. Its principal function is to
house the blower or supercharger impeller and diffuser
vanes. There are openings on the outside circumfer-
ence of the housing for attaching the individual induction
pipes, a small opening for the attachment of the mani-
fold pressure line, and internal-passages which lead to
the supercharger drain valve.

4 Accessory section. The accessory

section provides mounting pads for the accessory units
such as the fuel pumps, vacuum pumps, lubricating-oil
pumps, tachometer generators, generators, magnetos,
starters, two-speed supercharger control valves,

Figure 7-4. Opposed-Type Crankcase

Figure 7-5. Radial-Type Crankcase

7-3
TM 1-1500-204-23-1

oil-filtering screens, Cuno filters, and other items of ac- The parts are the main journal, crankpin, crank cheek
cessory equipment. In some aircraft powerplants, the or crank arm, and the counterweights and dampers.
cover for the supercharger rear housing is made of an The following paragraphs describe crankshaft types
aluminum-alloy or a magnesium-alloy casting in the form and general maintenance.
of a heavily ribbed plate that provides the mounting pads
for the accessory units; but in other powerplants, the (1) Types. Opposed-type and radial-type en-
housings for the accessory units may be mounted di- gine crankshafts are described in the following para-
rectly on the rear of the crankcase. Regardless of the graphs.
construction and location of the accessory housing, it
contains the gears for driving the accessories which are (a) Opposed-type crankshaft. Atypical
operated by engine power. six-cylinder opposed-type crankshaft is shown in fig-
ure 7-6. This crankshaft is a one-piece, six-throw,
(2) Maintenance. Crankcase maintenance 60-degree crankshaft machined from an alloy-steel
consists of inspection for cracks, warping, damage to (SAE 4340) forging. The crankpins and main bearing
machined surfaces, warn bushings and bearing bores, journals are ground to close limits of size and surface
loose or bent studs, corrosion damage, and other con- roughness.
ditions which may lead to failure in service. Refer to the
applicable maintenance manual. (b) Radial-type crankshaft. Figure 7-7
shows a single-throw 360-degree crankshaft used on
NOTE single-row radial engines. It may be of single-piece or
two-piece construction with two main bearings (one on
Two-piece crankcases are manufactured with each end). This single piece crankshaft must be used
matched parts; therefore it one half must be with a master rod having the large end split.
discarded, the entire crankcase is replaced.
(2) Maintenance. Crankshaft maintenance is
b. Crankshafts. The crankshaft transforms the critical to safe engine operation. The dimensions of the
reciprocating motion of the piston and connecting rod journals, the balance, and the alignment of the shaft
into rotary motion for turning the propeller. It is a shaft must be within tolerances when inspected and mea-
composed of one or more cranks or throws. sured. The crankshaft should be inspected by the mag-
netic methods to detect flaws and defects. Refer to
the applicable maintenance manual for specific mainte-
nance procedures and tests.

Figure 7-6. Opposed-Type Crankshaft (Six-Cylinder) (Six-Throw)

7-4
 TM 1-1500-204-23-1

Figure 7-7. Radial-Type Crankshaft (Single-Throw)

c. Bearings. A bearing is any surface which sup-

ports, or is supported by, another surface. A good bear-
ing must be composed of a metal that is strong enough
to withstand the pressure imposed on it and should per-
mit the other surface to move with a minimum of friction
and wear. The parts must be held in position within very
close tolerances to provide efficient and quiet operation,
and yet allow freedom of motion. To accomplish this,
and at the same time reduce friction of moving parts so
that power loss is not excessive, lubricated bearings of
many types are used.

(1) Types. The three different types of bearings

in general use are plain, roller and ball. They are shown
in figure 7-8 and described in the following paragraphs.

(a) Plain bearings. Plain bearings are usu-

ally made of nonferrous metals, such as silver, bronze,
aluminum, and various alloys of copper, tin, or lead.
Plain bearings are generally used for the crankshaft,
cam ring, camshaft, connecting rods, and the accessory
drive shaft bearings.
Figure 7-8. Bearing Types
(b) Ball bearings. A ball bearing assembly
consists of grooved inner and outer races, one or more
(c) Roller bearings. Roller bearings are
sets of balls, and in bearings designed for disassembly,
made in many types and shapes, but the two types
a bearing retainer. They are used for supercharger im-
generally used in the aircraft engine are the straight
peller shaft bearings and rocker arm bearings in some
roller and the tapered roller bearings. Tapered roller
engines. Special deep-groove ball bearings are used in
bearings are always used in pairs. Straight roller
aircraft engines to transmit propeller thrust to the engine
nose section.

7-5
TM 1-1500-204-23-1

bearings are used where the bearing is subjected to ra- end; rebushing; and replacement of the bearings. Refer
dial loads only. In tapered roller bearings, the inner-and to the applicable maintenance manual before accom-
outer-race bearing surfaces are cone shaped. Such plishing any maintenance procedures.
bearings will withstand both radial and thrust loads.
Straight roller bearings are used in high-power aircraft e. Pistons, Pins, and Rings. Pistons, pins, and
engines for the crankshaft main bearings. They are also rings, as shown in figure 7-10, are described and main-
used in other applications where radial loads are high. tained as explained in the following paragraphs.

(2) Maintenance. Clean, inspect, and replace (1) Pistons. The piston of a reciprocating en-
bearings in accordance with the applicable maintenance gine is a cylindrical member which moves back and forth
manual. within a steel cylinder. The piston acts as a moving
wall within the combustion chamber. As a piston moves
d. Connecting Rods. The connecting rod is the down the cylinder, it draws in the fuel-air mixture. As it
link which transmits forces between the piston and the moves upward, it compresses the charge, ignition oc-
crankshaft. Connecting rods must be strong enough to curs, and the expanding gases force the piston down-
remain rigid under load and yet be light enough to re- ward. This force is transmitted to the crankshaft through
duce the inertia forces which are produced when the rod the connecting rod. On the return upward stroke, the
and piston stop, change direction, and start again at the piston forces the exhaust gases from the cylinder.
end of each stroke.
(2) Pins. The piston pin joins the piston to the
(1) Types. There are three types of connecting connecting rod. It is machined in the form of a tube from
rod assemblies, as shown in figure 7-9. The plain, fork- a nickel steel alloy forging, casehardened and ground.
and-blade, and master-and-articulated connecting rod The piston pin is sometimes called a wristpin because of
assemblies are described in the following paragraphs. the similarity between the relative motions of the piston
and the articulated rod and that of the human arm.
(a) Plain connecting rods. Plain connect-
ing rods are used in opposed engines. The end of the (3) Rings. The piston rings prevent leakage of
rod attached to the crankpin is fitted with a cap and a gas pressure from the combustion chamber and reduce
two-piece bearing. The bearing cap is held on the end to a minimum the seepage of oil into the combustion
of the rod by bolts or studs. To maintain proper fit and chamber. The rings fit into the piston grooves but spring
balance, connecting rods should always be replaced in out to press against the cylinder walls; when properly
the same cylinder and in the same relative position. lubricated, the rings form an effective gas seal. Rings
are always used in sets.
(b) Fork-and-blade connecting rods. The
fork-and-blade rod assembly is used primarily in V-type (4) Maintenance. Pistons and pins are in-
engines. The forked rod is split at the crankpin end to spected and checked for cleanliness, wear, scoring,
allow space for the blade rod to fit between the prongs. corrosion, cracks, and any apparent damage. New
A single two-piece bearing is used on the crankshaft end rings are installed each time the engine is overhauled.
of the rod. Refer to the applicable maintenance manual when
accomplishing maintenance on pistons, pins, and rings.
(c) Master-and-articulated connecting
rods. The master-and-articulated rod assembly is f. Cylinders. The portion of the engine in which
only used in radial engines. In a radial engine the the power is developed is called the cylinder. The cylin-
piston in one cylinder in each row is connected to the der provides a combustion chamber where the burning
crankshaft by a master rod. All other pistons in the row and expansion of gases take place, and it houses the
are connected to the master rod by an articulated rod. piston and the connecting rod.

(2) Maintenance. The maintenance of con- (1) Description. The cylinder used in the air-
necting rods involves visual inspection for nicks, cracks, cooled engine is the overhead valve type shown in figure
bending, corrosion, and other damage; magnetic parti- 7-11. Each cylinder assembly consists of the cylinder
cle inspection; checking alignment for parallelism and head and the cylinder barrel.
convergence between the bearing end and the piston

7-6
 TM 1-1500-204-23-1

Figure 7-9. Connecting Rod Assemblies

7-7
TM 1-1500-204-23-1

Figure 7-10. Piston, Pin, and Ring Assemblies

(2) Maintenance. Cylinder maintenance pro- tion, such as compression, fuel mixture, or ignition, must
cedures are explained in the following paragraphs. All function properly to maintain cylinder compression.
openings to a cylinder must be completely closed and
sealed during the compression and power strokes in or- NOTE
der to maintain proper compression and thus prevent
power loss. The requirements for proper sealing are: Dark stains adjacent to the cylinder head and
good piston rings with no leakage between pistons and barrel seam must not be misinterpreted. During
walls of the combustion chamber, tightly closing intake engine operation, the high temperature thread
and exhaust valves, and proper valve timing to ensure lubricant used during barrel and head assembly
highest efficiency obtainable when engine is operating may be extruded at the seam leaving a heavy
at its normal rpm. Compression loss at any of these discoloration. Such a condition is in no way
points results in reduced engine efficiency. Early de- hazardous to engine operation; therefore, ver-
tection and correction of these faults will prevent cylin- ification of cylinder failure must be by means
der breakdown. Since most engine difficulties can be other than stains alone. A cylinder should be
traced to a small number of cylinders, engine malfunc- removed for head separation only if it displays
tion can be corrected by locating defective cylinders and visible damage and/or fails the normal compres-
taking corrective action. Each phase of cylinder opera- sion test.

7-8
 TM 1-1500-204-23-1

(a) Identification. Cylinders will be color

coded around the barrel between the attaching flange
and the lower barrel cooling fin with a ½-inch wide band
of enamel, heat-stable, cadmium sulphide paint (see
figure 7-12). The cylinder sizes and colors are listed
below:

• Standard Cylinder — Aluminum or

Black

• Chrome Plated — International Or-

ange

• 0.010 Inch Oversize — Green

• 0.015 Inch Oversize — Gray

• 0.020 Inch Oversize — Yellow

NOTE

Chrome-plated cylinders are further identified

as illustrated in the following example: 6-44,
SAX-3, 20 would designate the third cylinder
plated by San Antonio Air Material Area in June
1944, and the cylinder was 0.020 inch oversize
when plated.

(b) Liquid lock. When an engine is shut

down, the warm residual oil clinging to the power section Figure 7-11. Cylinder Assembly
surfaces flows downward toward lower cylinders. Some
of this oil seeps past piston rings, accumulating in the
combustion chamber. When sufficient liquid is present,
the true compression ratio will be raised and extremely
high pressure will be produced when the piston moves
down on the compression stroke. These pressures can
damage the cylinder, piston, or rod. The piston may
actually press the liquid, forming what is known as a
hydraulic or liquid lock (see figure 7-13). Observe the
following precautions:

Do not rotate propeller in reverse direction of

normal engine rotation. This will push the liquid
into intake pipes and return to cylinders on the
next intake stroke.

• When propeller is rotating in the nor-

mal direction, the operator must be
alert for any sign of piston being
forced against high compression,
evidenced by a sudden resistance,
slowdown, or stoppage which would
indicate an excess amount of liquid
in the lower cylinder.
Figure 7-12. Marking of Cylinder

7-9
TM 1-1500-204-23-1

• Liquid locks are partial or complete. 2 Determine whether blowby has been
Hesitation in propeller rotation usu- eliminated by turning engine by hand
ally denotes a partial lock. If propeller or turning it through with starter.
stops, it usually denotes a complete
liquid lock. Forcing engine through a 3 When blowby is still present, perform
complete liquid lock will cause imme- a compression test.
diate engine failure.

• Liquid locks are also caused by oil

in intake pipes as a result of preser-
vation, fuel discharged into the in-
take system while crankshaft is not
rotating, or oil flowing from push rod
housing into rocker box, then seep-
ing through intake or exhaust valve
guides into intake or exhaust ports.

• Due to the mechanical advantage of

a long propeller blade and the fact
that two or more men per blade are
used for propeller pull-through, possi-
bility of bending a rod by manual pull-
through is more likely than by starter
pull-through. This is particularly true
when a partial liquid lock is present,
since the piston with a partial liquid
lock will be very near the top of the
stroke when force is required to rotate
the crankshaft against the liquid lock.
Liquid lock may bend the connecting
rod slightly, but not enough to move
the lower piston ring out of the cylin-
der skirt, on the downward stroke, in
which case internal failure may occur
within the next 50 hours.

• If liquid lock is suspected, remove

a spark plug from cylinder involved
and allow liquid to drain out. Turn
propeller several revolutions to make
certain all liquid has drained from
cylinder and induction lines, then in-
stall clean spark plug.

(c) Valve blowby. Valve blowby is indicated

by a hissing or whistling sound when engine is pulled
through by propellor, turned with starter, or while idling at
low speed. Correct valve blowby by first checking valve
clearance and adjust as necessary. If valve clearance
is excessive, proceed using the following procedures:

NOTE

If valve is stuck in the valve guide, correct clear-

ance cannot be determined.
Figure 7-13. Liquid Lock
1 Stake valve by placing a fiber drift on
rocker arm and valve stem, and then
drift with a hammer.

7-10
 TM 1-1500-204-23-1

NOTE 8 Determine average cylinder com-

pression values by totaling all cylin-
When adjusting clearance and staking valve der compressions and dividing total
do not correct blowby and raise compression obtained by number of cylinders. If
above minimum value as specified in the appli- any one cylinder is 20 percent below
cable maintenance manual, replace cylinder as the average, or if any one cylinder
described in applicable maintenance manual. is below the minimum compression
value for that engine, that cylinder
(d) Compression test. A cylinder compres- must be replaced.
sion test locates defective cylinders. Replacement of
these defective cylinders will prevent an unsatisfactory NOTE
condition from progressing to the point of complete
cylinder failure and eventual engine failure. Cylinders A variance of any one cylinder of 20 percent
with compression below standard shall be replaced, below the average of all cylinder compression
thus preventing the use of engines with a large variation readings of engine being checked warrants ad-
of compression between individual cylinders. ditional investigations. Two additional checks
should be made prior to any detailed work to
verify information obtained in first compression
check.

Ensure that ignition switch is placed in OFF po- 9 The following conditions may possi-
sition after engine warmup has been accom- bly affect engine compression:
plished. Damage may otherwise result.
• Incorrect valve tappet clear-
1 When engine is cold, operate it a ances
short time to ensure that cylinder
walls and piston rings are properly • Worn, scuffed, or damaged
lubricated. pistons

2 Remove one spark plug from each • Broken piston ring

cylinder and insert compression
tester. • Excessive wear of piston
rings and cylinder walls
3 Either disconnect starter booster coil • Burned or warped valves
or ground all disconnected spark plug
lead. • Carbon particle between
face and seat of valve
4 Place throttle in FULL open position;
keep fuel tank selector valve closed. • Incorrect valve timing

5 Use battery cart or auxiliary power NOTE

unit to provide power for energizing
engine starter. When a compression test on one or more cylin-
ders of any row of cylinders is needed, the com-
6 Using engine starter, crank engine at pression of all cylinders on the affected row
least four revolutions. will be tested, compression reading totaled, and
minimum compression established in the same
NOTE manner as when checking compression on all
cylinders.
The tester contains a restrictive orifice to elimi-
nate acceleration errors, and two compression
impulses are required to obtain an accurate
compression reading.

7 Analyze compression reading ob-

tained.

7-11
TM 1-1500-204-23-1

(e) Cylinders with below minimum com- 4 Operate engine at roughest speed
pression. Engines having cylinders with below between 1200 and 1600 rpm or at
minimum required compression will be processed using rpm up to ignition check speed until
the following procedures: a cylinder head temperature reading
of 302 to 338°F (150 to 170°C) is ob-
1 Remove rocker box covers on cylin- tained or until temperature stabilizes
ders with low compression. at a lower reading.

2 Turn crankshaft until piston is on top NOTE

dead center of compression stroke
and check intake and exhaust valves In cases where engine roughness is encoun-
for clearance. tered at more than one speed, or there is an
indication that a cylinder ceases to operate at
3 When valves are held open due to idle speed or higher speeds, it will be desirable
negative clearance, adjust valves to to run engine at each of these speeds and per-
proper clearance. form a cold cylinder check to pick out all dead
or intermittently operating cylinders.
4 Check for excessive leakage past pis- In cases where lower output or engine vibra-
ton by squirting engine oil into cylin- tion is encountered at speeds above 1600 rpm,
der, pulling engine through compres- when operating with ignition switch on BOTH,
sion stroke, and then checking com- engine should be run at the speed where the
pression. difficulty is encountered until cylinder head tem-
perature reaches 302 to 338°F (150 to 170°C),
5 Continue cylinder in service if com- or until temperature has stabilized at a lower
pression is up to required minimum. value.
(f) Cold cylinder check. The tendency for 5 Stop engine by moving mixture con-
any cylinders to be cold or only slightly warm indicates trol to IDLE CUT-OFF position. When
lack of combustion or incomplete combustion within the engine ceases firing, turn off both in-
cylinder. Perform this check using an approved cold dividual and master ignition switches.
cylinder indicator.
6 Measure and record relative tem-
1 Head aircraft into wind to minimize ir- peratures of each cylinder, starting
regular cooling of individual cylinders. with any cylinder and proceeding in
numerical order around engine, by
2 Open cowl flaps. pressing tip of indicator pickup rod
of cold cylinder tester against each
NOTE cylinder.
Do not close cowl flaps under any circum- NOTE
stances, as the resulting heat will affect the
readings obtained and overheat the ignition It is essential that a firm contact be made at the
leads. same relative location on each cylinder in order
to obtain temperature value. This measurement
3 Start engine. After engine is running, must be performed in the shortest possible time
place ignition switch to position where after engine ceases firing.
excessive rpm drop is obtained. In
cases where an excessive rpm drop 7 Recheck cylinders that have low val-
has occurred on both magnetos, or ues and two cylinders having high-
where excessive manifold pressure est readings to determine amount of
is obtained at a given rpm, perform cooling during check.
check twice, once on LEFT and once
on RIGHT position. 8 Compare temperature readings ob-
tained in order to determine which
cylinders are dead or operating inter-
mittently.

7-12
 TM 1-1500-204-23-1

9 Examine magneto ground leads to

determine that RIGHT switch posi-
tion fires front plugs and LEFT switch
position fires rear plugs. Make this Do not damage adjacent fins. Inadequate cylin-
examination prior to changing spark der cooling may result.
plugs, making ignition harness test on
cylinders which are operating, or are 1 Repair cracked, nicked, or broken
operating intermittently. In addition, cooling fins by profiling damaged
examine ignition leads. area using a file to smoothly round all
edges. Corners shall have at least a
NOTE ¼-inch radius and removed area nut
shall not exceed one percent of the
In cases where the cylinder is completely dead total fin area.
on the BOTH position, the difficulty may be due
to incorrect valve clearances, impeller oil seal NOTE
leaks, leaking intake pipes, or lack of compres-
sion (blowby). Magnetic or dye-penetrant inspect fins that are
profiled to outside of dome to ensure that crack
10 Repeat cold cylinder check for other does not extend into cylinder dome.
magneto positions on ignition switch
when necessary. Additional cold 2 Repair broken or loose studs in
cylinder checks will be conducted at tapped hole by using helical inserts.
different speeds in event any rough-
ness is still encountered during igni- NOTE
tion system check.
When more than two adjacent nuts are known
NOTE to have been loose during engine operation, or
when more than two adjacent studs have failed,
Cooling of the engine between checks is not cylinder will be replaced and all studs on the
necessary as airflow created by propeller and cylinder mounting pad replaced.
cooling effect of incoming fuel-air mixture into
cylinder will be sufficient to cool any cylinders 3 Place cover on a surface plate and,
which are functioning on one check and fail to using a feeler gauge, measure clear-
function on the following check. ance between surface plate and
rocker box cover mounting surface.
(g) Chalk test. The chalk test should be Refer to the applicable maintenance
used when the cold cylinder tester is not available. Test manual for allowable limits.
using the following procedures:
NOTE
1 Mark each cylinder with a piece of
Accomplish procedures 4, 5, and 6 when sur-
white marking chalk, A-A-320.
face does not meet specified limits.
2 Run engine as outlined in paragraph
4 Place a small amount of valve grind-
(e) above.
ing compound, A-A-1203, on a lap-
ping plate.
3 Examine each mark after engine
shutdown. Cylinders having marks NOTE
unchanged in color are dead or oper-
ating intermittently. The marks for a In the event no grinding compound is available,
normal operating cylinder will change a fine abrasive cloth, Federal Specification P-C-
to a pink color. 451, may be used.

(h) Cylinder repair. Cylinder repair can be

accomplished by using the following procedures as ap-
plicable:

7-13
TM 1-1500-204-23-1

5 Position rocker box cover mounting The head of each valve opens and closes these cylin-
surface down on lapping plate, and der ports. The valves used in aircraft engines are the
use a figure eight motion to keep an conventional poppet type. The valves are also typed by
even pressure on cover. their shape and are called either mushroom or tulip be-
cause of their resemblance to the shape of these plants.
6 When warpage cannot be eliminated Figure 7-14 shows various shapes and types of these
without exceeding allowable limits valves.
given in the applicable maintenance
manual, replace rocker box cover. (1) Description . The valve head has a ground
face which forms a seal against the ground valve seat
7 Replace leaking seals with like ser- in the cylinder heads when the valve is closed. The
viceable items. valve stem acts as a pilot for the valve head and rides
in the valve guide installed in the cylinder head for this
8 Replace individual piston rings that purpose. The valve stem is surface-hardened to re-
are damaged upon installation of a sist wear. The neck is the part that forms the junction
complete cylinder and piston assem- between the head and the stem. The tip of the valve
bly. Refer to illustrated parts break- is hardened to withstand the hammering of the valve
down manual of applicable engine for rocker arm as it opens the valve. A machined groove on
correct size and type ring. the stem near the tip receives the split-ring stem keys.
These stem keys form a lockring to hold the valve spring
9 Replace cracked or broken rocker retaining washer in place.
arms.
(2) Maintenance. Proper valve operation is of
10 Replace bent pushrods. vital importance to satisfactory operation of the engine
from the standpoint of stability and cylinder wear. Valve
11 Replace bent or cracked pushrod clearances establish valve timing when the engine is op-
housing. erating, and since cylinders receive fuel-air mixture from
a common supply, the valve clearances should be
(i) Cylinder replacement. Cylinders will be
replaced for the following reasons as described in the
applicable maintenance manual:

• Low compression

• High oil consumption

• Excessive valve guide clearance

• Loose intake pipe flanges

• Loose or defective spark plug inserts

(steel or brass)

• External damage, such as cracks

• Spark plug copper runout

NOTE
Engines that have spark plug copper runout on
more than 25 percent of the cylinders will be
removed from service. Carbon deposits must
not be confused with copper runout.

g. Valves. The fuel-air mixture enters the cylin-

ders through the intake valve ports, and burned gases
are expelled through the exhaust valve ports. Figure 7-14. Valve Types

7-14
 TM 1-1500-204-23-1

uniform. Temperature changes affect air-cooled en- of cracked or broken stems shall be
gines to a greater extent than other engines, and there processed for disposition in accor-
must be sufficient valve clearance to prevent valve from dance with procedures established
holding open when extreme cold is encountered, since by Part 3, Chapter XV, DOD Directive
holding open will make cold weather starting extremely 4160.21M . Disposal of these nonre-
difficult. Inadequate clearance or excessive clearance pairable valves shall be affected by
is conducive to valve failure; therefore, proper settings one of the following methods:
are essential to engine operation.
• Burial, at least 30 inches below
(a) Measuring and adjusting valve clear- ground level, in a select location
ance. When rough engine operation, backfiring, loss where future excavation is un-
of compression, hard starting, or any malfunction which likely.
can be attributed to improper operation or clearance of
valves occurs, valve clearance shall be measured and • By dumping at sea.
adjusted, using the following procedures:
2 Values determined to be suitable for
1 Measure and adjust valve clearance reclamation shall be prepared for
in accordance with specific instruc- shipment in accordance with provi-
tions contained in applicable engine sions of AR 746-1.
maintenance manual.
(c) Establishing crankshaft position using
2 Locate top dead center piston posi- top center indicator and protractor. The proper
tion. crankshaft position must be established prior to check-
ing or setting valves using the following procedures:
3 Use feeler gauge (shaped so that end
of gauge can be slipped in a straight 1 Determine ratio of top center indica-
line between valve and rocker arm tor, as shown in figure 7-15, pointer
roller or adjusting screw) specified in travel to crankshaft travel.
tools section of maintenance manual.
2 Install indicator in either spark plug
NOTE hole of number one cylinder.
Do not use excessive force to insert gauge
between valve stem and adjustment screw or 3 Adjust arm of indicator so that full
rocker arm roller. scale deflections will be obtained as
piston moves through its full stroke.
4 Adjust valve clearances found to
be out of adjustment according to 4 Install protractor and pointer speci-
specific procedures in engine main- fied in engine maintenance manual
tenance manual. on one of engine accessory drive
pads.
(b) Reclamation and disposition of
sodium-filled valves. The reclamation procedure for 5 Rotate crankshaft in normal direction
sodium-filled valves consists primarily of rebuilding the of rotation until piston is coming up on
facing of exhaust valves and repairing the stems. compression stroke.

Severe personal injury may result when

sodium-filled valves are mutilated. The metallic
sodium used in these valves, when brought into
contact with the skin (contacts moisture), gives
off highly flammable hydrogen gas.

1 Sodium-filled valves definitely deter-

mined to be nonrepairable as a result Figure 7-15. Top Center Indicator

7-15
TM 1-1500-204-23-1

NOTE

The compression stroke may be detected by a Use piston position indicator with 18mm threads
buildup of air pressure when thumb is held over for 18mm spark plug threads and 14mm threads
open spark plug hole. for 14mm spark plug threads. Damage to
threads may otherwise result.
6 Continue rotating crankshaft until
1 Remove spark plug and install piston
piston contacts arm of indicator and
position indicator, as shown in figure
moves pointer to any marker on indi-
7-16, with correct arm and calibrated
cator face.
scale.
7 Note mark reached and record pro- 2 Rotate crankshaft in direction of rota-
tractor reading. tion until piston is coming up on com-
pression stroke.
8 Move crankshaft slowly in direction of 3 Separate body from indicator assem-
rotation until indicator pointer shows bly and screw housing into spark plug
that piston has moved to top of stroke bushing until it seats firmly. Insert in-
and is going down. dicator assembly into body, as shown
in figure 7-16.
9 Stop turning crankshaft when pointer 4 Push slide pointer upward in slot until
moves to exact same position as in it reaches end of slot and is stopped
step 6. by pivot arm.
10 Read and record protractor reading in 5 Pull crankshaft slowly in direction of
degrees. rotation until arm moves pointer max-
imum distance and starts to move
NOTE back.

True top dead center is halfway between two

protractor readings.

11 Back up crankshaft and rotate it for-

ward in direction of rotation until pro-
tractor pointer indicates top dead cen-
ter (in degrees).

12 Loosen pointer and set to zero with-

out moving crankshaft.

NOTE

When reinstalling pointer, allow for gear back-

lash by moving pointer opposite its direction of
rotation.

13 Recheck top dead center position to

ensure that a given piston position will
result in equal protractor readings be-
fore and after zero mark.

(d) Establishing crankshaft position upon

piston position indicator. The following steps outline
another method of establishing the crankshaft position:

Figure 7-16. Installation of Piston Position

Indicators

7-16
 TM 1-1500-204-23-1

6 Set calibrated scale until zero mark Engines without a propeller reduction gear will have the
on scale and scribe on pointer are timing mark, a scribe mark or a pin, on the propeller shaft
aligned. and a corresponding reference mark on the surface of
the nose section next to the shaft. Refer to the applica-
7 Move pointer back to top of slot or ble maintenance manual for location of such marks.
until it contacts pivot arm.
NOTE
8 Turn crankshaft in direction opposite
When using timing marks to position the crank-
normal rotation until pivot arm returns
shaft, sight straight across the stationary pointer
to top of slot.
or mark on the nose section to the other mark.
Any angle incurred in sighting will cause error
9 Recheck zero mark of calibrated when positioning the crankshaft.
scale against reference mark on slide
pointer.
h. Accessories. Accessory units such as fuel
pumps, vacuum pumps, oil pumps, generators, alter-
10 Move slide pointer to top of slot or nators, magnetos, starters, filters, superchargers, and
until it contacts pivot arm. turbochargers are attached to the engine. Refer to the
applicable maintenance manual for specific mainte-
11 Rotate crankshaft in direction of rota- nance procedures.
tion. Movement of slide pointer by the
pivot arm will indicate crankshaft po- i. Ignition System. The ignition system must de-
sition in relation to true top dead cen- liver a high-tension spark to each cylinder of the engine
ter on the calibrated scale. in firing order at a predetermined number of degrees
ahead of true top dead center. Voltage output of the sys-
(e) Alternate methods of locating leaky in- tem must be such that the spark will jump the spark plug
take exhaust valves. Alternate methods of locating gap under all operating conditions with no tendency for
leaky intake and exhaust valves are listed in the follow- electrical leaks. Timing and replacement of parts make
ing paragraphs. up most of the ignition system maintenance.
1 Engine run test. Prior to stopping (1) Magneto system. The magneto, a special
engine, run it up to 1000 rpm and type of engine-driven ac generator, uses a permanent
move mixture control to IDLE CUT- magnetic source. The magneto develops the high volt-
OFF. The engine will turn over six age which forces a spark to jump across the spark
or more revolutions after combustion
ceases. A very slight burning of an
exhaust valve will be evidenced by a
pronounced slush from the affected
cylinder. This sound occurs each
second revolution of the engine.

2 Wheeze test. Perform wheeze test

for locating leaky intake and exhaust
valves by pulling piston to top dead
center; locate faulty valve by listening
for noise in exhaust collector or intake
duct which indicates air leaking past
respective valve.

3 Compressed air test. Admit com-

pressed air into cylinder through
spark plug hole. Restrain piston at
top of dead center. Locate leaking
valve by listening for noise in exhaust
collector and intake duct.

(f) Built-in timing marks. Some engines

have reference timing marks built into the engine, as
shown in figure 7-17. Figure 7-17. Built-In Timing Marks

7-17
TM 1-1500-204-23-1

plug gap in each cylinder. Magneto operation is timed to 4 Connect timing light and turn ignition
the engine so that a spark occurs only when the piston switches to ON position.
is on the proper stroke at a specified number of crank-
shaft degrees before the top-dead-center piston posi- 5 Apply even and equal torque to each
tion. Maintenance of magnetos consists primarily of re- of cam retaining screws in direction
placing defective magnetos or components as explained opposite normal rotation to remove
in the following procedures: gear train backlash.

(a) Prior to installation, perform internal tim- 6 While holding backlash out, turn
ing check. crankshaft until points begin to open
as indicated by timing light.
1 Check breaker point adjustments,
breaker point dwell on master cam 7 If necessary, adjust magneto so that
lobe, and distributor alignment check. timing light indicates points are begin-
ning to open at proper firing position.
2 Use reference marks on breaker cam,
distributor rotor, and magneto hous- (d) Install and time low-tension ignition sys-
ing incorporated on most assemblies tem magneto-to-engine, at a definite crankshaft posi-
to perform internal timing check. tion, using the following procedures:
(b) Time high-tension ignition system mag- 1 Depress magneto timing plunger and
neto-to-engine, at a definite crankshaft position as fol- turn magneto shaft until plunger en-
lows: gages fully in notch of magneto shaft.
1 Position crankshaft to timing or spark 2 Position magneto in place while hold-
advance position using a piston posi- ing plunger.
tion indicator.
3 If magneto does not line up with cen-
2 Align internal timing marks, and slide
terline of engine, remove magneto,
magneto into place.
release plunger, and turn magneto
drive shaft 90 degrees. Repeat un-
3 Shift magneto to retard position,
til magneto lines up properly.
and turn magneto to advance until
breaker points begin to open as indi-
cated by timing light. 4 Hold plunger depressed and turn
magneto counterclockwise on its
4 Install mounting nuts, magneto cover, flange as far as necessary to remove
and leads. gear backlash.

(c) Check timing of high-tension ignition sys- 5 Install magneto bolts securely in
tem magneto after a new magneto is installed or if incor- place.
rect timing is suspected, as follows:
(e) Check timing of low-tension ignition sys-
1 Determine correct crankshaft position tem magneto after a new magneto is installed or incor-
and check internal magneto timing rect timing is suspected.
marks.
1 Determine correct crankshaft posi-
2 Turn crankshaft one-fourth turn in op- tion.
posite direction of normal rotation.
2 Rotate engine one-fourth turn in op-
3 If magneto has an impulse coupling, posite direction of normal rotation and
rotate crankshaft in normal direction slide pointer of piston position indica-
beyond timing cylinder top-dead-cen- tor to top of scale.
ter position; when impulse coupling
clicks, rotate crankshaft in opposite 3 Turn engine in direction of rotation
direction to approximately 5 degrees until slide pointer is starting to move
advance of timing position. down.

7-18
 TM 1-1500-204-23-1

4 Depress and hold timing plunger on (b) Repair or replace defective parts as nec-
magneto, while continuing rotation of essary. Keep all parts clean and free of foreign matter.
engine, until timing plunger is fully en-
gaged. NOTE
The high-tension system manifold is never
5 See that timing indicator shows cor-
taken apart in the field, as this will destroy the
rect degree of advanced timing.
elastic gel seal.
(2) Ignition harness. The ignition harness, as
1 Clean dirt and grease from harness
shown in figure7-18, contains an insulated wire for each
by wiping with a clean, dry cloth.
cylinder that the magneto serves in the engine. One end
of each wire is connected to the distributor block and the
other end is connected to the proper spark plug. The ig-
nition harness serves a dual purpose. It supports the
wires and protects them from damage by engine heat, Cleaning Solvent, HFE-71DE, is toxic to eyes,
vibration, or weather. It also serves as a conductor for skin, and respiratory tract, and decomposes into
stray magnetic fields that surround the wires as they other hazardous products when exposed to ex-
momentarily carry high-voltage current. By conducting treme heat. Wear chemical protective gloves
these magnetic lines of force to the ground, the igni- and goggles/face shield. Avoid repeated or pro-
tion harness cuts down electrical interference with the longed contact. Use only in well-ventilated ar-
aircraft radio and other electrically sensitive equipment. eas. If ventilation is not adequate, use approved
When the radio and other electrical equipment are pro- respirator as determined by local safety/indus-
tected in this manner, the ignition harness wiring is said trial hygiene personnel. Keep away from open
to be a shield. Without this shielding, radio communica- flames, welding, or other sources of extreme
tion would become virtually impossible. The ignition har- heat.
ness check consists of a visual and an electrical check Isopropyl Alcohol, TT-I-735, is flammable and
using the following procedures: toxic to eyes, skin, and respiratory tract. Wear
protective gloves and goggles/face shield.
(a) Examine all accessible parts of distribu- Avoid repeated or prolonged contact. Use only
tors, harnesses, and leads for chafing, broken insula- in well ventilated areas (or use approved res-
tors, corrosion, moisture, damaged or dirty terminals, pirator as determined by local safety/industrial
and security of mounting at the time specified in the ap- hygiene personnel). Keep away from open
plicable maintenance manual. flames, sparks, or other sources of ignition.

2 Clean terminals with Isopropyl Alco-

hol, TT-I-735, or HFE-71DE.
NOTE
Replace ignition harness leads when more than
three wire strands are broken in one inch of
harness length or if insulation is damaged.

(c) Perform a high-voltage breakdown test

when an ignition malfunction occurs and after cable
replacement in rewireable harness or leads. Use an
approved high-voltage tester, and test for serviceability
as follows:

1 Remove all leads from spark plugs.

2 Remove spark plug elbow assembly

from ignition lead.

3 Examine lead insulation for evidence

of chafing, breaks, or holes. Replace
Figure 7-18. Ignition Harness parts as required.

Change 5 7-19
TM 1-1500-204-23-1

4 Ground all leads, except one for num- 1 Check all accessible parts of harness
ber 1 cylinder, to engine. and leads for chafing, broken conduit,
5 Connect ground lead of tester to en- corrosion, or misaligned pins in elec-
gine, and connect high-tension lead trical connectors at intervals specified
to number 1 cylinder lead. in inspection requirements manual.
6 Test and record any leakage de-
tected.
7 Test remaining leads. Do not attempt to repair harness without the
8 When two leads from same distrib- proper special tools. Damage to harness may
utor show leakage, remove ground otherwise result.
from both leads and repeat test. 2 Tighten all loose connectors and tape
When leakage is stopped by remov- over frayed sections of nylon covered
ing ground from other lead, leakage harness.
is probably between two leads (in dis- 3 Test all low tension wiring and distrib-
tributor block). When disconnecting utor blocks, connection plates, etc.,
ground of other lead does not stop for continuity. Test insulation resis-
leakage, check for leaks between tance with a tester capable of deliv-
individual leads and shielding. ering 1000 volts dc (maximum) at 1
milliampere, or an ohmmeter (20,000
ohms per volt). The insulation resis-
tance should exceed 1 megohm, un-
Cleaning Solvent, HFE-71DE, is toxic to eyes,
less otherwise specified.
skin, and respiratory tract, and decomposes into
other hazardous products when exposed to ex-
treme heat. Wear chemical protective gloves (3) Spark plugs. The function of the spark plug
and goggles/face shield. Avoid repeated or pro- in an ignition system is to conduct a short impulse of
longed contact. Use only in well-ventilated ar- high voltage current through the wall of the combustion
eas. If ventilation is not adequate, use approved chamber. Inside the combustion chamber it provides
respirator as determined by local safety/indus- an air gap across which this impulse can produce an
trial hygiene personnel. Keep away from open electric spark to ignite the fuel-air charge. For spark plug
flames, welding, or other sources of extreme service, maintenance instructions, and list of approved
heat. spark plugs, refer to TB 55-2925-200-25.

Isopropyl Alcohol, TT-I-735, is flammable and (4) Ignition switches. All units in an aircraft ig-
toxic to eyes, skin, and respiratory tract. Wear nition system are controlled by an ignition switch in the
protective gloves and goggles/face shield. cockpit. The type of switch used varies with the number
Avoid repeated or prolonged contact. Use only of engines on the aircraft and the type of magnetos used.
in well ventilated areas (or use approved res- All switches, however, turn the system off and on in
pirator as determined by local safety/industrial much the same manner. The ignition switch is different
hygiene personnel). Keep away from open in at least one respect from all other types of switches in
flames, sparks, or other sources of ignition. that when the ignition switch is in the OFF position, a cir-
cuit is completed through the switch to ground. In other
NOTE electrical switches, the OFF position normally breaks or
Rotate crankshaft to a position that will eliminate opens the circuit. The following procedures are for igni-
distributor finger leakage. tion switches general maintenance:
9 When a recheck indicates that distrib- (a) Replace defective switches and broken
utor block may be at fault, scrub thor- ground wires.
oughly with Isopropyl Alcohol, TT-I-
735, or HFE-71DE, dry thoroughly, (b) Tighten all loose switch and cable termi-
and apply a thin coat of wax. Mix nal attaching nuts.
1 part wax to 5 parts trichloroethy- (c) For specific details on any ignition switch,
lene, Federal Specification O-T-634, refer to applicable maintenance manual.
maintained at a temperature of 130 to
140°F (54 to 60°C). (5) Booster system. Starting aids such as an
10 Repeat steps 1 through 9 above. induction vibrator or booster coil must be used to provide
enough voltage to the spark plug. The induction vibrator
(d) The low-tension system operates at rela- (or starting vibrator), as shown in figure 7-19, consists
tively low voltages (150 to 400 volts) and is not seriously essentially of an electrically operated vibrator,
affected by moisture. Check system as follows:

7-20 Change 5
 TM 1-1500-204-23-1

a condenser, and a relay. These units are mounted on 1 Remove front spark plug from most
a base plate and enclosed in a metal case. The booster accessible cylinder.
coil assembly as shown in figure 7-20, consists of two
coils wound on a soft iron core, a set of contact points, 2 Turn crankshaft until piston is ob-
and a condenser. General maintenance of the booster served to be in top position on com-
system is described in the following procedures: pression stroke.

(a) Repair induction vibrators in accordance 3 Reconnect spark plug and ground
with the applicable maintenance manual and table 7-1. plug shell to engine.

(b) Replace defective booster coils and all 4 Place carburetor in IDLE CUT-OFF
broken or frayed wiring. Tighten all loose connections. position.

(c) Replace magneto if impulse coupling is 5 Place main fuel valve in CLOSED po-
defective. sition.

(d) Test ignition booster system for proper

operation as follows:

Figure 7-19. Induction Vibrator

Change 5 7-21
TM 1-1500-204-23-1

Figure 7-20. Booster Coil

7-22
 TM 1-1500-204-23-1

Table 7-1. Repairing Induction Vibrators.

Trouble Probable cause Remedy

Unit fails to function Not grounded Ensure mounting bolts contact
grounding plate.
Loose or disconnected positive cable Ensure terminal clip is secured
to positive cable and positive
terminal post.
Loose or disconnected MAG or IGN. SW Ensure both cables are secured to
TERMINALS terminal nuts with springs. Tighten
nuts until a firm contact is made
with the terminal.

Cleaning Solvent, HFE-71DE, is toxic to eyes, skin, and respiratory tract, and decomposes into other
hazardous products when exposed to extreme heat. Wear chemical protective gloves and goggles/face
shield. Avoid repeated or prolonged contact. Use only in well-ventilated areas. If ventilation is not ad-
equate, use approved respirator as determined by local safety/industrial hygiene personnel. Keep away
from open flames, welding, or other sources of extreme heat.

Isopropyl Alcohol, TT-I-735, is flammable and toxic to eyes, skin, and respiratory tract. Wear protective
gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in well ventilated areas
(or use approved respirator as determined by local safety/industrial hygiene personnel). Keep away from
open flames, sparks, or other sources of ignition.
Dirt between points Draw paper, Federal Specification
UU-P-268, dipped in Isopropyl
Alcohol, TT-I-735, or HFE-71DE,
across points and air dry.

6 Turn fuel booster pump to OFF posi- complete internal failure or expiration of operating time
tion. limits. (Refer to AR 750-23.)

7 Turn ignition switch to BOTH position. a. Expiration of Operating Time Limit. Engine
removal and replacement shall be accomplished in ac-
8 Place master ignition switch in ON cordance with TM 55-1500-328-25 when normal Maxi-
position. mum Allowable Operating Times (MAOT) are accumu-
lated in accordance with the applicable aircraft -20 main-
9 Engage starter, observing all ground tenance manual (Chapter 3, Section IV ).
safety rules.
b. Sudden Engine Stoppage. Sudden stoppage
10 Note continual flow of high voltage is defined as the complete stalling of the engine due to
across spark plug points. a propeller or rotor accident or gear box failure. Such
engines shall be replaced.
7-5. ENGINE REMOVAL CRITERIA. The life of an
aircraft engine between overhauls is dependent upon NOTE
many factors, such as quality of original manufacture or
last overhaul, the type of operation being accomplished, Replace engine when engine is stalled by pro-
and the efficiency of preventive maintenance. It is pos- peller or rotor striking an immovable object,
sible to establish a maximum expected life of an engine such as a ramp or building or when engine is
based on service records and engineering data. At over- operating at any rpm and is stalled suddenly
haul depots, it has been found that many engines are due to some internal cause such as gear box
changed needlessly. A complete investigation of the en- or crankshaft failure.
gine should be made before removal, except in cases of

Change 5 7-23
TM 1-1500-204-23-1

c. Sudden Reduction in Engine RPM. When the NOTE

propeller or rotor strikes a small object which results in
a sudden reduction in engine rpm, the engine shall be • When there is runout of more than 0.015 inch
thoroughly checked using the following procedures: full indicator reading of crankshaft or propeller
drive shaft at front cone seat location, remove
(1) Make a thorough external examination engine. Even though runout of crankshaft or
of engine crankcase and nose section to propeller drive shaft at front cone seat is less
determine whether any parts have been than 0.015 inch full indicator reading, examine
damaged. When damage is found which rear cone seat location.
cannot be corrected by line maintenance,
remove engine. • When any runout is found at rear cone seat
location, which is not in same plane as runout
(2) Remove magnetic sump plugs, if present, at front cone seat location, remove engine.
and engine oil screens or filters. Examine
for presence of metal particles. • When crankshaft or propeller drive shaft
runout does not exceed these limits, install
(3) Remove engine sump plugs, drain oil into serviceable propeller and make an additional
a clean container, strain through a clean check by tracking propeller at tip in same plane
cloth, and examine cloth and strained oil perpendicular to axis of rotation to assure that
for metal particles. blade track tolerance is within limits.
NOTE (7) Start engine and examine for smooth
• Metal particles found in the sumps or in oil operation and adequate power output.
screens or filters will not be considered the re- When engine operates properly during
sults of an internal failure caused by sudden this ground check, shut engine off and
stoppage, since the screens or filters are lo- again examine oil system for metal
cated at the oil inlet to the engine. Sudden stop- particles.
page, therefore, will not permit circulation of the
oil to the extent that metal particles would be de-
posited on the screens or filters.
• When heavy metal particles are found in the
oil, it indicates a definite engine failure, and en-
gine must be removed. However, when metal
particles present are similar to fine filings, con-
tinue examination of engine to determine its ser-
viceability.

(4) Remove propeller and examine

crankshaft, or propeller drive shaft on
reduction-gear engines, for misalignment.

(5) Clamp a test indicator to nose section of

engine and remove front or outside spark
plugs from all cylinders on radial engines
and top spark plugs on all opposed
engines.

(6) Turn crankshaft and observe if crankshaft

or propeller shaft runs out at either front
or rear propeller cone seat location, as
shown in figure 7-21. Figure 7-21. Checking Propeller Shaft Runout

7-24
 TM 1-1500-204-23-1

(8) When there are no heavy metal particles A visual inspection as to color and hardness will oc-
in engine, give engine a two hour flight casionally be sufficient to determine the kind of metal
test. present. When visual inspection does not positively
identify the metal, the kind of metal present may be
NOTE determined by a few simple tests performed with a
permanent magnet, electric soldering iron, or approxi-
When engine operated properly during flight mately 2 ounces of hydrochloric acid and nitric acid as
test, examine oil system for metal particles. If explained in the following paragraphs.
no metal is found, continue engine in service,
but examine oil screens for presence of metal
after 10 hours of operation. If no indication
of internal failure is found after 20 hours of
operations, engine requires no further special Exercise care in handling acid. Injury or death
examination. to personnel may otherwise result.

d. Metal Particles in Oil. Generally, metal parti- NOTE

cles on engine oil screens or on magnetic sump plugs
indicate partial internal failure of the engine. However, The information in this paragraph is not in-
due to the construction of aircraft oil systems, it is possi- tended to be a substitute for, nor release from
ble that metal particles may have collected in sludge in the requirement for compliance with the Army
the oil system at the time of previous engine failure; con- Oil Analysis Program (AOAP) program directed
sequently, this must be taken into account when metal in accordance with TB 55-6650-300-15.
particles are found in engine oil screens or on magnetic
sump plugs. Frequently, carbon breaks loose from the (1) Steel particle identification. Steel parti-
interior of the engine in large pieces which have the out- cles can be isolated by means of a permanent magnet.
ward appearance of metal. However, carbon can be dis-
tinguished from metal by placing the foreign material on (2) Tin particle identification. Tin particles
a flat metal object and hitting with a hammer. If material can be identified by their low melting point. A soldering
is carbon, it will disintegrate when struck with a hammer, iron should be cleaned, heated to approximately 260°C
whereas metal will either remain intact or change shape, (500°F), and thinned with 50-50 solder (50 percent
depending upon its malleability. lead to 50 percent tin). Wipe off excess solder. A tin
particle dropped on heated iron will melt and fuse with
the solder. Take care to avoid excessive overheating of
iron during this test.
An oil soaked rag can very easily cause spon-
(3) Aluminum particle identification. Alu-
taneous combustion unless placed in a tightly
minum particles may be identified by their respective
closed container, such as a quart or pint can
reaction with hydrochloric acid. When a particle of
with a press-fit lid.
aluminum is dropped into hydrochloric acid it will fizz
with a rapid emission of bubbles. The particle will grad-
NOTE ually disintegrate and form a black residue (aluminum
chloride).
Before removing an engine for suspected inter-
nal failure, as indicated by foreign matter on the
oil screens or oil sump plugs, collect all obtain- (4) Silver and copper particle identification.
able metal particles for analysis and samples. Silver and copper (or bronze) may be identified by their
To save fine metal particles, it may be neces- respective reactions in nitric acid. When a silver parti-
sary to strain the oil through a cloth. The cloth cle is dropped into nitric acid, it will react rather slowly,
and metal particles can be placed in a clean producing a whitish fog in the acid. When a particle of
metal container and sent with engine for over- copper (or bronze) is dropped into nitric acid it will re-
haul. act rapidly, producing a bright green cloud in the acid.
There is no need in this instance to separate copper from
bronze.
e. Identification of Metal Particles. Metal parti-
cles found in an engine may be of five kinds: steel, tin,
aluminum, silver, and copper (or bronze).

7-25
TM 1-1500-204-23-1

f. Significance of Metal Particles. Generally, 3 After faulty cylinders have been

when metal particles are found and kind of metal present changed or when no faulty cylinders
is determined, serviceability of engine will depend upon are found, test engine in accordance
quantity and form of metal. Granular metal particles, in with the applicable maintenance
any amount greater than a trace, require a very careful manual.
inspection of engine, as presence of these particles
is usually an indication of an impending failure. Each 4 If more than 2 additional steel flakes
kind of metal, however, must be judged individually. or 15 aluminum flakes are found dur-
Paragraphs (1) through (5) are intended as a guide in ing screen and sump inspection after
judging serviceability of engine after kind of metal has engine runup, remove engine. If less
been determined. than these quantities are found, en-
gine may be released for service in
(1) Steel particles. When steel particles are accordance with the applicable main-
found in splinter or in granular form, the engine must tenance manual.
be removed. Thin steel flakes, when found in quanti-
ties not greater than 20 flakes, may not require engine NOTE
removal. A small quantity of steel flakes will not cause Ring fuzz may be on oil sump plug of any nor-
engine bearing failure. When thin steel flakes accom- mal engine. These very fine hairlike particles
panied by aluminum flakes are found, these flakes are are the result of normal seating of piston rings
probably the result of a warped piston ring land or hole and cylinders and are not cause for any concern
burned in a piston. Replacement of a defective piston regarding serviceability of engine.
and cylinder assembly will correct the difficulty. When
not accompanied by aluminum flakes, it is possible that
(2) Tin particles. Tin in any quantity may be
steel flakes are from foreign matter introduced into en-
disregarded. Since tin is used only in plating engine
gine through oil tank.
parts and in thickness not greater than 0.0005 inch,
granular tin will not be found.
(a) Test engine in accordance with the appli-
cable maintenance manual. If more than five additional
(3) Aluminum particles. When aluminum par-
flakes are found on oil screen and sump inspection after
ticles are found, perform the following procedures:
runup, remove engine. If five or less flakes found, the
engine may be released for service in accordance with
the applicable maintenance manual. (a) When granular aluminum particles are
found, proceed as follows:
(b) When not more than 20 thin steel flakes NOTE
are found and they are accompanied by thin aluminum
flakes, proceed as follows: The presence of aluminum particles in granular
form may be an indication of piston failure.
1 Carefully inspect cylinders by visual
examination of cylinder bore and by 1 Inspect cylinders by visual examina-
compression check in an effort to lo- tion of cylinder bores and a compres-
cate faulty piston. A bright streak sion check in an effort to locate a
along cylinder barrel or any evidence faulty piston.
of scuffing would be an indication of
a warped piston ring land. Warped 2 When not more than two faulty pis-
lands are predominant in winter oper- tons are found, faulty pistons and
ations and occur most frequently on cylinder assemblies will be changed
lower cylinders. before continuing with procedure.
When more than two faulty pistons
2 When not more than two faulty cylin- are found by inspection, remove en-
ders are found, replace faulty piston gine. After faulty pistons and cylinder
and cylinder assemblies before con- assemblies have been changed, or
tinuing with procedure. When more when no faulty pistons are found,
than two faulty cylinders are found by continue with procedure.
inspection, remove engine.
3 Drain oil system, flush oil tank, and
clean oil screens.

4 Test engine in accordance with the

applicable maintenance manual.

7-26
 TM 1-1500-204-23-1

5 If not more than two additional gran- Silver is used in plating numerous other parts, and sil-
ular particles are found during screen ver flakes, not exceeding 10 in number, do not neces-
and sump inspection after runup, en- sarily indicate a part failure. Since silver is quite soft,
gine may be released for service in some small flakes will occasionally be released by nor-
accordance with the applicable main- mal working of these parts. A very small quantity of
tenance manual. silver from master rod bearings will make a large num-
ber of tiny flakes as it passes through roller bearings or
(b) When aluminum flakes are found, pro- gears within engine. Large quantities of silver flakes in-
ceed as follows: dicate an excessive loss of bearing or plating surface
and engine must be removed as a precautionary mea-
NOTE sure.

Aluminum flakes may not necessarily require (5) Copper or bronze particles. Copper or
engine removal. In winter operations, when bronze particles, in granular form and in quantities
warped piston ring lands are frequent, consid- greater than a few particles, indicate disintegration of a
erable quantities of aluminum from pistons may bushing or valve guide and engine must be removed.
be discharged into engine oil system. It will be Copper or bronze flakes, in quantities not exceeding 10
necessary to exercise judgement before contin- flakes, do not necessarily indicate part failure. Bronze
uing with the following procedure; for instance, flakes may be formed in small quantities through normal
if oil sump or screen is found chocked with a seating of bushings or valve guides. Larger quantities
mass of aluminum flakes or particles, regard- of copper or bronze flakes, however, may indicate
less of size, it will probably be necessary to re- excessive loss of bushing metal and engine must be
move engine even though faulty piston can be removed as a precautionary measure.
located.
g. Additional Metal Particles Test. This test is
1 Make a careful inspection of cylinders made to subject engine to sufficient operations to cause
by examination of cylinder bores and any additional metal in oil system to collect on oil screen
a compression check in an effort to and in main sump and also to reveal any incipient trou-
locate faulty piston. ble. This additional metal will determine whether engine
needs to be removed or allowed to continue in service.
2 When not more than two faulty pis- Test using the following procedures.
tons are found, change faulty piston
and cylinder assemblies before con- (1) Drain and flush external oil system.
tinuing with procedure. When more
than two faulty pistons are found, re- (2) Run engine to bring it to operating tempera-
move engine. If two or less faulty pis- tures and make a minimum of three power checks. (Al-
tons are found, continue with proce- low engine to cool between checks). Take care not to
dure. exceed allowable limits for ground operation.
3 Drain oil system, flush oil tank, and (3) Again remove oil screens and examine for
clean oil screen. metal accumulation. Examine main sump plug and
screen for metal accumulation. If engine is released for
4 Test engine in accordance with the service, it must be watched closely for next 25 hours for
applicable maintenance manual. any indications of malfunctions or internal failure.

5 If more than five additional aluminum h. Excessive Spark Plug Copper or Silver
flakes are found during screen and Runout. If copper runout is noted, replace cylinder
sump inspection after runup, remove from which spark plug was removed as this indi-
engine. If less than this quantity is cates the cylinder temperature has exceeded 1981°F
found, engine may be released for (1083°C). Silver runout may be caused on a fine wire
service in accordance with the appli- electrode-type spark plug if plug is subjected to preig-
cable maintenance manual. nition and/or detonation. Excessive temperature may
cause the silver spindle of the center electrode to flow
(4) Silver particles. Silver particles in granular toward the firing end of the electrode. Copper or silver
form indicate a master rod bearing failure in advanced runout indicates affected cylinders should be replaced.
stages. When these particles are found in any quantity, Engines having runout on more than 25 percent of the
remove engine. cylinders should be removed.

7-27
TM 1-1500-204-23-1

i. Low Cylinder Compression. Prior to removing

cylinders for low compression, check and adjust valve (b) Examine oil system. When examination
clearance. Check cylinder compression. Replace cylin- of oil screens or filters discloses an abnormal amount of
der when compression is less than established limits. metal particles, remove engine. When no metal parti-
cles are found, operate engine as specified.
j. Parts Failure. When some portion of a steel
part, such as a piston ring, valve, valve spring, washer, (c) When examination of engine discloses no
rocker arm, or rocker arm bearing cannot be located visible damage as a result of overspeeding, restrict air-
and removed, the engine will be replaced, so other parts craft to local flights for a period of 10 hours.
within the engine will not be damaged.
m. Excessive Manifold Pressure. Engines
k. Basic Mechanical Failure. Remove engine incorporating turbosuperchargers or auxiliary stage su-
when any internal component such as impeller, boss, perchargers are subject to excessive manifold pressure
casting, propeller shaft, or studs, become cracked, when automatic controls malfunction or fail. A manifold
nicked, broken, or damaged to the extent that safe pressure overboost control is usually employed to re-
operation cannot be continued. Failures of this type duce the possibility of overboost occurring. However,
are limited to internal components of the engine such when overboost occurs, combustion temperatures rise,
as impeller, impeller clutch, crankshaft, supercharger and detonation or preignition may result and cause se-
housing, and reduction gear housing, since external rious structural damage to the engine. When manifold
failures, such as cylinders or engine accessories, can pressure exceeds value specified in the flight manual,
be corrected by replacing the unserviceable assembly. it is considered an overboost condition and the engine
will be removed.
l. Engine Overspeed. When engine speeds ex-
ceed limits specified in the applicable maintenance man- n. Excessive Maintenance. If an aircraft engine
ual, the removal or inspection of the engine will be de- requires consistent excessive maintenance or is a defi-
pendent upon the amount of overspeed reported. When nite hazard to flight, it should be replaced, provided com-
engine speeds exceed limits, accomplish the following plete engine conditioning will not correct the difficulty.
procedures: Excessive and consistent oil fouling of spark plugs could
cause excessive maintenance. However, if fouling is
(1) When overspeed is above maximum rpm, limited to certain cylinders, the difficulty may be elim-
replace engine. inated by replacing defective cylinders, ignition leads,
distributor block, or opening-clogged rocker box drains.
(2) When overspeed is below maximum rpm,
accomplish the following: o. Excessive Oil Consumption. Oil is consumed
in the engine by being burned in the combustion cham-
(a) Examine engine for cracked, open, or ber, lost in the form of mist or vapor from the breather,
broken cylinder heads and barrels, and bent push rod or leakage where propeller shafts and other shafts pro-
housing. trude from the crankcase. Consumption varies with en-
gine power setting; however, one or more cylinders foul-
NOTE ing due to excessive oil consumption may call for cylin-
der rather than engine change.
In the event a cylinder head is cracked or broken
and no particles of pistons rings have entered (1) Oil consumption. Some of the factors
crankcase of engine (determined by inspection which affect oil consumption are engine speed, temper-
of magnetic sump plug or oil screen for metal), ature, wear condition, and lubricant characteristics such
remove damaged cylinder and piston and ex- as viscosity-temperature coefficient, volatility, and flash
amine articulating and master rods for misalign- point. Each is explained in the following paragraphs.
ment. If rods are satisfactory, replace cylinder
and piston assembly with a serviceable unit and (a) Engine speed. The most important fac-
continue engine in service as specified below. tor affecting oil consumption normally is engine speed.
Oil pressure increases with engine speed until the op-
erating range pressure of the engine is reached, then
a pressure relief valve maintains a constant pressure.
Usually, maximum pressure is reached at relatively low
speeds. The effect of engine speed on oil

7-28
 TM 1-1500-204-23-1

pressure between pump and main bearing is negligi- (d) Lubricant characteristics. An increase
ble. However, centrifugal force increases oil pressure in oil viscosity decreases oil consumption only up to the
at crankpins which increases flow through the bearings point at which the slower draining of the more viscous
and sprays more oil on cylinder walls. The rings do not oil from the cylinder wall, and tendency of the rings to
follow the cylinder as closely at higher speeds, and a ride over the oil film causes more oil to pass the piston
greater amount of oil is passed to the combustion cham- and flow into the combustion chamber.
ber instead of being scraped back to the crankcase.
(2) Aircraft range as related to oil consump-
(b) Engine temperature. High engine tem- tion. Remove an engine if oil consumption is high
perature and low oil viscosity tend to increase losses enough to limit range of aircraft. Variations in oil system
of oil from crankcase seals and breathers. Oil loss capacity of different aircraft causes maximum oil con-
increases due to increased blowby, or gas flow, past sumption to vary according to type aircraft and type of
piston rings at higher engine speeds. Blowby raises mission being performed (see figure 7-22).
crankcase pressure and forces oil or oil vapor out of the
crankcase. 7-6. ENGINE CONDITIONING. Engine conditioning
provides a standard method for detecting engine mal-
(c) Engine wear. Engine wear in the form functioning prior to development of serious trouble and
of worn bearings increases clearance and allows in- establishes a systematic routine for keeping the engine
creased oil loss. Worn pistons and cylinders provide in condition to provide maximum trouble-free perfor-
space for thicker oil films and increase loss due to mance. The types of engine conditioning are complete
failure of rings to seal. engine conditioning and minor engine conditioning.

Figure 7-22. Oil Consumption Chart

7-29
TM 1-1500-204-23-1

a. Complete Engine Conditioning. Complete It forms a long curved channel which conducts air
engine conditioning is a complete investigation of the and fuel-air mixture to the supercharger section. The
condition of an engine and correction of any difficulty channel consists of an air scoop, temperature control-
detected. Complete engine conditioning will be given ling device, and a thermometer. General maintenance
engines being overhauled with the exception of idle procedures are explained in the following paragraphs.
mixture and speed, fuel, oil, and water pressure adjust-
ments, and final check and adjustment of the engine a. Inspection, Maintenance, Cleaning, and Re-
after the engine is installed on the aircraft. Perform this placement. Perform the following procedures for
conditioning using the instructions contained in table general inspection, maintenance, cleaning, and re-
7-2. placement of air induction system components:

b. Minor Engine Conditioning. Minor engine (1) Check induction system for foreign matter
conditioning is the investigation and correction of any and articles to prevent such items from damaging im-
malfunction revealed during flight or through the cock- peller or clogging air passages.
pit checks (daily, intermediate, and complete cockpit
checks). Perform the following procedures for minor (2) Install flexible channel, joining certain types
engine conditioning: of induction systems together, in such a manner to pre-
vent flexible channel from being sucked down and re-
(1) Perform a complete cockpit check (steps 6 stricting air flow.
through 14, table 7-2) when a new engine is installed,
when an aircraft is removed from storage, at each major (3) Correct leaks in induction systems soon as
and minor inspection, and when minor conditioning fails possible after detection, as fuel-air mixture will be ad-
to correct a malfunction. The engine cockpit check will versely affected.
be handled in the following manner:
(4) Clean air filters at intervals specified in ap-
(a) Record all readings on cockpit check plicable maintenance manual using the following proce-
sheet as shown in figure 7-23. dures:

(b) File form in aircraft flight log folder for fu-

ture reference by both maintenance and flight person-
nel.
Degreasing Solvent, MIL-PRF-680, is com-
NOTE bustible and toxic to eyes, skin, and respiratory
tract. Wear protective gloves and goggles/face
The daily check will be carried out by the air shield. Avoid repeated or prolonged con-
crew and will only be recorded in the flight log tact. Use only in well ventilated areas (or use
when performance is unsatisfactory. The ser- approved respirator as determined by local
viceability of the engine is established by the air safety/industrial hygiene personnel). Keep
crew by comparing its readings against those away from open flames or other sources of
recorded on the complete cockpit check made ignition.
by the maintenance crew.
(a) Immerse filter in degreasing solvent, MIL-
(2) Perform steps 6 through 13, 15, and 17, ta- PRF-680, and agitate to remove all imbedded dirt parti-
ble 7-2. cles.

(3) Perform intermediate check after last flight (b) Drain by placing on a 25-degree angle
of day. The check may be made any time after the last draining rack and allowing to dry thoroughly.
flight of the day and before the next flight by either the
air crew or maintenance personnel. Any difficulties en- (c) When completely dry, immerse filter in
countered during flight are corrected at this time. The a mixture of 1 part corrosion-preventive compound,
intermediate check is outlined in steps 12 through 15 MIL-C-5545, and three parts lubricating oil, MIL-L-6082,
and 17, table 7-2. The readings obtained are recorded Grade 1120, at a temperature of 70°F (21°C) for 2 to 5
in the flight log only when engine performance is unsat- minutes.
isfactory.

7-7. AIR INDUCTION SYSTEM. The air induction

system supplies air to the carburetor or master control.

7-30 Change 5
 TM 1-1500-204-23-1

Table 7-2. Engine Conditioning Table

Complete conditioning When Personnel

steps Procedure performed responsible
Step 1. Ignition System Time all phases of ignition. This Complete Maintenance
Timing includes breaker point-to-magneto timing, Conditioning
magneto-to-engine timing, and, distributor
finger-to-engine timing.
Step 2. Compression Test Test cylinder compression. Complete Maintenance
Conditioning
Step 3. Valve Adjustment Check valves and adjust clearances Complete Maintenance
if necessary. Visually inspect valve Conditioning
mechanism.
Step 4. Ignition Harness Check ignition harness for high voltage Complete Maintenance
Check leakage. Conditioning
Step 5. Spark Plug Install new or reconditioned set of spark Complete Maintenance
Installation plugs. Conditioning
Step 6. Check for Hydraulic Pull propeller through to determine whether Complete Maintenance
Lock combustion chambers are clear. Conditioning
Cockpit Check Air Crew
Daily Check Air Crew
Step 7. Blowby Check While performing step 6, listen for an Complete Maintenance
extended hissing sound from exhaust stack Conditioning
or stacks.
Cockpit Check Air Crew
Daily Check Air Crew
Step 8. Engine Start Start Engine. Complete Maintenance
Conditioning
Cockpit Check Air Crew
Daily Check Air Crew

7-31
TM 1-1500-204-23-1

Table 7-2. Engine Conditioning Table — Continued

Complete conditioning When Personnel

steps Procedure performed responsible
Step 9. Engine Warmup Warm up engine at smoothest specified Complete Maintenance
rpm, oil pressure permitting. Continue Conditioning
warmup until normal operating
temperatures are obtained as indicated by Cockpit Check Air Crew
green arc on gauges. Daily Check Air Crew
Step 10. Power Check Set engine at specified rpm setting. Allow Complete Maintenance
engine and instruments to stabilize. Conditioning
Manifold pressure readings for different Cockpit Check Air Crew
engines of the same type and model
installed on the same type aircraft should Daily Check Air Crew
not vary over 1 inch Hg at a given rpm
when checks are performed at the same
geographical location.
A higher than normal manifold pressure
indicates engine is not operating properly.
In case of high manifold pressure, take
manifold pressure readings at several
lower rpm settings to establish rpm
manifold pressure pattern for engine.
See performance chart for rpm-manifold
pressure relationships for current aircraft.
Step 11. Ignition System After completing step 10, perform Step 17. Complete Maintenance
Conditioning
Cockpit Check Air Crew
Daily Check Air Crew
Step 12. Cruising Mixture Set engine speed at rpm specified in Complete Maintenance
Check performance chart with mixture control in Conditioning
AUTO-RICH position. After engine and
instruments have stabilized, move mixture Cockpit Check Air Crew
control to AUTO-LEAN and observe Daily Check Air Crew
rpm change. Return mixture control to
AUTO-RICH position. A change of rpm,
other than that allowed in performance
chart, indicates an excessively rich or lean
carburetor or master control or fuel injection
lines leaking.

7-32
 TM 1-1500-204-23-1

Table 7-2. Engine Conditioning Table — Continued

Complete conditioning When Personnel

steps Procedure performed responsible
Step 12. Cruising Mixture Check valve for nozzle not holding, pumps
Check - continued not synchronized, vapor vents stuck, low
cylinder head temperature, or improper
spark plug gap. On carburetor engine, idle
adjustment will cause rich or lean mixture.
Step 13. Idle Speed Check Close throttle completely. Engine should Complete Maintenance
idle at specified rpm and cylinder head Conditioning
temperature of 150 to 170°C (302 to 338°F)
if equipped with individual exhaust stacks Cockpit Check Air Crew
or at lower specified rpm if equipped with Daily Check Air Crew
an exhaust collector ring.
Intermediate Air Crew or
Maintenance
Step 14. Idle Mixture Check Check idle mixture and adjust mixture and Complete Maintenance
speed. Conditioning
Cockpit Check Air Crew
Daily Check Air Crew
Intermediate Air Crew or
Maintenance
Step 15. Acceleration and Perform acceleration and deceleration Complete Maintenance
Deceleration Check checks. If turbosupercharger is installed, Conditioning
check with turbosupercharger off.
Cockpit Check Air Crew
Daily Check Air Crew
Intermediate Air Crew or
Maintenance
Step 16. Engine Backfire Because of the nature of this test, it Complete Maintenance
Test should be conducted only after prescribed Conditioning
inspection periods or when trouble is
encountered. Conduct test with cylinder
head temperatures not less than 180°C
(356°F) and not more than maximum
allowable for engine involved.

7-33
TM 1-1500-204-23-1

Table 7-2. Engine Conditioning Table — Continued

Complete conditioning When Personnel

steps Procedure performed responsible
Step 16. Engine Backfire Place turbosupercharger in OFF position.
Test - continued Carburetor air filters should be by passed.
Set engine at specified rpm setting. Move
carburetor mixture control to AUTO-LEAN.
Move ignition switch from BOTH to RIGHT
and then to LEFT for a sufficient length
of time in each position to permit engine
operation to stabilize. When moving
ignition switch from BOTH TO RIGHT or
LEFT, a high rmp drop will normally occur.
If the engine does not backfire from either
switch position, it is considered satisfactory
in this test. If it backfires, one or more
phases of engine operation are not correct.
Step 17. Ignition Switch Set engine speed at specified rpm. Complete Maintenance
Check Momentarily move ignition switch to OFF Conditioning
and determine that engine completely
ceases firing. Return switch to BOTH as Daily Check Air Crew
rapidly as possible to eliminate possibility of Intermediate Air Crew or
backfiring. Check master switch same way. Maintenance
Step 18. Spark Plug Check Make cold cylinder check. Replace only Complete Maintenance
defective plugs and repeat steps 6 through Conditioning
16.

7-34
 TM 1-1500-204-23-1

Figure 7-23. Engine Conditioning Cockpit Check Sheet

7-35
TM 1-1500-204-23-1

(d) Place filter on a 25-degree angle draining NOTE

rack in a room where temperature is 70°F (21°C) and
allow to drain for 2 to 4 hours. Drain accordion-pleated Exhaust ducts, waste gates, nozzle boxes, and
filters for 8 hours. turbines are subjected to extremely high tem-
peratures. For this reason, cracks develop be-
(e) When necessary, use forced draining af- cause of the continued expansion and contrac-
ter gravity draining has been accomplished by using a tion of the metal as temperature changes occur.
1/16-inch orifice and 100 psi air temperature.
7-8. EXHAUST SYSTEM. The exhaust system con-
(5) Adjust carburetor air doors so they operate ducts exhaust gases from the engine to the atmosphere
freely through full range of travel or to position selected with minimum exhaust back pressure. Short exhaust
as specified in applicable maintenance manual. stacks are incorporated on some engines, while others
join a collector ring which expels exhaust gases through
(6) Replace damaged intake pipes. Detect a tail pipe. Perform the following general maintenance
leaks in intake pipes by presence of fuel stains at cylin- procedures on exhaust systems:
der impeller end. When leakage is found after 25 hours
of operation (since new), loosen intake pipe packing a. Check ball joints for excessive or insufficient
nuts. Replace any defective packing and retighten nuts. clearances, and retighten or replace ball joints as nec-
essary to obtain free movement.
NOTE
b. Replace all parts that have hot spots or damage
Do not tighten packing nuts without loosening beyond repair.
and examining the packing first.
c. To prevent exhaust port studs from seizing, and
b. Turbocharger and Supercharger Mainte- to retard corrosion, apply a special lubricant as follows:
nance. Visual inspection of all visible parts should
be accomplished daily to observe oil leaks, exhaust (1) When engine or cylinder is removed or
leaks, cracks in the metal of hot sections, loose or installed, apply light coating of 10 percent molybde-
insecure units, and other unacceptable conditions. num disulphide lubricant, MIL-M-7866, and 90 percent
Refer to the applicable maintenance manual for specific grease, MIL-G-3545, to threads of cylinder exhaust port
maintenance procedures. Ensure the following items studs.
are checked.
(2) To retard corrosion of nuts, apply this mix-
• Mounting of all units ture to exterior of exhaust port stud nuts.
• Oil leaks or dripping from any unit
d. Tighten all nuts, bolts, and clamps in exhaust
• Security of oil lines system in accordance with maintenance manual for en-
gine involved.
• Security and condition of electric wiring
7-9. CARBURETION AND FUEL INJECTION. Fuel
• Cracks in ducting and other metal parts in- is metered to the engine at a predetermined ratio to air-
cluding the turbine and housing flow by the fuel metering system. Fuel metering systems
differ in design, but their function is the same, regardless
• Warping of metal ducts of type or engine model. Improper maintenance of the
fuel metering system will result in rough engine perfor-
• Operation of the complete system to deter- mance, detonation, spark plug fouling, low power out-
mine performance to discover undesirable put, poor acceleration, and engine or part failure.
sounds, and to note evidence of vibration;
unusual sounds and appreciable vibration a. Inspection. Inspect carburetors for mounting
require removal and replacement of the tur- flange cracks and evidence of leakage and fuel strainers
bocharger to correct the faulty condition. for foreign matter broken screens, corrosion, and distor-
tion.

7-36
 TM 1-1500-204-23-1

b. Depreservation. Carburetors are depreserved (2) When difficulty is encountered with PD and
to make them operational after they have been pre- PR series injection-type carburetors, attributed to stick-
served for extended storage. Observe the following ing or binding of automatic mixture control unit, clean
precautions: unit as follows:

• Depreserve float-type carburetors which

do not employ diaphragms by flushing float
chamber with the type of fuel used to op-
erate applicable engine, then drain oil and Degreasing Solvent, MIL-PRF-680, is com-
fuel mixture from float chamber. Flush until bustible and toxic to eyes, skin, and respiratory
all trace of preservative oil is removed. tract. Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged con-
• Depreserve diaphragm-type carburetors by tact. Use only in well ventilated areas (or use
draining oil from fuel chambers and pas- approved respirator as determined by local
sages and flushing with fuel. Fill carburetor safety/industrial hygiene personnel). Keep
with type of fuel to be used to operate appli- away from open flames or other sources of
cable engine. Soak diaphragm for at least ignition.
8 hours. This restores fuel diaphragms to
normal operating condition. (a) Remove unit from carburetor, being care-
ful not to remove seal or lockwire or loosen siphon lock-
c. Adjusting Idle Mixture and Idles Speed. If an ing nut.
engine will not respond to idle mixture and speed adjust-
ment, it is an indication that some other phase of engine (b) Wash bushing with Degreasing Solvent,
operation is incorrect. Adjust idle mixture and idle speed MIL-PRF-680.
using the following procedures:
(c) Dry thoroughly with compressed air.
(1) Make idle mixture adjustments with oil and
cylinder head temperatures at normal values. (d) Polish bushing sleeve with crocus cloth,
Federal Specification P-C-458, until it is bright.
(2) Back idle speed stop off so that idle speed is
controlled during adjusting procedure by manually con- (e) Blow out any polishing dust that tends to
trolling throttle. cling to inside walls.

(3) Retard throttle to designated rpm.

(4) Screw idle mixture in or out in small incre-

ments as required until proper idle mixture is estab- DELETED
lished.
(f) Clean needle with Degreasing Solvent,
(5) After each idle mixture adjustment, increase MIL-PRF-680, and dry with compressed air.
power to field barometric pressure for approximately 1
minute to clean intermittent firing spark plugs caused by (g) When needle is corroded, clean with De-
excessively rich or lean mixture. greasing Solvent, MIL-PRF-680, dry with compressed
air, polish with crocus cloth, Federal Specification P-C-
(6) Set idle speed stop to desired rpm. 458, and lubricate with grease molybdenum disulfide
MIL-G-21164.
d. Repair or Replacement. Repair or replace
carburetor using the following procedures: (h) Reassemble and install lockwire or seal,
if broken.
(1) When improper operation of float-type car-
buretor is suspected, perform a test by manually leaning
mixture with mixture control or by enriching mixture by
use of primer. Replace complete unit when changes in
rpm, other than those within allowable limits, resuit.

Change 5 7-37
TM 1-1500-204-23-1

(3) All components of PS series injection type (4) Connect all lines.
carburetor are self-contained in one assembly. Any dif-
ficulty that cannot be corrected by adjusting idle mixture (5) Tighten mounting bolts in accordance with
or speed or unplugging vapor bleed requires replace- limits specified in maintenance manual.
ment of carburetor.
(6) Tighten and lockwire all other nuts and bolts.
e. Preservation. When carburetors are removed
for placement of storage or for rework, they should be (7) Check throttle and mixture control lever for
preserved using the following procedures: freedom of movement; connect linkage.

(8) Remove lockwire from throttle valves.

Exercise care to keep the preservative oil out (9) Ensure that vapor vent lines are free from
of the air chambers of the regulator unit, and obstructions.
from contacting the air metering portion of the
carburetor, including the main venturi, impact 7-10. REMOVAL AND INSTALLATION OF RECIP-
tubes, and automatic mixture control. Damage ROCATING ENGINES. Preparation for removal,
to carburetor may otherwise result. preparation for installation, and installation of reciprocat-
ing engines are explained in the following paragraphs.
(1) Remove drain plugs from bottom of fuel
chamber on float-type carburetors and drain out all a. Preparation for Removal. The following
fuel. With drain plugs reinstalled, fill float chamber with preparations should be made prior to removing engines:
lubricating oil, MIL-L-6081, Grade 1010.
(1) Provide personnel with maintenance man-
(2) Drain fuel and air chambers and fuel control ual, aircraft log book, and, when applicable, DA Form
unit by removing drain plugs on PD and PR series in- 2410.
jection-type carburetors. Replace plugs to air chambers
and inject lubricating oil, MIL-L-6081, Grade 1010, (un- (2) Provide proper special tools, hoist, and en-
der 10 to 15 psi regulated pressure) until fuel outlet on gine stand for engine as given in maintenance manual.
fuel control unit shows oil seepage. Remove drain plugs Provide ground support equipment and hand tools.
and allow excess oil to drain out. Reinstall drain plugs.
(3) Provide working area wrth drip pans, fire
(3) Remove drain plugs from main fuel chamber extinguishers, and NO SMOKING signs. Provide oily
on PS series injection-type carburetors and force lubri- waste cans, Federal Specifications RR-C-114, for stor-
cating oil, MIL-L-6081, Grade 1010, into fuel inlet at 8 age of all rags used for cleaning engine components
to 10 psi until oil seeps from fuel discharge nozzle. Re- and wiping up fuel and oil.
move drain plug on bottom of main regulator assembly
and allow all excess oil to drain. Reinstall drain plug. (4) Ensure that aircraft is properly grounded and
chocked and battery is disconnected. Remove neces-
f. Installation. Install carburetors using the follow- sary cowling.
ing procedures:
b. Removal. Remove engine from the aircraft in
(1) Remove all burrs and gasket particles from accordance with basic instructions given herein and in
carburetor and engine mating surfaces. the specific engine maintenance manual.

(2) Cover fuel lines, subject to contamination by (1) Preserve engine in accordance with para-
foreign matter, with masking tape, Federal Specification graph 7-12 .
PPP-T-42.
(2) Disconnect all control rods and cables, mag-
(3) Place carburetor on engine; close and se- neto conduits, fuel and oil lines, thermometer tubes,
cure throttle valves in closed position with lockwire. tachometer shafts or wires, and like connections.

7-38
 TM 1-1500-204-23-1

(3) Remove propeller, or clean propeller control (3) Attach main oil line to oil pump inlet, then
systems, depending on condition or time in service. connect oil scavenge line, oil tank vent line, oil pressure
gauge line, and any other required oil lines.
(4) Drain fuel from metering system and con-
necting lines to eliminate fuel spillage during removal. (4) Connect and adjust throttle control and car-
buretor air heater control.
(5) Remove remote fuel pump adapters,
propeller hub attaching parts, starters, ignition ana- (5) Install and adjust propeller governor and
lyzer synchronizer, generators, vacuum pumps, air control.
pumps, hydraulic pumps, propeller governors, and
engine-driven fuel pump. (6) Install propeller. Tighten retaining nut to
specified torque value.
(6) Forward engine accessories to depot in sep-
arate containers. (7) Connect, check, and safety any other lines
and controls which are required on the aircraft.
(7) Install cover plates and plugs in engine and
accessory openings. Plug or cap all lines disconnected (8) Accomplish depreservation run in accor-
to accomplish engine removal. dance with paragraph 7-13.

(8) Review TB 55-1500-328-25 for determina- (9) Lubricate exhaust port studs and nuts.
tion of accessories to accompany engine.
7-11. ENGINE MOUNTING SYSTEMS. The engine
(9) Lubricate exhaust port studs and nuts. mounting system consists primarily of an engine mount
and vibration dampers. The basic engine mount con-
c. Preparation for Installation. In addition to the sists of a welded chrome-molybdenum steel tubing
preparations outlined in paragraph a, the following ex- structure rigid enough to carry forces imposed by the
aminations must be made prior to installation: engine. Vibration isolators or dampers are used to
eliminate the transmission of excessive vibration from
(1) Examine any fuel, oil, or hydraulic lines for the engine to the aircraft structure. Perform the fol-
serviceability. Particular emphasis should be given to lowing procedures for general maintenance of engine
all lines that run through firewall. mounting systems:

(2) Ensure that all disconnected lines, hoses, a. Visually inspect engine mounting system in ac-
control rods, cables, and wiring on firewall are in appro- cordance with applicable inspection requirements man-
priate position required for connection to engine. ual.

d. Installation. Procedures to be followed in in- NOTE

stalling the engine will vary according to type of engine
and aircraft involved and whether or not a power pack- When rubber parts of isolators must be cleaned
age is used. The general procedure contained herein to establish their physical condition, use soap,
and in the specific engine maintenance manual will ap- A-A-50, and water only.
ply.
b. Repair of engine mounting system is limited to
(1) Swing engine into position with a suitable the following steps:
hoist and install engine mounting bolts. Tighten mount-
ing bolts to specified torque value. (1) Repair distorted, bent, cracked, or chafed
areas.
(2) Connect magneto ground wire, install prop-
erly prepared carburetor, and connect fuel lines.

7-39
TM 1-1500-204-23-1

NOTE (5) Secure all loose metal components to the

container with tape, PPP-T-60, to prevent a possible
Excessive damage requires replacement. spark during shipment.

(2) Tighten loose mountings to obtain torque b. Preservation of Operable Engines to be Re-
values specified in maintenance manual. moved for Overhaul. Engines to be removed from
aircraft for overhaul, that can be operated without fur-
(3) Repair or replace vibration isolators that ther damaging the engine or any of its parts, shall be
show any evidence of radial slippage. preserved using the following procedures:

(4) Properly secure all engine mount retaining

bolts with safety wire.

(5) Replace vibration isolators when metal or While injecting the preservation compound,
rubber parts indicate sagging or deterioration. be sure none of the compound is injected into
airstream of the carburetor or master control.
Do not inject the compound upstream of the
7-12. PRESERVATION OF RECIPROCATING EN-
throttle valve. Damage may otherwise result.
GINES. Corrosion of aircraft metals and alloys is
primarily a light against moisture. There are two main
types of surface corrosion; direct chemical attack on (1) Drain oil system and refill with corrosion pre-
metal, and electrochemical action in which the metal ventive MIL-C-6529, Type II.
being corroded becomes a part of an electrolytic cell
NOTE
in the presence of moisture. Both reactions are effec-
tively retarded in the absence of moisture. Corrosion Type II corrosion preventive consists of a ready
will not occur in a clean atmosphere when moisture mixed blend of 1 part corrosion preventive, MIL-
is not permitted to reach the metal surface. Preserve C-6529, Type I and 3 parts new lubricating oil,
reciprocating engines using the following paragraphs. MIL-L-6082, Grade 1100.
a. Preservation of Accident-Involved Engines. (2) Prior to starting engine for final run, connect
Engines removed from an aircraft that has been involved discharge nozzle.
in an accident in which engine failure or malfunction is
known or suspected to have been a factor should not be NOTE
treated with corrosion protective. No attempt should be
made to operate, motor, or disassemble an accident-in- Discharge nozzles shall conform to designs set
volved engine. All accident-involved engine must be forth in figure 7-24 and be modified in length
transported to an overhaul depot or a designated in- and thread configuration to suit engine type and
vestigation area within 10 days after the accident. The point of application.
accident-involved engine shall be preserved using the
following procedures: (3) Locate nozzle in a position so that corrosion
preventive mixture is properly distributed to all cylinders.
(1) Without disconnecting lines or fittings, make Modify nozzle discharge are to provide sufficient restric-
every effort to prevent remaining fuel and oil in engines tion to prevent exhausting corrosion preventive supply
from leaking out. prior to cessation of engine rotation.

(2) Plug all ports and cap all fittings and lines. NOTE
Seal openings with applicable covers.
For radial engines, precautions shall be taken to
(3) Install engine in bottom half of metal, ensure that the quantity of mixture aspired and
reusable shipping and storage container. the location employed provides an even amount
of coating for both upper and lower cylinders.
(4) Ground engine to container to prevent a pos-
sible explosion of dangerous vapors which may be ig-
nited by static electricity or a spark.

7-40
 TM 1-1500-204-23-1

Figure 7-24. Discharge Nozzle for Corrosion Preventive Mixture

(4) Thermostatically control corrosion pre- (b) With engine operating at 1500 rpm, re-
ventive supply tank to maintain corrosion preventive, lease corrosion preventive mixture through nozzle. As
MIL-C-6529, Type II at a temperature of 221 to 250°F soon as white smoke appears at upper cylinder exhaust
(105 to 121°C). stacks for radial engines and at all stacks for opposed
engines, move mixture control to IDLE CUT-OFF posi-
(5) Connect an air pressure line providing 60 to tion and allow engine to stop. Continue aspiration of
80 psi dry compressed air to the tank. Mixture capacity mixture until engine ceases to fire.
of the tank will be as follows:
(7) Drain preservation mixture from oil system
• One quart for engines up to 1340 cubic while engine is warm, exercising care to keep corrosion
inch displacement. preventive mixture clean for future use.
• Two quarts for engines up to and includ- (8) Clean filter and screen and coat with corro-
ing 2000 cubic inch displacement. sion preventive mixture and reinstall.
• Three quarts for engines up to 3350 cu- (9) When rocker box covers have been re-
bic inch displacement. moved for any reason, rocker box interior shall be
treated as follows:
(6) Make final engine run with oil system ser-
viced with corrosion preventive as follows: (a) Drain oil from each rocker box from which
cover is removed.

(b) Spray-coat rocker arms, valve stems,

At no time will engine be operated in excess of springs, push rods, rocker box covers, and rocker boxes
1500 rpm while the oil system is serviced with with corrosion preventive, ML-C-16173, Grade 2.
corrosion preventive mixture. Damage may oth-
erwise result.

(a) Operate engine on service fuel for a pe-

riod of 15 minutes.

7-41
TM 1-1500-204-23-1

(c) Reinstall covers with new gaskets and (17) Seal breather openings with oil and mois-
tighten holddown nuts to values specified in applicable ture-resistant covers, dehydrator plugs, or pressure sen-
engine maintenance manual. sitive tape, Federal Specification PPT-60.

NOTE (18) Perform dehydration of intake manifold as

follows:
The above rocker box preservation procedures
are mandatory for all 0-435 series engines. (a) Secure carburetor throttle valve in open
position with lockwire.
(10) Spray interior of each cylinder with corro-
sion preventive, MIL-C-6529, Type II maintained at a (b) Install one 16-unit bag of desiccant, MIL-
temperature of 221 to 250°F (105 to 121°C). Spray as D-3464, in intake.
follows:
(c) Seal openings with moisture-resistant
(a) Spraying shall be accomplished with pis- covers or barrier material, MIL-B-121, Grade A, secured
ton at bottom dead center. Spray cylinders in sequence with pressure sensitive tape, Federal Specification
of firing order. Continue in this manner until all cylinders PPP-T-60.
are sprayed.

Do not turn protective cap during installation

The crankshaft must not rotate after final spray- or removal as damage may occur to contact
ing as preservation coating will be scraped from spring.
cylinder walls.
(19) Protect spark plug lead terminals by in-
(b) Final-spray cylinders without rotating stalling applicable protective cap.
crankshaft.
(20) Preserve magnetos by applying oil to cam,
(c) Install cylinder dehydrator plugs, spring, and other steel pads. Seal all external openings
MIL-I-6131, Type II, in each spark plug opening. with pressure sensitive tape, Federal Specification PPP-
T-60.
(11) Spray interior of exhaust ports and seal in-
dividuals ports with applicable exhaust port plug. NOTE

(12) Preserve carburetors in accordance with Keep oil from breaker points.
approved preservation procedures.
(21) Install a crankcase dehydrator plug.
(13) Remove thrust bearing cover plate
and spray-coat bearing with corrosion preventive, (22) Install engine in a metal shipping container
MIL-C-6529, Type II. Reinstall cover. as follows:

(14) Coat exposed propeller shaft with corro- (a) Place preserved engine in a serviceable
sion preventive, MIL-C-16173, Grade 2 wrap propeller container in accordance with instructions supplied with
shaft with barrier material, and MIL-B-121, Grade A, container.
when applicable plastic cylinder protector is not avail-
able. (b) Close container and tighten closure bolts
to proper torque.
(15) Seal oil line fittings with plugs conforming
to MIL-C-5501.

(16) Remove cover plates from all accessory

drives and spray-coat all drives with corrosion preven-
tive, MIL-C-6529, Type II. Reinstall all cover plates.

7-42
 TM 1-1500-204-23-1

Use only dehydrated air with a maximum rela- Use dehydrated air with a relative humidity of
tive humidity of 30 percent for pressurizing ship- 30 percent for all spraying operations. Damage
ping containers in order to keep humidity as low may otherwise result.
as possible in the air surrounding the engine.
(2) Spray exhaust valves with corrosion preven-
(c) Pressurize container to 5 psi with dehy- tive, MIL-C-6529, Type II. Spraying shall be through ex-
drated air. haust port with exhaust valves fully open.

(d) Retighten engine container flange nuts to NOTE

original torque after 1 hour elapsed time.
Engines with collector rings may be sprayed
(e) After container has been pressurized, use through spark plug ports with exhaust valves
soapy water to check for leaks. If a second pressure fully open.
check in 24 hours does not indicate a leak, engine is
ready for storage or shipment. (3) Place and secure two 8-unit bags of desic-
cant, Military Specification MIL-D-3464, in carburetor air
(f) Maintain all markings and stencils on ship- intake scoop or carburetor adapter.
ping container intact without additions or deletions.
(4) Cover open end of scoop with a suitable an-
c. Preservation of Inoperable Engines. Engines chored, barrier paper, MIL-B-131.
that cannot be operated and are to be removed from air-
craft shall be treated as far as practicable as shown in (5) Firmly attach a red cloth streamer to bags
paragraph 7-11b. Spray all possible interior surfaces, as containing desiccant and bring loose end out in such a
the engine will be shipped or stored without the protec- manner that not less than 18 inches of cloth streamer will
tion afforded it by a final operation using a corrosion-pre- be visible on outside of carburetor air intake scoop. In
ventive compound in the lubrication system. An appro- order to prevent streamer from action as a wick, a 3- to
priate entry shall be made on DA Form 2408-16 and DD 4-inch length of lockwire shall be left between streamer
Form 1577-2, stating inability to accomplish preserva- and desiccant
tion run of the engine. DA Form 2408-5 also will be
sent with the, engine, if applicable. DA Form 2410 will (6) Install 16 units of desiccant, MIL-D-3464, in
be completed and mailed in accordance with DA PAM exhaust outlet on engines incorporating an exhaust col-
738-751. lector ring. Place a total of four units of desiccant in ex-
haust openings on engines that do not have an exhaust
d. Intermediate Storage of Engines Mounted on collector ring.
Aircraft. Intermediate storage shall be completed
within 24 hours after ground runup. When it is not (7) Firmly attach a red cloth streamer to bags
definitely known that the aircraft will be operated within containing desiccant and bring loose end out a minimum
45 days, the engine shall be preserved for intermediate of 18 inches. Use a 3- to 4-inch length of lockwire be-
storage and an entry shall be made on the applicable tween cloth and desiccant to prevent streamer from act-
DA Form 2408 series stating this work has been ac- ing as a wick.
complished. The procedure for intermediate storage
is the same as previously outlined in paragraph 7-11 b (8) Seal all openings, joints, drain holes, and
with the following additional procedures: outlets with barrier material, MIL-B-121, and secure with
pressure sensitive tape, Federal Specification PPP-T-
(1) Drain fuel from engine-driven fuel pump 60.
and flush interior with lubricating oil, MIL-L-6081, grade
1010, while rotating engine crank-shaft. Seal fuel lines
with suitable plugs.

7-43
TM 1-1500-204-23-1

(9) Use following procedure as alternate

method of exhaust sealing: (2) Engines undergoing repair or inspection that
cannot be operated shall be pulled through by hand or
(a) Remove exhaust stacks at cylinder outlet. starter at least eight revolutions on the third day of idle-
ness.
(b) Install cylinder exhaust outlet cover be- NOTE
tween exhaust stack opening and exhaust stack flange.
A ground runup shall be accomplished on the
NOTE seventh day of idleness. When runup can-
not be accomplished on the seventh day, the
Engines with individual exhaust stacks have crankshaft shall be pulled through and cylin-
stacks removed and a cylinder exhaust outlet ders sprayed as outlined in paragraph 7-11b.
cover installed between exhaust stack flange Storage of aircraft engines in this manner shall
and cylinder exhaust outlet. not exceed 14 days.

(c) Fabricate covers locally. (3) Upon conclusion of a ground runup on en-
gines in flyable storage, make entries on applicable DA
(10) Seal all openings such as distributor vents Form 2408-13.
and engine breathers with moisture proof plugs and
covers. Pressure sensitive tape, Federal Specification NOTE
PPP-T-60, (red) may be used.
Check the applicable aircraft maintenance man-
ual for specific instruction pertaining to Flyable
(11) Cover all engines installed on aircraft using
Storage.
engine covers furnished with aircraft. Provide lower por-
tion of cover with a drain hole to prevent accumulations
7-13. DEPRESERVATION OF RECIPROCATING EN-
of water.
GINES. The instructions contained in this section shall
be followed prior to making the initial start to newly in-
(12) Locally fabricate placard for engines with stalled engines and engines installed in aircraft being
propellers installed, and conspicuously display placard removed from temporary and indefinite storage, regard-
on propeller blade. Placard shall have following infor- less of time in storage.
mation:
DO NOT TURN PROPELLER ENGINE PRESERVED NOTE
IN ACCORDANCE WITH APPLICABLE MAINTE-
NANCE INSTRUCTIONS Newly installed engines shall be given a dep-
reservation run as soon as possible, but not
e. Flyable Storage. Engine installed on aircraft later than 4 hours after preoiling has been ac-
which will not be flown for an indefinite period of time, but complished. If more than 4 hours has elapsed
are maintained in a flyable status or undergoing short- since preoiling engine, complete preoiling pro-
term maintenance, shall be treated as follows: cedure shall again be accomplished.

(1) Engine serviced with normal lubricant shall a. Preoiling. Proper preoiling lubricates internal
be given a ground runup each third day of idleness. gears and bearings, expels air from internal oil pas-
sages, and averts internal engine failures due to lack
NOTE of lubrication. Accomplish preoiling either indoors or by
applying engine preheat prior to preoiling when oper-
The runup consists of engine operation at a ating in temperature below 0°F (-18°C). For preoiling
speed greater than idle for a period of 5 min- engines on aircraft using the diverter-segregator oil
utes or until highest allowable oil inlet temper- system, it is necessary to follow special instructions
ature is attained. Every 14 days a 15-minute contained in applicable aircraft maintenance manual.
normal ground preflight shall be accomplished. Preoil using the following procedures:

7-44
 TM 1-1500-204-23-1

NOTE
(2) Preoil engine by one of the following meth-
Engines need not be preoiled after oil change or ods:
after oil system components have been discon-
nected for normal maintenance. However, af-
ter oil change or after disconnecting oil system
components located in the system between oil Devices having heating elements in direct con-
tank and engine oil pump, it will be necessary tact with preoiling mixture or oil shall not be
to disconnect oil inlet line at the pump and drain used. Damage may otherwise result.
a sufficient amount of oil from the line to deter-
mine there is no obstruction or air in the system.
(a) Preoil engine having a dry sump-type oil
system using a pressure tank.
(1) Prepare engine for preoiling as follows:
(b) Preoil engine having a wet sump by rotat-
(a) Service oil tank, oil sump, or crankcase ing crankshaft with starter and utilizing normal engine oil
with engine oil specified in applicable maintenance man- supply and oil pump to provide pressure.
ual.
(3) Provide suitable viscosity by heating and
(b) Provide an external power source. maintaining lubricant used for preoiling at a temperature
between 110° to 175°F (38° to 80°C) when using preoil-
(c) When spark plugs have been installed, ing equipment incorporating provisions for heating.
remove one spark plug from each cylinder to reduce When preoiling with engine oil pump or with equipment
load on starter. not incorporating a heating element, dilute lubricant,
at a temperature lower than 30°F (-1°C), with gasoline
(d) Place engine controls in following posi- in accordance with percentage calculated from chart
tions, as applicable: shown in figure 7-25. Mix thoroughly prior to preoiling.

(4) Preoil O-series engines by servicing oil sys-

Ignition switch OFF tem with grade oil specified for engine, and the turn en-
Throttle gine through with starter until oil pressure is indicated on
OPEN
aircraft oil pressure gauge.
Mixture control IDLE CUT-OFF
(5) Preoil all radial engines as follows:
Fuel shutoff valve OFF
Oil shutoff valve OPEN

(e) Provide suitable containers of approxi- Do not energize starter over 15 seconds. Allow
mately 5 gallons capacity to catch oil that drains from starter to cool after each energizing. Damage
sumps during preoiling operation. to starter may otherwise result.

(f) On engines which utilize crankcase (a) Prime oil pump by removing applicable
breathers and which are equipped with a hydromatic plug and rotating crankshaft with starter until all air is ex-
propeller, remove plug from propeller dome and pour pelled from vent and a steady flow of oil is coming from
a sufficient amount of preoiling lubricant into dome to vent. Reinstall plug.
bring lubricant level to plug hole. Reinstall and safety
the plug in propeller dome. NOTE

NOTE On engines not having a plug, disconnect oil in-

let line and allow sufficient oil to drain to assure
This step is not required for engines having air in the line is eliminated.
propeller shaft breathers, reversible-type pro-
pellers, or engines not equipped with hydro- (b) Remove drain plugs from front and rear
matic propellers. sumps on installations having sumps in these locations.

7-45
TM 1-1500-204-23-1

Figure 7-25. Percent Dilution Versus Temperature for Grade 1100 Oil

(c) Connect preoiler to preoiling fitting. NOTE

(d) Rotate engine with starter and commence Newly installed engines will be given an initial
preoiling until oil is flowing freely from sump plug holes start as soon as possible, but not later than 4
and pressure is indicated on oil pressure gauge in air- hours after preoiling has been accomplished.
craft. When any period of time in excess of 4 hours
has elapsed since engine was preoiled, com-
(e) Cease operation and replace sump plugs. plete preoiling procedure shall again be accom-
plished before attempting initial start of engine.
(f) Remove rocker box covers from number
one cylinder or both top covers on double row engines b. Depreservation Run. The depreservation run
and continue preoiling until oil is obtained from all rocker eliminates the necessity of removing or draining intake
arms that have been removed. pipes prior to installation of engine in the aircraft. Per-
form depreservation run using the following procedures:
(g) Disconnect preoiler and reinstall all parts
removed.

7-46
 TM 1-1500-204-23-1

NOTE
(4) Start engine and run at 800 to 1500 rpm for
Newly installed engines shall be given a dep- 30 seconds to 1 minute. Operation may be accom-
reservation run as soon as possible, but not plished on either primer or carburetor, or both, to obtain
later than 4 hours after preoiling has been ac- smoothest possible operation.
complished. If more than 4 hours has elapsed
since preoiling engine, complete preoiling pro- NOTE
cedure shall again be accomplished.
• Normally, smoothest engine operation is ob-
(1) Prior to starting engine, remove one spark tained at higher engine speeds and a higher
plug from each cylinder below the horizontal centerline air velocity through intake pipes will result. In
of engine. Refer to TB 55-2925-200-25 for proper spark cases where extreme cold temperatures exist,
plugs to be utilized during depreservation run. engine to be started should be preheated prior
to starting and should be allowed to run longer
NOTE than the 1-minute period, provided excessive vi-
bration is not encountered.
On seven-cylinder engines which would neces-
sitate removal of spark plugs from four cylin- • Corrosion-preventive compound, if present
ders, thereby resulting in excessively rough op- in intake pipes, will have adequate time to be
eration, the one cylinder below the horizontal heated and flow from intake pipes through ex-
centerline on right side of engine when viewing ternal drain or into combustion chamber and
engine at propeller end may be left operative. be expelled into exhaust system or through
This permits operation of four cylinders rather depreservation valve.
than three, which greatly stabilizes engine op-
eration. (5) Stop engine by closing throttle and discon-
tinuing use of primer or by moving mixture control to
(2) Install approved depreservation valve in IDLE CUT-OFF position.
each open plug hole.
(6) Install spark plugs, ignition leads, engine
NOTE cowling, etc., and proceed to start engine using pre-
scribed starting procedures outlined in the applicable
Install length of hose on each depreservation flight manual.
valve to vent large quantities of oil overboard.
This eliminates a fire hazard and accumulation NOTE
of oil around cylinder or baffles.
Spark plugs used for depreservation runs shall
(3) All spark plug leads, except those removed be replaced with new or overhauled spark plugs
to permit installation of depreservation valves, will re- before placing the engine in service.
main connected to spark plugs. Install metal shipping
caps to disconnected leads.

NOTE

The metal shipping caps ground out the ignition,

thereby eliminating excessive voltage buildup
in the magneto and possibility of flash-over at
terminal end of ignition lead.

7-47/(7-48 blank)
 TM 1-1500-204-23-1

CHAPTER 8
GENERAL TURBINE ENGINE MAINTENANCE

8-1. GENERAL. The maintenance instructions and a. Regularly police parking areas, runways, taxii-
procedures contained in this chapter are general and ap- ways, and runup and exhaust areas to ensure against
plicable to turbine engines used on Army aircraft. Main- the presence of foreign objects which could enter the
tenance instructions that are specific and peculiar to par- engine. Special attention shall be given to cleaning of
ticular engines are contained in the applicable mainte- cracks and expansion seams in hard surfaced areas
nance manuals and will be used in conjunction with gen- where engines will be operated, as tests have indicated
eral information contained in this chapter. that these are the main source of foreign objects which
are ingested.
8-2. ENGINE TYPES AND DESIGNATIONS.
Turbine engine types and designations are explained in b. Periodically instruct personnel concerned with
the following paragraphs. aircraft maintenance of foreign object hazards to ensure
that maximum preventive measures are taken.
a. Types. Types of aircraft turbine engines are the
centrifugal-flow and axial-flow turbine engines. Centrifu- c. Ensure that air inlet and tailpipe dust excluders
gal-flow engines, as shown in figure 8-1, compress the are installed at all times when engines are not being
air by centrifugal force. The air enters the air inlet and operated, except when it is known the engine will again
is directed to the compressor inducer vanes through cir- be operated immediately following shutdown.
cumferential inlets located in front and back of the im-
peller. Axial-flow engines, as shown in figure 8-2, com- d. Prior to each engine start, thoroughly inspect
press the air axially. The air enters the air inlet and flows and clean inlet ducting. Remove all loose nuts, bolts,
in a relatively straight path in line with the axis of the en- tools, or other objects which would cause engine dam-
gine. age and possible subsequent failure.

b. Designation Examples. On gas turbine en- e. After work has been accomplished, inspect to
gine designations, such as T53-L-1, T denotes gas ensure that all accessories and attaching parts are se-
turbine with drive shaft, numeral 53 is assigned to the cure and that work areas are cleared of foreign objects
engine by the services, L denotes the manufacturer, prior to engine operation.
and 1 denotes major modification.
f. Provide properly marked receptacles (FOD
8-3. TURBINE ENGINE THEORY. The gas turbine cans) in all work areas into which trash, ferrous and
engine is a type of internal combustion engine that nonferrous scrap, safety wire, etc., may be placed.
produces power by a continuous and self-sustaining
process of compression, combustion, expansion, and g. Adhere to applicable gas turbine-powered air-
exhaust. Air is compressed in the compressor section, craft taxiing and parking procedures as outlined in appli-
mixed with atomized fuel and burned in the combustion cable technical bulletins. This minimizes damage due to
chambers. As the fuel burns, the resultant gases ex- objects being thrown by the exhaust blast into the intake
pand through turbine wheels to convert heat energy to of other aircraft.
useful power.
h. Ensure that gas turbine-powered aircraft take-
8-4. TURBINE ENGINE PRECAUTIONS. The off and landing procedures are such as to avoid the in-
following precautions shall be observed during mainte- take of foreign objects blasted from runways and runway
nance of turbine engines: shoulders by preceding aircraft.

i. Use inlet duct runup screens during all ground

operations, including taxiing to and from takeoff position,
with the following exceptions:

• Inlet duct runup screens are not required

on aircraft using centrifugal flow engines.

Change 3 8-1
TM 1-1500-204-23-1

Figure 8-1. Centrifugal-Flow Engine

Figure 8-2. Axial-Flow Engine

8-2
 TM 1-1500-204-23-1

• When necessary to properly evaluate en- Personnel shall adhere to following precautionary mea-
gine performance or when icing conditions sures:
exist, inlet duct runup screens should be
removed. Runup with screens removed • Change clothes daily.
shall be made in a designated, thoroughly
cleaned area. • When possible, gloves shall be worn. Wash
or change gloves daily.

• Hands shall be thoroughly washed before

Inlet duct runup screens shall not be installed eating, drinking, smoking, or using toilet.
and removed with engines operating above idle
rpm. Loose items of clothing shall not be worn. • Scrub body thoroughly each day.
Objects which might be drawn into the intake
ducts shall not be carried when installing or re- 8-5. TURBINE ENGINE DESIGN AND CONSTRUC-
moving screens. Damage to equipment may TION. A typical turbine engine consists of an air inlet,
otherwise result. compressor section, combustion section, turbine sec-
tion, exhaust section, accessory section, and the nec-
• Inlet duct runup screens may be left off essary systems for starting, lubrication, fuel supply, and
during taxiing to and from takeoff position auxiliary purposes, such as anti-icing, cooling, and pres-
when requirements or existing conditions surization. The major components of all turbine engines
make the use of screens impractical. Since are basically the same; however, the nomenclature of
specific conditions warranting removal of the component parts of various engines currently in use
screens as specified above cannot be pre- will vary slightly due to the difference in manufacturer
determined, specific conditions may be terminology. These differences are reflected in the ap-
determined by each command as neces- plicable maintenance manuals.
sary to conduct their operation. Approval
of screen removal should include any ad- a. Inlet Ducts. There are two basic types of inlet
ditional precautions necessary to assure ducts, the single entrance and the divided entrance duct.
safe operation of engine. Single entrance inlet ducts are used with axial-flow en-
gines, as shown in figure 8-3, to obtain maximum ram
j. Use only nonmetallic-head hammers when re- pressure through straight flow. Divided entrance inlet
quired to install parts on engine. ducts, as shown in figure 8-4, provide the opportunity to
diffuse the incoming air so it enters the plenum chamber
k. When possible, use appropriate hoist or lifting with the low velocity required to utilize a centrifugal-flow
yoke on heavy or bulky pads, such as tailpipes. engine. Inlet ducts may be classified as:

l. Tighten jack screws, attaching screws, bolts, • Nose inlets, located in the nose of the fuse-
and nuts in small increments on opposite planes. lage or powerplant pod or nacelle.

• Wing inlets, located along the leading edge

of the wing, usually at the root for single-
engine installations.
Lead poisoning is an accumulative disease that
can be fatal. Preventive rather than curative • Annular inlets, encircling, in whole or in
measures shall be stressed. part, the fuselage or powerplant pod or
nacelle.
m. A turbine engine that has operated on fuel
containing tetraethyl lead may have a yellow powder on
• Scoop inlets, which project beyond the im-
mediate surface of the fuselage or nacelle.
those sections that are exposed to combustion gases:
for example, tail pipes and combustion chambers. • Flush inlets, which are recessed in the side
Extreme care shall be used by all personnel handling of the fuselage, powerplant pod, or nacelle.
such parts to prevent internal contamination of the body
through open cuts, sores, or inhaling.

8-3
TM 1-1500-204-23-1

Figure 8-3. Single Entrance Inlet Duct (Axial-Flow Engine)

Its primary functions is to supply air in sufficient quantity

to satisfy the requirements of the combustion burners.
The compressor must increase the pressure of the mass
of air received from the air inlet duct and then discharge
it to the burners in the quantity and at the pressure re-
quired. A secondary function of the compressor is to
supply bleed-air for various purposes in the engine and
aircraft.
(1) Centrifugal-flow compressor. The cen-
trifugal-flow compressor consists basically of an impeller
(rotor), a diffuser (stator), and a compressor manifold,
as shown in figure 8-6. The compressor achieves its
purpose by picking up the entering air and accelerating
it outwardly by centrifugal action.
(2) Axial-flow compressor. In the axial-flow
engine, the air is compressed while continuing in its
Figure 8-4. Divided Entrance Inlet Duct
original direction of flow, thus avoiding the energy loss
(Centrifugal-Flow Engine)
caused by turns. From inlet to exit the air flows along
b. Particle Separators. Particle separators, as an axial path and is compressed at a ratio of approxi-
shown in figure 8-5, prevent foreign particles from mately 1.25:1 per stage. The axial-flow compressor has
entering the compressor section of turbine engines. two main elements, a rotor and a stator, as shown in fig-
Air enters the engine through the swirl frame. Swirl ure 8-7. The rotor has blades fixed on a spindle. These
vanes direct the air into a rotating or swirling pattern. blades impel air rearward in the same manner as a pro-
Sand, dust, and other foreign objects are separated peller because of their angle and airfoil contour. The
by centrifugal action. These objects are carried to the rotor, turning at high speed, takes in air at the com-
outer section of the main frame and into the scroll case. pressor inlet and impels it through a series of stages.
Particles are drawn from the scroll case by the blower The action of the rotor increases the compression of the
and are blown out the aircraft discharge duct. The air at each stage and accelerates it rearward through
relatively clean air that remains after particles are sep- several stages. With this increased velocity, energy is
arated is carried to the front frame deswirl vanes, which transferred from the compressor to the air in the form
straighten the air flow before it enters the compressor of velocity energy. The stator blades act as diffusers
inlet. at each stage, partially converting high velocity to pres-
c. Compressor Section. The compressor sec- sure. Each consecutive pair of rotor and stator blades
tion of a turbine engine has many functions. constitutes a pressure stage. The number of rows of
blades (stages) is determined by the amount of air and
total pressure rise required. The greater the number of
stages, the higher the compression ration.

8-4
 TM 1-1500-204-23-1

Figure 8-5. Particle Separator

d. Diffuser Section. The diffuser increases the Can-Type. The can-type combustion is typical of
compressor discharge area and reduces the speed of the type used on both centrifugal and axial-flow engines.
the centrifugal impeller airflow, causing the air pressure Figure 8-8 illustrates the arrangement for can-type com-
to increase. This pressurized air is directed to the bustion. The engine combustion cans are numbered in a
combustor through the diffuser case. The diffuser case clockwise direction facing the rear of the engine with the
mounts on the rear flange of the compressor stator. No. 1 can at the top. The can-type combustion consist
It directs compressor discharge air to the combustion of an outer case or housing, which is perforated stain-
chamber. less steel (highly heat resistant) (See Figure 8-9).

e. Combustion Section. The combustion section f. Turbine Section. The turbine transforms a por-
houses the combustion process, which raises the tem- tion of the kinetic (velocity) energy of the exhaust gases
perature of the air passing through the engine. This into mechanical energy to drive the compressor and ac-
process releases energy contained in the air-fuel mix- cessories. This is the sole purpose of the turbine and
ture. The major part of this energy is required at the tur- this function absorbs approximately 60 to 80 percent of
bine to drive the compressor. The remaining energy cre- the total pressure energy from the exhaust gases. The
ates the reaction or propulsion and passes out the rear turbine assembly consists of two basic elements, the
of the engine in the form of a high-velocity jet. The lo- stator and the rotor, as does the compressor unit. These
cation of the combustion section is directly between the two elements are shown in figure 8-10.
compressor and the turbine sections. The combustion
chamber is always arrange coaxially with the compres-
sor and turbine regardless of type, since the chambers
must be in a through-flow position to function efficiently.

8-5
TM 1-1500-204-23-1

Figure 8-6. Centrifugal-Flow Compressor Components

g. Exhaust Section. The exhaust section of a tur- (1) Governors. The speed-sensitive control
bine engine is made up of several components, each of and speed-set governor are discussed in the following
which has its individual functions. Although the com- paragraphs.
ponents have individual purposes, they also have one
common function: they must direct the flow of hot gases (a) Speed-sensitive control. The speed-
rearward in such a manner as to prevent turbulence and sensitive control, as shown in figure 8-11, is mounted
at the same time impart a high final or exit velocity to the on the tachometer pad of the accessories housing. It
gases. contains three switches which are actuated at certain
speeds by a flyweight system. During a start, one
h. Accessory Section. The accessory section of switch turns on the fuel and ignition, parallels fuel
a turbine engine has various functions. The primary pump elements, energizes the starting fuel enrichments
function is to provide space of the mounting of acces- system when fuel enrichment switch is on, and closes
sories necessary for operation and control of the en- the drip valve. Another switch shuts off the ignition,
gine. Generally, it also includes accessories concerned deenergizes the drip valve (which is then held closed
with the aircraft, such as electric generators and fluid by fuel pressure), and shifts the fuel pumps from par-
power-pumps. Secondary functions include acting as allel to series operation. Still another switch shifts the
an oil reservoir and/or oil sump, and housing the acces- temperature datum control from start limiting and limits
sory drive gears and reduction gears. the temperature datum valve to a certain reduction of
engine fuel flow.
i. Governors and Fuel Controls. Governors and
fuel controls used on turbine engines are explained in
the following paragraphs.

8-6
 TM 1-1500-204-23-1

(b) Speed-set governor. The speed-set

governor, as shown in figure 8-12, controls the po-
sition of the governor servo. It is a centrifugal, per-
manent-droop type governor driven by the engine
high-speed rotor (N2) through a gear train. As engine
speed increases, the fly-weights tend to move outward,
lifting the speed set pilot valve. Conversely, when en-
gine speed decreases, the fly-weights move inward and
the pilot valve is lowered. The power lever in the cockpit
positions the speed-setting cam in the fuel control unit
to manipulate a system of levers and thus control the
compression of the speeder spring. The speeder spring
exerts force on the speed-set pilot valve. The condition
of on-speed indicates the speeder spring force and the
flyweight force are equal.

(2) Fuel controls. Fuel controls can be divided

into two basic groups: hydromechanical and electronic.
The fuel control senses power lever position, engine
rpm, either compressor inlet pressure or temperature,
and burner pressure of compressor discharge pressure.
These variables affect the amount of thrust that an en-
gine will produce for a given fuel flow.

(a) Hydromechanical fuel controls.

Hydro-mechanical fuel controls are extremely compli-
cated and are composed of speed governors, servo
systems, sleeve and pilot valves, feedback or follow up
devices, and metering systems.

(b) Electronic fuel controls. Electronic fuel

controls contain the same items as the hydro-mechani-
cal fuel control as well as amplifiers, thermocouples, re-
lays, electrical servo systems, switches, and solenoids.

Figure 8-7. Rotor and Stator Components of an

Axial-Flow Compressor

Figure 8-8. Can-Type Combustion Chamber Arrangement

8-7
TM 1-1500-204-23-1

Figure 8-9. Can-Type Combustion Chamber

Figure 8-10. Turbine Assembly Elements

8-8
 TM 1-1500-204-23-1

j. Ignition Systems. Turbine ignition systems are This high-energy current can quickly cause electrode
operated for a brief period during the engine-starting cy- erosion, but the short periods of operation minimize this
cle, and, as a rule, more trouble-free than the typical aspect of igniter maintenance. The electrode gap of the
reciprocating engine ignition system. Most turbine en- typical igniter plug is designed much larger than that of
gines are equipped with a high-energy, capacitor-type a spark plug, since the operating pressures are much
ignition system. lower and the spark can arc more easily than is the case
for a spark. Finally, electrode fouling, so common to the
(1) System components. A typical ignition spark plug, is minimized by the heat of the high-intensity
system includes two exciter units, two transformers, two spark. Typical igniter plugs are shown in figure 8-14.
intermediate ignition leads, and two high-tension leads.
Thus, as a safety factor, the ignition system is actually k. Fuel Systems. The fuel system must deliver to
a dual system, designed to fire two igniter plugs. Figure the combustion chambers not only in the right quantity,
8-13 shows one side of a typical ignition system. but also in the right condition for satisfactory combus-
tion. The fuel nozzles form part of the fuel system and
(2) Igniter plugs. The igniter plug of a turbine atomize or vaporize the fuel so that it will ignite and burn
engine ignition system differs considerably from the efficiently. The fuel system must also supply fuel so that
spark plug of a reciprocating engine ignition system. Its the engine can be easily started on the ground and in
electrode must be capable of withstanding a current of the air. This means that the fuel must be injected into the
much higher energy than the electrode of a conven- combustion chambers in a combustible condition when
tional spark plug. the engine is being turned over slowly by the starting
system, and that combustion must be sustained while
the engine is accelerating to its normal running speed.

Figure 8-11. Speed-Sensitive Control

8-9
TM 1-1500-204-23-1

Figure 8-12. Speed-Set Governor

8-10
 TM 1-1500-204-23-1

Figure 8-13. One Side of a Typical Ignition System

(1) Fuel controls. Regardless of the type, all (b) Duplex fuel nozzle. The duplex fuel noz-
fuel controls accomplish essentially the same functions, zle is the nozzle most widely used in present-day gas
but some sense more engine variables than others. turbine engines. The duplex nozzle usually requires a
The fuel control senses power lever position, engine dual manifold and a pressurizing valve or flow divider
rpm, either compressor inlet pressure or temperature, for dividing primary and main fuel flow into a desirable
and burner pressure or compressor discharge pressure. spray pattern for combustion over a wide range of oper-
These variables affect the amount of thrust that an ating pressures. A nozzle typical of this type is shown in
engine will produce for a given fuel flow. figure 8-16.

(2) Fuel nozzles. The fuel nozzles inject fuel (3) Fuel filters. A low-pressure filter is installed
into the combustion area in a highly atomized, precisely between the supply tanks and the engine fuel system
patterned spray so that burning is completed evenly and to protect the engine-driven fuel pump and various con-
in the shortest possible time and in the smallest possi- trol devices. An additional high-pressure fuel filter is in-
ble space. Fuel nozzle types vary considerably between stalled between the fuel pump and the fuel control to
engines, although for the most part fuel is sprayed into protect the fuel control from contaminants. The three
the combustion area under pressure through small ori- most common types of filters in use are the micron filter,
fice in the nozzles. The two types of fuel nozzles gener- the wafer screen filter, and the plain screen mesh filter.
ally used are the simplex and the duplex configurations. The individual use of each of these filters is dictated by
the filtering treatment required at a particular location.
(a) Simplex fuel nozzle. The simplex fuel
nozzle was the first type nozzle used in turbine engines 8-6. TURBINE ENGINE INSPECTION AND MAINTE-
and was replaced in most installations with the duplex NANCE. Turbine engines shall be inspected and main-
nozzle, which gave better atomization at starting and tained in accordance with the applicable maintenance
idling speeds. The simplex nozzle, as shown in figure manual. General procedures for various components
8-15, is still being used to a limited degree. Each of the and systems are explained in the following paragraphs.
simplex nozzles consists of a nozzle tip, an insert, and
a strainer made up of fine-mesh screen and a support.

8-11
TM 1-1500-204-23-1

Figure 8-14. Typical Igniter Plugs

8-12
 TM 1-1500-204-23-1

When the difference between a recorded ITT and the

baseline ITT is 20°C (68°F) or greater the aviator will
make an entry on DA Form 2408-13 to notify the main-
tenance officer. A difference of 30°C (86°F) or greater is
cause for grounding the aircraft until troubleshooting de-
termines the cause of the excessive ITT. New ITT base-
line values for HIT should be established after perform-
ing a baseline engine performance check. A new engine
performance check should be made when an engine is
changed, when the fuel control unit is adjusted or re-
placed, or when repairs are made to the engine hot sec-
tion.

c. Hot Start Inspection. A hot start occurs when

Figure 8-15. Simplex Fuel Nozzle
exhaust gas temperature exceeds normal starting tem-
perature limit.
a. General Procedures. The following pro-
cedures shall be adhered to during turbine engine NOTE
maintenance:
A hot start may be expected when a greater-
(1) Mark location of all attaching support brack- than-normal starting fuel flow is observed just as
ets, clamps, and clips prior to removing lines, tubes, or the power lever is moved into the IDLE position.
conduit to facilitate reassembly with a felt tip marker.
Use ink conforming to Federal Specification TT-I-544. d. Turbine Engine Analysis Check (TEAC). A
normal Turbine Engine Analysis Check (TEAC) is per-
(2) Use new O-rings, packing rings, cotter pins, formed for comparsion of normal TEAC data with base-
lockpins, gaskets, and washers. line data. This will confirm whether or not performance
degradation has occurred and to what degree. In addi-
(3) Apply lubricating grease, MIL-G-4343, on all tion, TEAC data can be an aid in determining the cause
O-rings prior to installation. of the performance loss (Refer to TEAC troubleshoot-
ing). A normal TEAC shall be performed whenever in-
(4) Apply thread compound, MIL-A-13881, to all stalled engine performance degradation is suspected or
threaded parts attached to the hot section. as part of a general test flight (if applicable).

(5) When gears are replaced, examine for pat- e. Foreign Object Damage Inspection. Most
tern wear and backlash. damage incurred by the engine is the result of ingestion
of foreign objects. Although screens are provided in
b. Health Indication Test. The Health Indication the lower aft cowling section and around the engine
Test (HIT) is the method by which the aviator in day-to- compressor inlet case to prevent entry of larger objects,
day flying monitors the aircraft engine condition. This sand and grit will enter and cause compressor damage.
is accomplished by the aviator selecting an N1 speed The resultant damage will be in the form of nicks or
(%) predicated upon the existing Free Air Temperature scratches on the compressor blades. Such a nick
(FAT). The Interstage Turbine Temperature (ITT) must or scratch can cause fatigue failure hours later, with
then relate to a predicated value (Baseline ITT) within disastrous effects to the entire engine.
a certain tolerance. ITT variation from baseline values
are logged by the aviator in accordance with the appli-
cable maintenance manual. This log, part of the engine
records, is available to the maintenance officer as an aid
in monitoring performance trends and in troubleshoot- When maintenance is performed on the engine,
ing. every effort shall be made to retrieve any ob-
ject (wire, rivets, nuts, screws, etc.) dropped
through the compressor inlet screen or into the
cowling, even if engine disassembly is required.
Damage to the engine may otherwise result.

8-13
TM 1-1500-204-23-1

8-14 Figure 8-16. Duplex Fuel Nozzle

 TM 1-1500-204-23-1

Figure 8-17. Compressor Blade Damage

f. Compressor Cleaning. Compressor cleaning • Weld cracks in combustion chambers that

consists of internal washing of the compressor with a do not exceed repair limitations, using
cleaning compound which is intended for use on an en- method and procedure which keeps distor-
gine displaying definite evidence of performance dete- tion to a minimum.
rioration due to an accumulation of foreign material de-
posits on the compressor blading. Refer to the applica- • Replace any turbine wheel blade found to
ble maintenance manual for specific procedures. have be out of repair limits. Check applica-
ble maintenance manual. Turbine blades
g. Cold Section Maintenance. Maintenance to will only be changed in matched pairs.
cold section components consists of repairing and re-
placing components as outlined in the specific engine • Replace tailpipes when cracked, bent, or
maintenance manual. distorted.

h. Compressor Blade Inspection and Repair. j. Turbine and Exhaust Maintenance. Mainte-
Compressor blades should be inspected for cracks, nance of the turbine and exhaust components consists
nicks, scores, scratches, buckling, and burns, as shown of repairing and replacing components as outlined in
in figure 8-17. Minor damage can be repaired if the the specific engine maintenance manual.
damage can be removed without exceeding the allow-
able limits established by the manufacturer. Typical k. Ignition System Maintenance. Maintenance
compressor limits are shown in figure 8-18. Repair in of the ignition system consists primarily of cleaning, in-
accordance with the applicable maintenance manual. spection, and replacement of components as explained
by the following paragraphs.
i. Hot Section Maintenance. The following are
repairs that can be made to the hot section of a turbine (1) Wiring harness. Perform wiring harness
engine: maintenance as explained by the following procedures:

8-15
TM 1-1500-204-23-1

Figure 8-18. Typical Compressor Blade Repair Limits

8-16
 TM 1-1500-204-23-1

1 Clean barrel of igniter plugs with a

wire brush . Buff threads with a cloth
wheel. Do not clean nose end and
Isopropyl Alcohol, TT-I-735, is flammable and electrode.
toxic to eyes, skin, and respiratory tract. Wear protec- 2 Replace plugs with cracked insula-
tive gloves and goggles/face shield. Avoid repeated or tion, damaged threads or pin con-
prolonged contact. Use only in well ventilated areas tacts, or when foreign material is
(or use approved respirator as determined by local found lodged in nose of plug .
safety/industrial hygiene personnel). Keep away from
open flames, sparks, or other sources of ignition. 3 Replace igniter plugs that fail to pro-
duce continuous and regular spark-
Cleaning solvent, HFE-71DE, is toxic to eyes, ing.
skin, and respiratory tract, and decomposes into other
hazardous products when exposed to extreme heat. (3) Ignition exciter. Refer to the applicable
Wear chemical protective gloves and goggles/face maintenance manual for ignition exciter maintenance.
shield. Avoid repeated or prolonged contact. Use
only in well ventilated areas. If ventilation is not ade- l. Turbine Bearing Maintenance. Turbine engine
quate, use approved respirator as determined by local bearings shall be inspected, removed, and replaced in
safety/industrial hygiene personnel. Keep away from accordance with the applicable maintenance manual.
open flames, welding, or other sources of extreme heat.
m. Thermocouple Maintenance. Replace ther-
(a) Clean lead assembly with Isopropyl Alco- mocouple leads that indicate a short or an open con-
hol, TT-I-735, or HFE-71DE. Replace any lead having dition. Clean carbon from thermocouples by dipping in
fraying shielding, bent or mutilated socket contacts or carbon removing compound, MIL-C-19853, and wiping
contact pins, and worn or stripped threads on coupling deposit away with a clean cloth.
nuts.
n. Oil Consumption. Check oil consumption in
NOTE accordance with the applicable maintenance manual.
The following formula can be used to calculate oil con-
Minor chafing or fraying to the extent of not more sumption in cc per hour.
than three broken strands in one inch of harness
length is permissible, providing there is no dam-
age to the underlying insulation. cc of oil added x 60 min
Recorded operating time 1 hr
in minutes
(b) Clean control harness leads with Iso- = Oil consumption time in cc/hr
propyl Alcohol, TT-I-735, or HFE-71DE; dry with air
blast. Replace harness when it is found to be open or o. Fuel System. Fuel system maintenance shall
shorted. be accomplished in accordance with the applicable
maintenance manual. General maintenance proce-
(2) Igniter plugs. Perform igniter plug mainte- dures are described in the following paragraphs.
nance as explained by the following procedures:
(1) Fuel control inspection and adjustment.
(a) Keep all igniter unit connections tight and Fuel control inspection and adjustment are explained in
all leads and conduit free from abrasions or other dam- the following paragraphs.
age. Accomplish the following steps when igniter plugs
fail to spark. (a) Fuel control inspection. Perform the
1 When two igniter plugs fail to spark, following procedures when inspecting fuel controls:
replace one plug and energize sys- 1 Inspect housing for cracks and leak-
tem. When plug sparks, replace age.
other plug and retest. Replace igniter 2 Inspect strainer element for nicks,
unit when plug fails to spark. tears, punctures, and broken wires.
2 When one plug fails to spark and a 3 Inspect springs and balls for corro-
new plug does not remedy defect, re- sion.
place igniter plug lead. If plug still fails
to spark, replace igniter unit. 4 Inspect cover for nicks, dents, and
scratches.
(b) Igniter plugs not heard firing when engine
is started shall be cleaned or replaced as follows:

Change 5 8-17
TM 1-1500-204-23-1

(b) Fuel control adjustment. Adjust fuel • Acceleration schedule

control in accordance with the applicable maintenance
manual. Typical adjustments are made to the following: (2) Fuel nozzle inspection and cleaning. In-
spect and clean fuel nozzles in accordance with the ap-
• Fuel selector plicable maintenance manual and the following para-
graphs.
• Compressor rotor ground idle speed
(a) Fuel nozzle inspection. Inspect fuel
• Air-bleed band closure
nozzles in accordance with table 8-1.
• Compressor rotor maximum speed

Table 8-1. Inspection of Primer Nozzles.

Inspect Usable limits Max. repairable limits Corrective action

1. Primer nozzle tip for carbon. Any amount not clogging Not repairable. Replace nozzle.
orifice.
2. Inlet fitting for missing or Two threads total, missing Two threads total, missing AVUM: Replace
damaged threads. or damaged, without or damaged, that can be nozzle.
high metal, if threads blended to usable limits. AVIM: Chase threads.
can be used without
cross-threading.
3. Retaining nut for:
a. Cracks. None allowed. Not repairable. Replace retaining nut.
b. Missing or damaged One thread total, missing Not repairable. Replace retaining nut.
threads. or damaged, without
high metal, if threads
can be used without
cross-threading.
c. Wrench damage on each Any amount, without high Not repairable. Replace retaining nut.
corner of hex flats. metal, if wrench won’t slip
on nut.
d. Distortion. Any amount if wrench will Not repairable. Replace retaining nut.
fit on nut.
e. Discoloration. Any amount. Not applicable. Not applicable.
f. Nicks and scratches, except Any number, 1/64 inch Not repairable. Replace retaining nut.
on threads. deep, without high metal.

8-18
 TM 1-1500-204-23-1

(b) Fuel nozzle cleaning. Clean fuel noz- (b) Main fuel filter cleaning. Clean filter
zles using the following procedures: with a cloth dampened in degreasing solvent. Dry using
compressed air.

Degreasing Solvent, MIL-PRF-680, is com-

bustible and toxic to eyes, skin, and respiratory DELETED
tract. Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged con- • When using compressed air for cleaning, use
tact. Use only in well ventilated areas (or use approved protective equipment for eyes and
approved respirator as determined by local face. Do not use more than 30 psig air pres-
safety/industrial hygiene personnel). Keep sure. Do not direct airstream toward yourself or
away from open flames or other sources of another person. Failure to comply could result
ignition. in injury to eyes or skin.

1 Clean using degreasing solvent and (4) Fuel control filter inspection and cleaning.
a brush. Inspect and clean fuel control filter in accordance with
the applicable maintenance manual and the following
2 Remove residue with a clean lint-free paragraphs.
cloth.
(a) Fuel control filter inspection. Inspect
filter for tears, punctures, broken wires, dents,
scratches, and corrosion.
When using compressed air for cleaning, use (b) Fuel control filter cleaning . Clean filter
approved protective equipment for eyes and using the procedures in paragraph (3).
face. Do not use more than 30 psig air pres-
sure. Do not direct air toward yourself or (5) Governor control inspection and adjust-
another person. Failure to comply could result ment. Inspect and adjust the governor control in ac-
in injury to eyes or skin. In case of injury, get cordance with the applicable maintenance manual.
medical attention.
8-7. REPLACEMENT CRITERIA FOR ENGINES
3 Blow filtered, compressed air through AND COMPONENTS. Replacement criteria for en-
primer nozzle. Hold nozzle tip in wa- gines and components are explained in the following
ter, and look for stream of air bubbles paragraphs.
coming from orifices. The nozzle is
clogged if there is no bubbling. Re-
a. Engine Replacement Criteria. The following
place nozzle if clogged
conditions require replacement of the engine:
(3) Main fuel filter inspection and cleaning. • When scheduled replacement time is accu-
Inspect and clean main fuel filter in accordance with mulated, as specified in the specific engine
the applicable maintenance manual and the following maintenance manual.
paragraphs.
(a) Main fuel filter inspection. Inspect the • When foreign objects enter air intake and
main fuel filter for cracks, corrosion, pitting, and element damage compressor.
contamination.
• When overspeeding occurs, inspection or
replacement shall be as indicated in the
specific engine maintenance manual.

Change 5 8-19
TM 1-1500-204-23-1

• When hot starts or tail pipe temperatures (5) Disconnect the turbine discharge pressure
exceed maximum allowable limit for given pickup line as shown in figure 8-19.
operating condition, inspection or replace-
ment shall be accomplished in accordance (6) Disconnect the electrical wiring and the ther-
with the applicable maintenance manual. mocouple leads from the connectors as shown in figure
8-20.
• When oil system is contaminated with metal
particles, proceed as directed in the main- (7) Disconnect the fuel line by removing the
tenance manual. bolts from the hose flange as shown in figure 8-21.
b. Component Replacement Criteria. Replace
individual turbine engine components as specified in the
applicable maintenance manual.

8-8. MARKING OF DEFECTS ON TURBINE EN-

GINES. Defects in removed parts may be marked by
use of a felt-tip marker.

8-9. TURBINE ENGINE MOUNTS. A typical engine

mounting system consists of bipod and tripod assem-
blies braced by tube assemblies. For specific details
of the system, refer to engine section of the applicable
maintenance manual. Repair bent, distorted, or chafed
areas of mount as specified in the applicable mainte-
nance manual. After repair of any component of engine
mount, accomplish a thorough visual and magnetic par- Figure 8-19. Turbine Discharge Pressure Pickup
ticle inspection. Line

8-10. PRESERVATION AND DEPRESERVATION OF

TURBINE ENGINES. The preservation and depreser-
vation procedures for each type of turbine engine is
specified in the applicable aircraft maintenance manual.

8-11. REMOVAL AND INSTALLATION OF TURBINE

ENGINES. Removal and installation of turbine engines
is explained in the following paragraphs. Refer to the
applicable maintenance manual.

a. Preparation for Removal. Accomplish the fol-

lowing general steps before removal:

(1) Adequately secure the aircraft either with

wheel chocks or with tiedown provisions; attach ground
wire or cable to aircraft.

(2) Open the nacelle doors and support them

with the struts. Verify that no external power is con-
nected to the aircraft and that the electric power switch
is off.

(3) Remove the mount access plates from both

sides of the nacelle structure.

(4) Remove the engine air-conditioning duct ac-

cess plate, and disconnect the duct from the engine. Figure 8-20. Electrical Disconnect

8-20
 TM 1-1500-204-23-1

Figure 8-21. Fuel Line Disconnect

(8) Disconnect the power control rod, as shown

in figure 8-22, from the power control lever cross-shaft
linkage at the threaded end disconnect. Secure the Figure 8-22. Power Lever Disconnect
power control rod to the nacelle structure.
c. Preparation for Installation. Installation of air-
b. Removal. The powerplant may be removed craft powerplants will be installed in accordance with the
from the aircraft by either of the two methods. One applicable maintenance manual.
method involves lowering the powerplant from the
nacelle by using an engine dolly. The other method re- d. Installation. Install engine in accordance with
quires hoists and a special sling to lower the powerplant applicable maintenance manual.
to a movable engine stand. Refer to the applicable
aircraft maintenance manual.

8-21/(8-22 blank)
 TM 1-1500-204-23-1

CHAPTER 9
GENERAL AIRFRAME MAINTENANCE

9-1. GENERAL. The maintenance instructions and These units are interconnected so that they permit prop-
procedures contained in this chapter are general and ap- erly sequenced retraction and extension of the landing
plicable to airframe maintenance of Army aircraft. Main- gear and the landing gear doors. Figure 9-2 shows a
tenance instructions that are specific and peculiar to par- typical hydraulic landing gear retraction system.
ticular airframes are contained in the applicable mainte-
nance manuals and will be used in conjunction with gen- b. Emergency Extension Systems. The emer-
eral information contained in this chapter. gency extension system lowers the landing gear if the
main power system fails. Some aircraft have an emer-
9-2. LANDING GEAR SYSTEMS. The landing gear gency release handle in the cockpit, which is connected
of an aircraft consists of main and auxiliary units, either through a mechanical linkage to the gear uplocks. When
of which may or may not be retractable. The main the handle is operated, it releases the uplocks and al-
landing gear forms the principle support of the aircraft lows the gear to free-fall, or extend, under their own
on land or water and may include any combination weight. On other aircraft, release of the uplock is accom-
of wheels, floats, skis, shock-absorbing equipment, plished using compressed air which is directed to uplock
brakes, retracting mechanism with controls and warn- release cylinders. Some installations are designed so
ing devices, cowling, fairing, and structural members that either hydraulic fluid or compressed air provides the
necessary to attach any of the foregoing to the primary necessary pressure, while others use a manual system
structure. The auxiliary landing gear consists of tail for extending the landing gears under emergency con-
or nose wheel installations, outboard pontoons, skids, ditions. Hydraulic pressure for emergency operation of
etc., with necessary cowling and reinforcement. the landing gear may be provided by an auxiliary hand
pump, an accumulator, or an electrically powered hy-
9-3. RETRACTABLE LANDING GEAR SYSTEMS. draulic pump, depending upon the design of the aircraft.
Retractable landing gear systems are explained in the
following paragraphs. c. Safety Devices. Accidental retraction of a
landing gear may be prevented by such safety devices
a. Types. The electric and hydraulic landing gear as mechanical downlocks, safety switches, and ground
retraction systems are explained in the following para- locks. Mechanical downlocks are built-in parts of a
graphs. gear-retraction system and are operated automatically
by the gear-retraction system. To prevent accidental
(1) Electric landing gear retraction system. operation of the downlocks, electrically operated safety
The electric landing gear retraction system is an elec- switches are installed.
trically driven jack for raising or lowering the gear, as
shown in figure 9-1. When a switch in the cockpit is (1) Safety switch. A landing gear safety switch,
moved to the UP position, the electric motor operates. as shown in figure 9-3, in the landing gear safety cir-
Through a system of shafts, gears, adapters, an ac- cuit is usually mounted in a bracket on one of the main
tuator screw, and a torque tube, a force is transmitted gear shock struts. This switch is actuated by a linkage
to the drag strut linkages. Thus, the gear retracts and through the landing gear torque links. The torque links
locks. If the switch is moved to the DOWN position, the spread apart or move together as the shock strut pis-
motor reverses and the gear moves down and locks. ton extends or retracts in its cylinder. When the strut is
compressed (aircraft on the ground), the torque links are
(2) Hydraulic landing gear retraction system. close together, causing the adjusting links to open the
Devices used in a typical hydraulically operated land- safety switch. During takeoff, as the weight of the air-
ing gear retraction system include actuating cylinders, craft leaves the struts, the struts and torque links extend,
selector valves, uplocks, downlocks, sequence valves, causing the adjusting links to close the safety switch.
turbine, and other conventional hydraulic components. As shown in figure 9-3, a ground is completed when the
safety switch closes. The solenoid then

9-1
TM 1-1500-204-23-1

Figure 9-1. Electric Retraction System

energizes and unlocks the selector valve so that the f. Retraction Test. Inspect landing gear for obvi-
gear handle can be positioned to raise the gear. ous damage, then accomplish retraction test, inspecting
for the following items:
(2) Ground locks. Ground locks prevent land-
ing gear collapse when the aircraft is on the ground. One • Landing gear for proper retraction and ex-
common type is a pin installed in aligned holes drilled tension
in two or more units of the landing gear support struc-
ture. Another type is a spring-loaded clip designed to fit • Switches, lights, and warning horn for
around and hold two or more units of the support struc- proper operation
ture together. All types of ground locks usually have red
streamers permanently attached to them to readily indi- • Landing gear doors for clearance and free-
cate whether or not they are installed. dom from binding

d. Gear Position Indicators. To provide a vi-

• Landing gear linkage for proper operation,
adjustment, and general condition
sual indication of landing gear position, indicators are
installed in the cockpit or flight compartment. Gear • Latches and locks for proper operation and
warning devices are incorporated on all retractable gear adjustment
aircraft and usually consist of a horn or some other
aural device and a red warning light. • Alternate extension or retraction systems
for proper operation
e. Nosewheel Centering. Aircraft are commonly
provided nosewheel steering capabilities through a sim- • Any unusual sounds such as those caused
ple system of mechanical linkage hooked to the rudder by rubbing, binding, chafing, or vibration.
pedals. Most common applications utilize push-pull rods
to connect the pedals to horns located on the pivotal por-
tion of the nosewheel strut.

9-2
 TM 1-1500-204-23-1

Figure 9-2. Hydraulic Landing Gear Retraction System Schematic

9-3
TM 1-1500-204-23-1

9-4. TROUBLESHOOTING OF LANDING GEAR

SYSTEMS. The troubleshooting procedures for elec-
trical and hydraulic landing gear systems is in the
applicable maintenance manuals.

9-5. SHOCK STRUTS. Shock struts, as shown in fig-

ures 9-4 and 9-5, are self-contained hydraulic units that
support an aircraft on the ground and protect the aircraft
structure by absorbing and dissipating the tremendous
shock loads of landing. Shock struts must be inspected
and serviced regularly to function efficiently.

a. Shock Strut Operation. The compression

stroke of the shock strut begins as the aircraft wheels
touch the ground; the center of mass of the aircraft Figure 9-3. Landing Gear Safety Circuit
continues to move downward, compressing the strut
and sliding the inner cylinder into the outer cylinder.
The metering pin is forced through the orifice and, by its
variable shape, controls the rate of fluid flow at all points
of the compression stroke. In this manner the greatest
possible amount of heat is dissipated through the walls
of the shock strut. At the end of the downward stroke,
the compressed air is further compressed, limiting the
compression stroke of the strut. The extension stroke
occurs at the end of the compression stroke as the
energy stored in the compressed air causes the aircraft
to start moving upward in relation to the ground and
wheels. At this instant, the compressed air acts as a
spring to return the strut to normal. It is at this point that
a snubbing or damping effect is produced by forcing the
fluid to return through the restrictions of the snubbing
device. (See figure 9-6.)

b. Shock Strut Servicing. The following proce-

dures are typical of those used in deflating a shock strut,
servicing with hydraulic fluid, and reinflating:

(1) Position the aircraft so the shock struts are in

the normal ground operating position. Make certain that
personnel, workstands, and other obstacles are clear of
the aircraft. (Some aircraft must be placed on jacks to
service the shock struts).

(2) Remove the cap from the air valve.

(3) Check the swivel hex nut for tightness with

a wrench.

Always stand to one side of the valve, since

high-pressure air can cause serious injury, e.g.,
loss of eyesight.
Figure 9-4. Landing Gear Shock Strut of the
Metering Pin Type

9-4
 TM 1-1500-204-23-1

Figure 9-5. Landing Gear Shock Strut of the

Metering Tube Type
(4) If the air valve is equipped with a valve core,
release any air pressure that may be trapped between
the valve core and the valve seat by depressing the
valve core.
(5) Remove the valve core.
(6) Release the air pressure in the strut by
slowly turning the swivel nut counterclockwise.
(7) Ensure that the shock strut compresses as
the air pressure is released. In some cases, it may be
necessary to rock the aircraft after deflating to ensure
compression of the strut.
(8) When the strut is fully compressed, the air
valve assembly may be removed.
(9) Fill the strut to the level of the air valve open-
ing with an approved type of hydraulic fluid . Figure 9-6. Shock Strut Operation

9-5
TM 1-1500-204-23-1

(10) Re-install the air valve assembly, using a (5) Fill the strut to the level of the filler port with
new O-ring packing. Torque the air valve assembly to an approved type hydraulic fluid.
the values recommended in the applicable maintenance
manual. (6) Attach the bleed hose to the filler port and
insert the free end of the hose into a container of clean
(11) Install the air valve core. hydraulic fluid, making sure that this end of the hose is
below the surface of the hydraulic fluid.
(12) Inflate the strut, using a high-pressure
source of dry air or nitrogen. (7) Place an exerciser jack or other suitable sin-
gle-base jack under the shock strut jacking point. Com-
NOTE press and extend the strut fully by raising and lowering
the jack until the flow of air bubbles from the strut has
Bottled gas should not be used to inflate shock completely stopped. Compress the strut slowly and al-
struts. On some shock struts the correct low it to extend by its own weight.
amount of inflation is determined by using a
high-pressure air gauge. On others it is deter- (8) Remove the exerciser jack, and then lower
mined by measuring the amount of extension and remove all other jacks.
(in inches) between two given points on the
strut. The proper procedure can usually be (9) Remove the bleed hose from the shock strut.
found on the instruction plate attached to the
shock strut. Shock struts should always be
(10) Install the air valve and inflate the strut.
inflated slowly to avoid excessive heating and
over inflation.
d. General Maintenance of Shock Struts. All
maintenance personnel should study all technical man-
(13) Tighten the swivel hex nut, using the torque
uals which pertain directly to the shock strut in question,
values specified in the applicable maintenance manual.
or aircraft maintenance publications which have a por-
tion of the instructions devoted to the particular shock
(14) Remove the high-pressure air line chuck strut in question. General maintenance for pneumatic,
and install the valve cap. Tighten the valve cap finger- rubber block, and spring steel shock struts is described
tight. in the following paragraphs.
c. Shock Strut Bleeding. If the fluid level of a (1) Pneumatic type. Use the following proce-
shock strut has become extremely low, or if for any other dures for maintenance of pneumatic type shock struts:
reason air is trapped in the strut cylinder, it may be nec-
essary to bleed the strut during the servicing operation.
(a) Clean the exposed part of the piston tube
Bleeding is usually performed with the aircraft placed on
using the following procedures:
jacks. In this position the shock struts can be extended
and compressed during the filling operation, thus ex- NOTE
pelling all the entrapped air. The following is a typical
bleeding procedure: Cleaning of piston tubes reduces excessive
wear and possible failure of shock strut packing
(1) Construct a bleed hose containing a fitting rings.
suitable for making an airtight connection to the shock
strut filler opening. The base should be long enough to 1 Remove ice, mud, dust, or sand, then
reach from the shock strut filler opening to the ground wipe using a clean cloth saturated
when the aircraft is on jacks. with hydraulic fluid MIL-H-5606.

(2) Jack the aircraft until all shock struts are fully 2 When extreme ice, dust, mud or sand
extended. conditions are encountered, wipe pis-
ton tubes before and after each flight.
(3) Release the air pressure in the strut to be
bled. 3 When operating aircraft in freezing
temperatures, piston tube can be
(4) Remove the air valve assembly. cleaned more easily.

9-6
 TM 1-1500-204-23-1

Immediately after landing, as ice will (2) Power control systems. Power brake con-
form on tube when aircraft is left trol valve systems, as shown in figure 9-8, are used on
standing without tube being cleaned aircraft requiring a large volume of fluid to operate the
of water, mud and slush. brakes. As a general rule, this applies to many large air-
craft. Because of their weight and size, large wheels and
(b) Maintain proper air-oil levels in struts as brakes are required. Larger brakes mean greater fluid
specified on data plates. Use hydraulic fluid, MIL-H- displacement and higher pressures, and for this reason
5606 . independent master cylinder systems are not practical
on heavy aircraft. In this system a line is tapped off from
(c) Replace pistons having nicks, scratches, the main hydraulic system pressure line.
or dents deep enough to cause leakage. Replace elon-
gated bushings. Replace struts that have cracked fit- (3) Power boost systems. A typical power
tings. boost brake system, as shown in figure 9-9, consists
of a reservoir, two power boost master cylinders, two
(d) When overhauling a pneumatic shock shuttle valves, and the brake assembly in each main
strut, all ferrous metal parts will be magnetic particle landing wheel. In this type of system, a line is tapped
inspected for cracks and flaws. Inspection will be ac- off the main hydraulic system pressure line, but main
complished in accordance with applicable maintenance hydraulic system pressure does not enter the brakes.
manual. Main system pressure is used only to assist the pedals
through the use of power boost master cylinders.
(2) Rubber block type. Replacement of com-
pression and rebound rubber blocks, or adjustment of b. Brake Assemblies. Brake assemblies com-
preload tubes shall be as specified in applicable aircraft monly used on aircraft are the single-disk, dual-disk.
maintenance manual. The single and dual-disk types are more commonly used
on small aircraft.
(3) Spring steel type. Repairs are limited to
burnishing minor nicks, burrs, or scratches. Replace (1) Single-disk brakes. With the single-disk
cracked struts. brake, braking is accomplished by applying friction to
both sides of a rotating disk which is keyed to the land-
9-6. LANDING GEAR ALIGNMENT. The alignment ing gear wheel. There are several variations of the sin-
of aircraft landing gear is too critical, and the tolerances gle-disk brake; however, all operate on the same princi-
too narrow to deal with the subject in a general man- ple and differ mainly in the number of cylinders
ner. Reference will be made to applicable aircraft main-
tenance manual for specific data relating to landing gear
alignment.

9-7. BRAKE SYSTEMS. Brake system types and

general maintenance are explained in the following
paragraphs.

a. Brake Types. The three types of brake systems

in general use are the independent, power control, and
power boost systems. Each is explained in the following
paragraphs.

(1) Independent systems. In general, the in-

dependent brake system is used on small aircraft. This
type of brake system is termed independent because it
has its own reservoir and is entirely independent of the
aircraft main hydraulic system. Independent brake sys-
tems are powered by master cylinders similar to those
used in the conventional automobile brake system. The
system is composed of a reservoir, one or two mas- Figure 9-7. Independent Brake System
ter cylinders, mechanical linkage which connects each
master cylinder with its corresponding brake pedal, con-
necting fluid lines, and a brake assembly in each main
landing gear wheel as shown in figure 9-7.

9-7
TM 1-1500-204-23-1

Figure 9-10 shows a single-disk brake installed on an

aircraft, with the wheel removed. The brake housing
is attached to the landing gear axle flange by mounting
bolts.

(2) Dual-disk brakes. Dual-disk brakes are

used on aircraft when more braking friction is desired.
The dual-disk brake is very similar to the single-disk
type, except that two rotating disks instead of one are
used.

Degreasing Solvent, MIL-PRF-680, is com-

bustible and toxic to eyes, skin, and respiratory
tract. Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged con-
tact. Use only in well ventilated areas (or use
approved respirator as determined by local
safety/industrial hygiene personnel). Keep
away from open flames or other sources of
ignition.

c. Brake Assembly Cleaning. Disassemble

brake assembly and clean parts with Degreasing Sol-
Figure 9-8. Power Control Brake System vent, MIL-PRF-680. Clean using a brush or air spray.
Remove all blistered, chipped, or loose paint.

d. Brake Assembly Inspection. Inspect brake

assemblies using the following general procedures:

(1) Visually inspect brake housing thoroughly

for cracks, chipped or worn mounting holes, stripped
threads, and corrosion.

1 BRAKE RESERVOIR 7 AIR VENT

2 POWER BOOST 8 MAIN SYSTEM
MASTER CYLINDER PRESSURE
3 EMERGENCY MANIFOLD
BRAKE CONTROL 9 EMERGENCY AIR
4 AIR RELEASE VALVE BOTTLE
5 WHEEL BRAKE 10 EMERGENCY AIR
6 SHUTTLE VALVE GAUGE

Figure 9-9. Power Boost Brake System

and the type of brake housing. Brake housings may be

either the one-piece or divided type.

Figure 9-10. Single-Disk Brake

9-8 Change 5
 TM 1-1500-204-23-1

(2) Inspect lining recesses in piston, center car-

rier, and anvil for indications of wear which could cause (1) Replace all seals, cups, and O-rings on an
loss of lining. Wear of anvil lining recess circumference availability basis when assembling brakes to prevent
in excess of 0.005 inch is cause for replacement. possible leakage and brake failure.

(3) Examine piston cavity for corrosion, exces- (2) Apply a light coat of insulating and sealing
sive wear, or for being out-of-round. When light corro- compound, MIL-I-8660, to surface of piston cavity and
sion extends more than 9/16 inch into piston cavity, or to O-ring or cup seal.
heavy corrosion is evident, replace brake assembly.
(3) Replace disks that have cracks extending
NOTE through disc. Any single crack that extends through
Corrosion is usually found in carrier housing and thickness of brake disk shall be reason for replacement.
in piston cavities. Corrosion in magnesium can Minor surface cracks and heat checks are normal and
be identified by the rough honeycombed ap- are not cause for replacement.
pearance of the pit. Pits are usually filled with a
yellow or gray powder. Heavy corrosion is de- (4) When necessary to replace one lining be-
fined as pits that exceed 0.025 inch in diameter cause of wear, all linings shall be replaced. Replace
or grouped with three or more pits of any diam- linings when any lining thickness is less than 1/16 inch,
eter in an area of ¼ inch square. or shows indications of being overheated.

e. Corrosion Treatment of Brake Assemblies . g. Brake Assembly Servicing. Service brake

Brake assemblies are manufactured from magnesium, assemblies in accordance with the applicable mainte-
aluminum, and steel. Most assemblies have magne- nance manual. The following are general procedures
sium housings which are very susceptible to corrosion, for all aircraft.
especially in piston cavities. Treat the surface using the
following procedures: (1) Check for leaks while system is under oper-
ating pressure.
(1) Remove sharp edges of corrosion pits with
crocus cloth, Federal Specification P-C-458, lubricated NOTE
with hydraulic fluid, MIL-H-5606 .
Tighten loose fittings with the pressure off.
(2) Rework minor dents, nicks, burrs, or gouges
to break all sharp edges of indentations which might re- (2) Check all flexible hoses carefully for
sult in a concentration of stress. Use a smooth cut hand swelling, cracking, or soft spots, and replace if evidence
file to accomplish this, followed by fine abrasive paper, of deterioration is noted.
Federal Specification P-P-101, to remove tool marks.
(3) Maintain the proper fluid level at all times to
(3) Condemn brake assemblies that have deep prevent brake failure or the introduction of air into the
scratches, gouges, or cracks exceeding limits estab- system.
lished in applicable aircraft maintenance manual.
h. Bleeding Brakes. Air in the system is indicated
(4) Accomplish surface treatment as outlined in by a spongy action of the brake pedals. If air is present in
TM 43-0105. the system, remove it by bleeding the system. There are
two general methods of bleeding brake system. Bleed-
ing from the top downward (gravity method) and bleed-
f. Repair and Replacement of Brake Assembly
ing from the bottom upward (pressure method). Each
Components. Repair or replace brake assembly
method is explained in the following paragraphs.
components in accordance with the applicable mainte-
nance manual and the following general procedures:

Care must be used when installing seals and

cups to prevent damage to feathered edges.

9-9
TM 1-1500-204-23-1

(1) Gravity method. A bleeder hose is at-

tached to the bleeder valve, and the free end of the
hose is placed in a receptacle containing enough hy-
draulic fluid to cover the end of the hose, as shown in
figure 9-11. The air-laden fluid is then forced from the
system by operating the brake. If the brake system is a
part of the main hydraulic system, a portable hydraulic
test stand may be used to supply the pressure. If the
system is an independent master cylinder system, the
master cylinder will supply the necessary pressure. In
either case, each time the brake pedal is released the
bleeder valve must either be closed or the bleeder hose
pinched off; otherwise, more air will be drawn back into
the system. Bleeding should continue until no more
air bubbles come through the bleeder hose into the
container.

(2) Pressure method. In the pressure method, Figure 9-12. Pressure Method of Bleeding Brakes
the air is expelled through the brake system reservoir
or other specially provided location. Some aircraft have 9-8. WHEEL MAINTENANCE. Aircraft wheels are
a bleeder valve located in the upper brake line. In us- manufactured from magnesium, aluminum, or steel
ing this method of bleeding, pressure is applied using alloy. These materials are susceptible to corrosion,
a bleed tank, as shown in figure 9-12. A bleed tank scoring, and gouging. Corrosion contributes to the
is a portable tank containing hydraulic fluid under pres- high replacement rate of wheels. Paint coatings should
sure. The bleeder tank is equipped with an air valve, air be maintained in good condition to prevent corrosion.
gauge, and a connector hose. The connector hose at- Fatigue cracks and complete wheel failure can result
taches to the bleeder valve on the brake assembly and from inadequate corrosion control, as well as scratches
is provided with a shutoff valve. Perform this method of and tool marks in critical stress areas. Care should be
bleeding strictly in accordance with the specific aircraft taken to ensure proper usage of tools. Maintain wheels
maintenance manual. using the following paragraphs.
j. Brake System Safety. Follow all safety precau- a. Wheel Cleaning. The following procedures de-
tions given by the applicable maintenance manual. If it scribe wheel cleaning:
is necessary to approach a wheel with a hot brake, do
so either from directly in front or directly behind the air- (1) Remove tire, tube, and bearing and dis-
craft. assemble the wheel. See TM 55-2620-200-24 for
demounting procedure.

Degreasing Solvent, MIL-PRF-680, is com-

bustible and toxic to eyes, skin, and respiratory
tract. Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged con-
tact. Use only in well ventilated areas (or use
approved respirator as determined by local
safety/industrial hygiene personnel). Keep
away from open flames or other sources of
ignition.

(2) Wash demounted wheel in degreasing sol-

vent, MIL-PRF-680.
Figure 9-11. Gravity Method of Bleeding Brakes
NOTE

Bearings should be cleaned and repacked if

wheel is removed or was submerged in water.

9-10 Change 5
 TM 1-1500-204-23-1

b. Wheel Inspection. Inspect aircraft wheels for (3) Distortion. Check wheel carefully for distor-
corrosion, cracks, distortion and damage using the fol- tion. Replace any wheel with this condition.
lowing procedures:
(4) Damage. Replace any wheel having dents,
(1) Visually inspect wheel thoroughly for signs nicks, burrs, or scratches if the damage cannot be re-
of corrosion, which can be identified by formation of pits paired within limits specified in applicable maintenance
in the metal and a powdery substance in and around manual.
exposed areas. Corrosion in split type wheel usually will
be found in the tie bolt area, torque key area, bearing NOTE
cavity area, and seal (tubeless tire) area. Corrosion in
these areas is considered critical. If one wheel half is determined non-repairable,
replace both halves.
(2) Visually inspect wheel for indications of
cracks, using at least a six-power magnifying glass. 9-9. TIRES AND TUBES. Aircraft tires, tubeless or
tube type, provide a cushion of air that helps absorb the
(3) Visually inspect for distortion and other dam- shocks and roughness of landings and takeoffs: they
age. support the weight of the aircraft while on the ground and
provide the necessary traction for braking and stopping
c. Repair of Wheels. Repair aircraft wheels in ac- aircraft on landing.
cordance with the applicable maintenance manual and
the following procedures: a. Cleaning. Clean aircraft tires and tubes in ac-
cordance with the applicable maintenance manual.
(1) Etching, corrosion, and minor defects are to
be removed to relieve all sharp corners or indentions b. Inspection. Inspection of tires and tubes is ex-
which might result in concentration of stresses. Use plained in the following paragraphs.
100-grit emery cloth, followed by final polishing with 240
grit emery cloth so as to maintain repair limitations. (1) Tire inspection. Inspect tires for leaks or
damage at valve, tread damage, sidewall damage, and
NOTE uneven wear when tire is mounted on wheel. When tire
is dismounted probe all damages to determine their ex-
Above rework limits are for use on all wheels tent. Repair damage if necessary. Inspect for bulges,
which do not have repair limitations in the spe- broken cords, and bead damage.
cific aircraft maintenance manual.
(2) Tube inspection. Inspect tubes for proper
(2) Chemical film-treat bare metal surfaces, fol- size, wrinkles, chafing, and thinning. Examine the tube
lowed by painting. carefully around the valve stem for leaks, signs of valve
pad separation, and bent or damaged valve stems.
d. Replacement Criteria for Wheels. Replace-
ment criteria for wheels with corrosion, cracks, distor- c. Balance. Balance in aircraft tires and tubes
tion, and other damage is explained in the applicable is very important. From a wear standpoint, when the
maintenance manual. wheels are in landing position a heavy spot in a wheel
assembly will have a tendency to remain at the bottom
(1) Corrosion. Wheel is unserviceable if it can- and thus will always strike the ground or runway first.
not be repaired within limits specified in applicable main- This results in severe wear at one area of the tire tread
tenance manual. and can necessitate early replacement. In addition,
unbalanced tires can cause severe vibration which may
(2) Cracks. If any cracks are found, wheel affect the operation of the aircraft.
should be condemned. If any questionable indication
of a crack is found, wheel should be inspected further d. Valve Cores. Valve cores must be replaced if
by means of fluorescent penetrants . Cracks present in leaks are present in the valve stem. Always inspect
split-type wheel usually are located in the tie bolt area, the valve to be sure the threads are not damaged; oth-
torque key area, and webbing and spoke area. Refer to erwise, the valve core and valve cap will not fit prop-
TM 55-1500-335-23, Nondestructive Inspection Meth- erly. If threads are damaged, the valve can usually be
ods. rethreaded, inside or outside, by use of a valve repair

9-11
TM 1-1500-204-23-1

tool, without demounting the tire from the wheel. Make 9-12. FLIGHT CONTROLS. The flight control sur-
certain that every valve has a valve cap on it, screwed faces are hinged or movable airfoils designed to change
on firmly with the fingers. The cap prevents dirt oil and the attitude of the aircraft during flight. Maintenance
moisture from getting inside the valve and damaging the of flight controls shall be accomplished by replacing
core. It also seals in air and serves as protection in case worn, damaged, or defective components, adjusting
a leak develops in the valve core. rigging components, and accomplishing preventive
maintenance to the system.
e. Installation. Install tires and tubes in accor-
dance with the applicable maintenance manual. a. Types. Ailerons, elevators, the rudder, flaps,
and trim tabs are the common types of flight controls.
9-10. SKI MAINTENANCE. Maintenance of skis shall Each is explained in the following paragraphs.
be as specified in the applicable aircraft maintenance
manual and the following paragraphs. (1) Ailerons. The motion of the aircraft about
the longitudinal axis is called rolling or banking. The
a. Ski Inspection. It is advisable to examine ski ailerons, as shown in figure 9-13, are used to control this
installations frequently to keep them maintained in air- movement. The ailerons form a part of the wing and are
worthy condition. If shock cord is used to keep the ski located in the trailing edge of the wing toward the tips.
runner in proper trim, periodically examine to assure that Ailerons are the movable surfaces of an otherwise fixed-
the cord has enough elasticity to keep the runner in its surface wing. The aileron is in neutral position when it
required attitude and the cord is not becoming loose or is streamlined with the trailing edge of the wing.
badly frayed. Replace old or weak shock cords. When
other means of restraint are provided, examine for ex- (2) Elevators. When the nose of an aircraft is
cessive wear and binding, and replace or repair when raised or lowered, it is rotated about its lateral axis. Ele-
such conditions are found. Examine the points of ca- vators are the movable control surfaces that cause this
ble attachment, both on the ski and the airplane struc- rotation, as shown in figure 9-14. They are normally
ture, for bent lugs due to excessive loads having been hinged to the trailing edge of the horizontal stabilizer.
imposed while taxiing over rugged terrain, or by trying The elevator can be moved either up or down. If the el-
to break loose frozen skis. If skis which permit attach- evator is rotated up, it decreases the lift force on the tail
ment to the wheels and tires are used, maintain proper causing the tail to lower and the nose to rise. If the el-
tire pressure, as underinflated tires may push off the evator is rotated downward, it increases the lift force on
wheels if appreciable side loads are developed in land- the tail, causing it to rise and the nose to lower. Low-
ing or taxiing. ering the aircraft’s nose increases forward speed, and
raising the nose decreases forward speed.
b. Ski Repair. Aluminum tubular members may
have negligible damage of surface scratches and (3) Rudder. Turning the nose of the aircraft
smooth contour dents not over 1/16 inch in depth. causes the aircraft to rotate about its vertical axis.
All damage, other than negligible, shall necessitate Rotation of the aircraft about the vertical axis is called
replacement unless otherwise specified in applicable yawing. This motion is controlled by using the rudder
aircraft maintenance manual. Steel tubular members as shown in figure 9-15.
may have negligible damage of surface scratches and
small dents not over 0.004 inch in depth. Repairable (4) Flaps. Flaps are high-lift devices attached
damage shall consist of straightening slight bends and to the trailing edge of the wing. The flap is controlled
rewelding existing welds. from the cockpit, and when not in use fits smoothly into
the lower surface of each wing. The use of flaps in-
9-11. FLOAT MAINTENANCE. In order to maintain creases the camber of a wing and therefore the lift of
floats in an airworthy condition, frequent inspections the wing, making it possible for the speed of the aircraft
should be made because of the rapidity with which to be decreased without stalling. This also permits a
corrosion takes place on aluminum alloy metal parts, steeper gliding angle to be obtained such as in the land-
particularly when the aircraft is operated in salt water . ing approach. Flaps are primarily used during takeoff
Examine metal floats and all metal parts on wooden or and landing. Figure 9-16 shows various types of flaps
fiberglass floats for corrosion and take corrective action used on aircraft.
in accordance with the applicable aircraft maintenance
manual. All maintenance of floats shall be as specified
in the applicable aircraft maintenance manual.

9-12
 TM 1-1500-204-23-1

Figure 9-13. Aileron Action

Figure 9-14. Elevator Action

9-13
TM 1-1500-204-23-1

Figure 9-15. Rudder Action

(5) Trim tabs. Trim tabs trim the aircraft in c. Repair of Flight Controls. Make all repairs to
flight. To trim means to correct any tendency of the flight controls in accordance with the applicable aircraft
aircraft to move toward an undesirable flight attitude. maintenance manual.
Trim tabs control the balance of an aircraft so that it
maintain straight and level flight without pressure on the d. Flight Control Operating Systems. Three
control column, control wheel, or rudder pedals. figure types of control systems commonly used are the cable,
9-17 shows a trim tab. Note that the tab has a variable push-pull, and torque tube systems. The cable sys-
linkage which is adjustable from the cockpit. Movement tem is the most widely used because deflection of the
of the tab in one direction causes a deflection of the structure to which it is attached do not affect its oper-
control surface in the opposite direction. Most of the ation. Many aircraft incorporate control systems that
trim tabs installed on aircraft are mechanically operated are combinations of all three types. The systems which
from the cockpit through an individual cable system. operate the control surfaces, tabs, and flaps include
However, some aircraft have trim tabs that are operated flight control system hardware, linkage, and mecha-
by an electrical actuator. Trim tabs are either controlled nisms. These items connect the control surfaces to the
from the cockpit or adjusted on the ground before taking cockpit controls. Included in these systems are cable
off. Trim tabs are installed on elevators, rudders, and assemblies, cable guides, linkage, adjustable stops,
ailerons. control surface snubber or locking devices, surface
control booster units, actuators operated by electric
b. Inspection of Flight Controls. Inspect all flight motors, and actuators operated by hydraulic motors.
control surfaces in accordance with the applicable air-
craft maintenance manual.

9-14
 TM 1-1500-204-23-1

e. Control Cables. Aircraft control cables are

generally fabricated from carbon steel or corrosion-re-
sistant steel wire and may consist of either flexible or
nonflexible type construction.

(1) Control cable sizes. Cable size is mea-

sured in diameter as shown in figure 9-18. Control ca-
bles vary in diameter, ranging from 1/16 to 3/8 inch. Fig-
ure 9-18 also shows common cable designations. Cable
designations are based on the number of strands and
the number of wires in each strand.

(2) Control cable inspection and mainte-

nance. Aircraft cable systems are subject to a variety
of environmental conditions and forms of deterioration,
such as wear, corrosion, and distortion. The following
are general procedures for control cable inspection and
maintenance:

(a) Inspect cables for broken wires by pass-

ing a cloth along length of cable. Cloth will snag when it
passes over broken wire. Figure 9-19 shows cross sec-
tions of a 7x7 and a 7x19 cable.

Figure 9-16. Types of Wing Flaps

Figure 9-18. Cable Cross Sections

Figure 9-17. Trim Tab Assembly

9-15
TM 1-1500-204-23-1

NOTES
1 WHENEVER CABLE WEARS IS FOUND,
CAUSE OF WEAR MUST BE
DETERMINED AND CORRECTED
2 ALL DIMENSIONS IN INCHES

Figure 9-19. Control Cable Cross Section and Wear Limits

9-16
 TM 1-1500-204-23-1

NOTE NOTE

• Breakage usually occurs in that length of a • Any 7x7 cable having three wires or less
cable normally passing over a pulley or through per inch worn not more than halfway through
a fairlead, as shown in figure 9-20. the wire diameter, or any 7x19 cable having
six wires or less per inch worn not more than
• Any cable not within specified allowable limits halfway through wire diameter, shall be consid-
listed in table shall be considered unserviceable ered serviceable if broken wires are present in
and must be replaced. the worn area.
• The cable shall be considered serviceable if
• In addition to limits specified in table 9-1 the broken wires are present but are not in the worn
maximum allowable number of broken wires area.
shall not occur in any two consecutive inches of
cable; that is, if six wires are broken in one inch • One less worn wire per inch is allowed for each
of a 7 x 19 cable, none would be allowed in the broken wire present in the same inch. If more
next consecutive inch. For any flexible cable, a than one worn area is found, but all are within
maximum of three broken wires per inch shall specified limits, the cable is satisfactory, pro-
be allowable in the length of cables passing vided no two worn spots are adjacent circum-
over pulleys, drums, or through fairleads. ferentially.
• Any wire worn completely through, or worn to
(b) Replace badly worn cables even if num-
a point of breaking, shall be considered unser-
ber of broken wires is less than specified for replace-
viceable.
ment.
• Kinked, twisted, or birdcaged cables must be
repaired or replaced.
• Wear will normally extend along the cable
equal to the distance the cable moves at that
location. Wear may occur on one side of the
cable only or on its entire circumference.
• Replace cables when the individual wire in
each strand appears to blend together (outer
wire worn 40 to 50 percent) as depicted in figure
9-19. Actual instances of cable wear beyond
recommended point are shown in figure 9-21.

(c) Move surface controls of the particular ca-

ble to the extremities to reveal the cable in the pulley
Figure 9-20. Typical Breakage Point contact, fairlead area, or drum.

9-17
TM 1-1500-204-23-1

Table 9-1. Cable Damage Limits.

Cable type Allowable broken wire

7x7 (flexible) 2 per inch of strand, provided not more than 3 exist
in that inch of cable
7x19 (flexible) 3 per inch of strand, provided not more than 6 exist
in that inch of cable
1x19 (nonflexible) None

(d) If the surface of the cable is corroded, re- (b) Convert indicator reading to tension
lieve cable tension and carefully force the cable open by pounds (see figure 9-22).
reverse twisting. Visually inspect the interior.
(c) Adjust cable tension to proper value by
NOTE either tightening or loosening turnbuckles.
Corrosion on the interior strands of the cable (4) Control cable emergency repair. If possi-
constitutes failure, and the cable must be re- ble, duplicate spare cables should be used for replace-
placed. ment. When spare cables are not available and immedi-
ate replacement is imperative, use one of the following
(e) If no internal corrosion is detected, re- methods of splicing.
move loose external rust and corrosion with a clean, dry,
coarse-weave rag or fiber brush. After thorough clean-
ing, apply corrosion preventive, MIL-C-16173 Grade
2, sparingly. Do not apply the material so thick that it
Care must be taken that splice does not foul
will interfere with the operation of cables at fairleads,
fairlead or pulley, nor in any other way prevent
pulleys, or grooved bellcrank areas.
proper movement of the cable.
NOTE
(a) Woven spliced terminals. Use woven
Do not use metallic wools or solvents to clean spliced terminals on cables 3/32 inch diameter or greater
installed cables. Use of metallic wool will imbed in place of swaged terminals. Fabrication Components
dissimilar metal particles in the cables and cre- needed are shown in table 9-2 . Perform the following
ate further corrosion problems. Solvents will procedures to fabricate woven spliced terminals:
remove internal cable lubricant allowing cable
strands to abrade and further corrode. 1 Sweat solder or wrap cable prior to
cutting to prevent fraying.
(3) Control cable tension adjustment. Rig
aircraft as outlined in the applicable aircraft main- Table 9-2. Fabrication Components.
tenance manual. After rigging, measure for proper
tension on control cables, using a tensiometer. Use the Nomenclature Specification
following procedures to measure cable tension.
Cable, corrosion-resistant MIL-W-83420
(a) Place cable under the two blocks on in- Wire rope, 1 tinned steel MIL-W-83420
strument, and pull lever on side of instrument down.
This pushes up on the center block, called a riser. The Cord, serving V-T-291
force required to raise the center block is indicated by a
Solder, tin-lead QQ-S-571
pointer on the scale.

9-18
 TM 1-1500-204-23-1

Figure 9-21. Control Cable Wear Limits

9-19
TM 1-1500-204-23-1

Figure 9-22. Cable Tensiometer

9-20
 TM 1-1500-204-23-1

2 Secure cable around a bushing or 15 After completion of third complete

thimble by means of a splicing clamp tuck, have the number of wires in
leaving 8 inches or more of free end. each free strand. Make another com-
Secure splicing clamp in a vise with plete tuck with remaining wires.
free end to the left of standing wire 16 At completion of fourth tuck, again
and away from operator. halve number of wires in free strands
3 Select free strand (1, figure 9-23) and make one final tuck with remain-
nearest standing length and sepa- ing wires.
rate this strand from rest of separate 17 Cut off all protruding strands and
ends. pound splice with a wooden or
4 Insert a marlin-spike under first three rawhide mallet to relieve strains in
stands (A, B, and C) of standing wires.
length nearest separated strands of 18 Serve splice with waxed line cord.
free end and separate them momen- Start ¼ inch from end of splice and
tarily by twisting marlin-spike. carry wrapping over loose end of cord
5 Insert free strand (1) under three sep- and along tapered splice to a point
arated strands through opening cre- between second and third tucks.
ated by marlin-spike. Pull free strand 19 Insert end of cord back through last
taut, using pliers. five wrappings and pull snug.
6 Unwind a second strand (2), located 20 Cut off end, and when a thimble is
to left of first strand tucked, and in- used as an end fitting, bend down
sert this second strand under first two points.
standing strands (A and B).
21 Apply two coats of shellac, Federal
7 Loosen third free length strand (3) lo- Specification TT-S-271, to the cord,
cated to left of first two, and insert it allowing 2 hours between coats.
under first standing strand (A).
22 Carefully inspect cable strands and
8 Remove center or core strand (7) splices for local failure. Weakness in
from free end and insert it under a woven splice is made evident by a
same standing strands (A and B). separation of strands of serving cord.
9 Temporarily secure core strand to (b) Wrapped solder splice . The wrapped
body of standing cable. solder splice may be used on 1/16-inch cable only to
10 Loosen strand (6) located to right of fabricate end fittings. The procedure is as follows (see
first strand (1) and tuck it under last figure 9-24) .
two strands (E and F) of standing ca- 1 Arrange cable and fittings as re-
ble. quired, allowing approximately 2 ¼
11 Tuck fifth free end (5) around fifth inches of free end.
standing strand (E). Tuck fourth free 2 Place assembly in a splicing clamp
end (4) around sixth standing strand and secure in a vise.
(F).
3 Starting as close as practical to
12 Pull all strands snug toward end fitting end fittings, press free end standing
with pliers. This completes first tuck. lengths of cable together tightly, and
13 Begin with first free strand (1) and wrap with a single layer of 0.020 inch
work in a counterclockwise direc- brass or copper wire, Federal Speci-
tion, tucking free strands under every fication QQ-W-343, leaving a space
other standing strand. of approximately 1/8 inch between
14 After completion of every tuck, pull every ½ inch of wrapping.
strands taut with pliers. Pull toward NOTE
end fitting. Care must be exercised to prevent standing
length from twisting during this operation.

9-21
TM 1-1500-204-23-1

Figure 9-23. Preparation of Woven Cable Splice

9-22
 TM 1-1500-204-23-1

9 Carefully inspect splice. A wrapped

soldered splice, easily bent with fin-
gers, is unsatisfactory because of
lack of solder penetration.

NOTE

Cracks in solder located between wrapping wire

and short space provide between wraps is a
positive indication of slippage in wrap soldered
splice.

(5) Testing of cables and splices. Test all ca-

bles and splices prior to installation using the following
procedures:

A suitable guard should be placed over cable,

during testing, to prevent injury in event of cable
failure.

(1) Arrange cable to simulate

installation, including pulleys, when
required.

(2) Apply test load (refer to table 9-3)

gradually to one end of the cable
Figure 9-24. Wrapped Solder Splice for 3 minutes.

4 Allow wrapping to extend approxi- Table 9-3. Cable Test

mately ¼ inch beyond free end.

5 Dip wrapping in tin-lead solder, Fed- Load in

eral Specification QQ-S-571. Cable size (inches) pounds1
1/16 288
NOTE
3/32 552
Carefully sweat solder into cable and about
1/8 1200
wrapping.
5/32 1680
6 Apply solder until wrapping wire is
barely discernible, and ensure that 3/16 2520
open spaces between wrap sections 7/32 3360
are thoroughly impregnated with sol-
der. ¼ 4200
9/32 4800
7 After splice has cooled, thoroughly
wipe clean and remove all solder 5/16 5870
residue. 3/8 8640
8 Wipe cable and impregnate spliced
section with corrosion preventive 1
60 percent of minimum allowable breaking strength
compound, MIL-C-16173, Grade I.

9-23
TM 1-1500-204-23-1

f. Control System Components. Control system

components are explained in the following paragraphs. (3) Fairleads. Fairleads, as shown in figure
9-27, are used to guide cables in a straight line through
(1) Turnbuckles. A turnbuckle assembly is a or between structural members of the aircraft. Inspect
mechanical screw device consisting of two threaded ter- fairleads for wear, breakage, alignment, cleanness, and
minals and a threaded barrel. Figure 9-25 shows a typi- security. Examine cable routing at fairleads to assure
cal turnbuckle assembly. Turnbuckles are fitted in the that deflection angles are no greater than 3 degrees
cable assembly for the purpose of making minor ad- maximum. Determine that all guides and anti-abrasion
justments in cable length and for adjusting cable ten- strips are secure and in good condition. Replace rubber
sion. One of the terminals has right-hand threads and or nylon grommets that show evidence of excessive
the other has left-hand threads. The barrel has match- wear. Replace worn or cracked phenolic fairleads.
ing right- and left-hand internal threads. The end of the Reposition fairleads that allow cables to chafe.
barrel with the left-hand threads can usually be identi-
fied by a groove or knurl around that end of the barrel. (4) Pulleys. Pulleys are used to guide cables
and change the direction of cable movement. Various
(a) Turnbuckle replacement criteria. cable system malfunctions may be detected by analyz-
Replace turnbuckles and turnbuckle barrels that are ing pulley conditions. These include such discrepancies
cracked, corroded, or have stripped threads. as too much tension, misalignment, pulley bearing prob-
lems, and size mismatches between cables and pulleys.
(b) Turnbuckle tolerances. Turnbuckle tol- Examples of these conditions are shown in figure 9-28.
erances are: three visible male (cable terminal) threads Inspect pulleys using the following procedures:
or four visible female (turnbuckle barrel) threads, each
of which should be free of evidence of corrosion at the (a) Reposition pulleys that do not align with
root of the threads. (The maximum of four visible female cables within 2 degrees. Replace inoperative or other-
(turnbuckle barrel) threads applies only to initial installa- wise defective pulleys.
tion of the cable, so that if the cable stretches, the turn-
buckle can be adjusted to the desired cable tension, at (b) Inspect pulleys for roughness, sharp
which time, more or less than four barrel threads may edges, and presence of foreign material embedded in
be exposed.) Safety all turnbuckles. the grooves.

(2) Cable terminals. Terminal fittings are gen- (c) Inspect pulleys for excessive grooving by
erally of the swaged type. They are available in the visual examination of the surface, and by rotating pulley
threaded end, fork end, eye end, single-shank ball end, and observing if the cable twists, rotates, or jumps up
and double-shank ball end. The threaded end, fork end, and down, as a result of interplay between the grooves
and eye end terminals are used to connect the cable of the pulley and the lay of the cable.
to a turnbuckle, bellcrank, or other linkage in the sys-
tem. The ball-end terminals are used for attaching ca- (d) Examine pulley bearings to assure
bles to quadrants and special connections where space proper lubrication, smooth rotation, freedom from flat
is limited. Figure 9-26 shows the various types of termi- spots, dirt, and paint spray. Inspect pulley bearings for
nal fittings. Visually inspect and replace clevis or termi- roughness, binding, noise, rust, lubricant leakage, and
nals that are scratched, nicked, dented, corroded, have excessive looseness compared to a new bearing.
stripped threads, or are found bent (distorted).
(e) Maintain pulley alignment to prevent the
NOTE cable from riding on the flanges and chafing against
guards, covers, or adjacent structure.
Minor nicks, scratches, corrosion pits, less than
0.005 inch deep, may be removed by cleaning
(f) Check all pulley brackets and guards for
and burnishing smooth, to restore the part to
damage, alignment, and security. Replace if cracked,
useful service.
corroded, or otherwise damaged.

(g) Periodically rotate pulleys, which turn

through a small arc, to provide a new bearing surface
for the cable.

9-24
 TM 1-1500-204-23-1

Figure 9-25. Turnbuckle Assembly

Figure 9-26. Types of Terminal Fittings

Figure 9-27. Fairleads

9-25
TM 1-1500-204-23-1

Figure 9-28. Pulley Wear Patterns

NOTE NOTE

It is good practice to rotate the pulley 90 de- Operation or adjustment of some accessories
grees while inspecting, so as to relocate the or flight controls requires a rotating motion
used area to another position and thereby pro- which often is accomplished by means of torque
long the life of the pulley. tubes. To effect changes in direction of the
torque tube, universal joints are required. The
(5) Control rods. Control rod assemblies are most common are MS20270 and MS20271,
used as links in mechanical systems to allow remote op- which are attached to the tube by bolts or rivets.
eration and adjustment of components. Push-pull link-
age is designed and constructed so that both torsional (a) Inspection of control tubes. The proce-
and compression forces will be transmitted to the com- dure which follows is common to all control tube assem-
ponent being operated. Two common types of push-pull blies. Refer to the applicable manual for inspection of
linkage are the control tube and the control rod. Control each particular component.
tubes, as shown in figure 9-29, consist of a metal tube,
usually made of steel or an aluminum alloy, and two rod 1 Check for bent or flattened tube.
ends. One rod end is attached to each end of the metal
tube, which may be swaged, expanded, or reamed at 2 Check tube for nicks, dents, gouges,
the ends to engage the rod ends. The rod ends are scores or scratches, corrosion, and
welded or riveted to the tube. cracks.

9-26
 TM 1-1500-204-23-1

Figure 9-29. Control Tube Assembly

NOTE NOTE

If in doubt as to presence of cracks in tube, Do not attempt tube repair if center one-third
strip the paint and make a magnetic-particle or of assembly is damaged. When replacing rod
fluorescent-penetrant inspection. ends that are riveted to control tube, rotate
tube 90 degrees and redrill prior to riveting. In
3 Check rod ends for security (loose riv- emergency, repair tubular type control rod by
ets), cracks or breaks, and damaged inserting a scarfed or fishmouth sleeve rein-
threaded portions. forcement.

(b) Repair of control tubes . Control tubes (c) Installation of control tubes. Install
can be repaired by methods similar to those used on control tube assembly and rod ends as a unit, and make
structural members. When repairing a control tube, a adjustments at time of installation. Consult applicable
perfect straightness must be obtained to preserve the aircraft manual for proper dimensions and settings. The
full strength of the tube. Sleeve reinforcements may be following are general procedures:
added to steel tubes with a scarfed or fishmouth cut and
then welded in place. Aluminum alloy tubes can be re- 1 Install checknut on tube assembly or
paired in the same manner, using rivets for attachment. threaded end of rod, and attach rod
If possible, the tube should be replaced and the termi- end to assembly.
nals salvaged. AN490 threaded rod ends should be re-
placed because of difficulty in picking up the original rivet 2 Adjust rod end to obtain correct
holes. length of tube assembly. Tighten
checknut against rod end to prevent
its coming loose.

9-27
TM 1-1500-204-23-1

NOTE 3 Check for evidence of corrosion.

Deleted 4 Check for bent or misaligned clevis

forks and elongated bolt holes.
3 Install tube assembly with correct
bolts, nuts, and washers. 5 Thoroughly clean, inspect, and lubri-
cate bearings in accordance with TM
NOTE 55-1500-322-25.
When connecting a ball bearing rod end, install (b) Repair of rod ends. Minor repairs may
a plain or countersunk washer, MS20002, of be accomplished using the following procedures:
appropriate size under the attaching nut and
bolt head to prevent any possibility of rod end
1 Smooth out small nicks and scratches
slipping off over the bearing retaining nut or bolt
with fine abrasive cloth, Federal
head. Attaching nut and bolt must clamp tightly
Specification P-C-451.
the inner race of bearing to face of washer
and supporting structure. Use caution when
installing washers so that full movement of rod 2 Correct minor thread irregularities by
end is not limited. Nuts and bolts that are only chasing threads with a tap or die.
fingertight do not use the bearing for the pur-
pose for which it was intended. Control tubes 3 Replace defective bearings.
using clevis rod ends may have washers, if
required, installed under bolt and nut heads on 4 Major defects will require replace-
outside of fork or between fork and bearing, if ment of rod end.
space permits. Tighten nuts to torque values
shown in applicable aircraft manual. (c) Installation of rod ends. Install rod ends
and control tube assembly as a unit. Refer to paragraph
4 Check for freedom of movement, full 9-12f(5)(c).
travel, and excessive side play.
(7) Bellcranks. Bellcranks, as shown in figure
5 Secure rod ends, bolts, and nuts with 9-30, change direction of motion and transmit motion to
applicable safety devices. parts such as control rods, cables, and torque tubes.
Replace all worn, bent, or otherwise defective bell-
(6) Rod ends. Rod ends are used on push-pull cranks.
linkage as attachment points and to effect minor ad-
justments. Rod ends are available with threaded, cle-
vis, and bearing ends. Those with internally threaded
shanks are used on threaded control rods or control
tube assemblies which have threaded rod ends. Other
rod ends are used to make up control tube assemblies.
Rod ends are used to make adjustments in control tube
length and usually are safetied with a checknut or lock-
wire.

(a) Inspection of rod ends. Clean and in-

spect rod ends using the following procedures:
Figure 9-30. Bellcrank
1 Check for cracks and breaks.

2 Check for threaded portion for dam-

aged threads.

9-28 Change 9
 TM 1-1500-204-23-1

(8) Mixing units. Mixing units combine four (b) Lubricate valve cranks and push-pull
motions from the cockpit (pitch, roll, yaw, and thrust) levers with a small amount of molybdenum-disulfide
and convert them into two outputs. Inspect and maintain technical powder, MIL-M-7866.
in accordance with the applicable maintenance manual.
(c) Pressure-test any repair made to heat ex-
(9) Drive chains. Replace defective links in changer tube before installation. A repaired tube is con-
chains and maintain in accordance with applicable sidered a temporary measure and will be replaced when
maintenance manual. parts become available.

(10) Speed rigs. Speed rigs are fitted in the NOTE

cable assembly for the purpose of making rapid minor
adjustments. Heaters with an engine exhaust heat source re-
quire an operational test for carbon monoxide
9-13. ENVIRONMENTAL CONTROL SYSTEMS. levels upon installation of the heater or following
Environmental control systems heat, cool, and remove extensive heat exchanger maintenance, modifi-
moisture from the air supplied to the crew or passenger cation, or suspected malfunction.
compartments.
The test will be performed at heat duct open-
ing with the heater full on and the engines
a. Types. The forced air heating system, combus- operating at full military power. An indication
tion heater, and pressurized system are used by Army of 50 parts per million (ppm/0.005 percent)
aircraft. Each is explained in the following paragraphs. or greater requires corrective action prior to
heater use. Suggested test equipment is:
(1) Forced air heating system. Heated air is Detector Kit, Carbon Monoxide, Colorimetric,
provided for crew comfort, deicing, defrosting, and anti- NSN 6665-00-618-1482 and Indicator Tubes,
icing. Air is forced into muffs or jackets installed around Carbon Monoxide, NSN 6665-00-276-7545 .
the tailpipes. The air routed through the muff or jacket
picks up heat by convection through the tailpipe mate- (2) Combustion heater. The combustion
rial. The heated air is then routed to an air-to-air heat heater provides heat by routing outside air past a burner
exchanger before going on to perform various heating section. The outside air picks up heat by convection
functions. Maintenance to this type of system is limited, from the burner section and is then routed to perform
and will consist of the following: various heating functions. Maintenance of heater be-
tween overhauls will normally consist of inspection,
cleaning, or replacement of parts as explained in the
following procedures:
Degreasing Solvent, MIL-PRF-680, is com-
bustible and toxic to eyes, skin, and respiratory
tract. Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged con- DELETED
tact. Use only in well ventilated areas (or use
approved respirator as determined by local
safety/industrial hygiene personnel). Keep
away from open flames or other sources of
ignition. Do not use a metal instrument, as it may dam-
age core passage.
(a) Wash all metal parts of heating system in
degreasing solvent, MIL-PRF-680. Wash flexible tubing (a) Clean core tip and body of spray nozzle
with mild soap, Federal Specification P-S-620, and wa- with degreasing solvent, MIL-PRF-680. Use a wooden
ter. stick to scrape off any dirt remaining on spray nozzle.

Change 5 9-29
TM 1-1500-204-23-1

The test will be performed at a heat duct open-

ing with the heater full on. An indication of
Degreasing Solvent, MIL-PRF-680, is com- 50 parts per million (ppm/0.005 percent) or
bustible and toxic to eyes, skin, and respiratory greater requires corrective action prior to heater
tract. Wear protective gloves and goggles/face use. Suggested test equipment is: Detec-
shield. Avoid repeated or prolonged con- tor Kit, Carbon Monoxide, Colorimetric, NSN
tact. Use only in well ventilated areas (or use 6665-00-618-1482 and Indicator Tubes, Car-
approved respirator as determined by local bon Monoxide, NSN 6665-00-276-7545.
safety/industrial hygiene personnel). Keep
away from open flames or other sources of (3) Pressurized system. A pressurized sys-
ignition. tem maintains the cabin pressure altitude at a constant
value. Pressurized air is pumped into the sealed fuse-
Aliphatic Naphtha, TT-N-95, is extremely lage from cabin superchargers. The superchargers de-
flammable and toxic to eyes, skin, and respi- liver a constant volume of air at all altitudes up to a de-
ratory tract. Wear protective gloves and gog- signed maximum. Air is released from the fuselage by
gles/face shield. Avoid repeated or prolonged a device called an outflow valve. The outflow valve,
contact. Use only in well ventilated areas by regulating the air exit, controls the pressure within
(or use approved respirator as determined the aircraft. Maintain in accordance with the applicable
by local safety/industrial hygiene personnel). maintenance manual.
Keep away from open flames, sparks, or other
sources of ignition.
b. Repair of Flexible Air Ducts. Cracked flexible
air ducts, constructed of fiberglass material, will be in-
spected and repaired on the aircraft when economically
feasible. Silicone damage shall not exceed 3.0 inches
Do not use chlorinated solvents in order to avoid in length and 1.5 inches wide with limits of two repairs
possible damage to filter element. per foot of duct or three percent of total surface area.
Reworked areas will be sanded or buffed to fair in with
(b) Clean filter element by passing air or de- adjoining material. Repair flexible air ducts using the fol-
greasing solvent, MIL-PRF-680, through it in reverse di- lowing procedures:
rection after removal from filter bowl. When these meth-
ods fail to clean element, it should be replaced. (1) Clean damaged area with Aliphatic Naptha,
TT-N-95. Allow cleaned area to air-dry a minimum of 30
(c) Use dry, filtered air to blow out any dust minutes.
that may have accumulated in ignition unit. Wipe out
any oil with a dry, clean cloth . (2) Apply to a brush coat of Room Temperature
Vulcanizing (RTV), MIL-A-46146, on damaged area with
(d) Secure all heater drain plugs with lock- a 0.5 inch overlap from edge of damaged area.
wire to prevent loss of plugs and resultant flame dis-
charge. Prepare drain plugs for safetying as follows: (3) Smooth and cure by air drying a minimum
of two hours at room temperature or until it is dry to the
1 Drill hex head bolts across a corner touch.
with a No. 52 drill.
NOTE
2 Drill countersunk hex head plugs For repair of damage to the fiberglass cloth, the
completely through and countersink limitation is no more than 10 percent of surface
drilled head 90 degrees by 3/32-inch area after completion of repair.
diameter on both sides of plug.
(4) Clean the complete circumference of the
3 Secure drain plugs to any suitable ad- air duct in the vicinity of damaged area with Aliphatic
jacent point using steel wire, ASTM Naptha. Allow cleaned area to air-dry a minimum of 30
A580 ANO A313. minutes.
NOTE
(5) Use brush to apply a thin coat of adhesive to
Combustion heaters require an operation test the complete circumference of the duct in the damaged
for carbon monoxide levels upon installa- area and smooth out adhesive.
tion of the heater or following extensive heat
exchanger maintenance, modification, or sus-
pected malfunction.

9-30 Change 7
 TM 1-1500-204-23-1

NOTE

Repairs of flexible ducts made of fiberglass

impregnated with chloroprene shall be made
with adhesive , NSN 8040-00-390-7960 (P/N
Bostick 4006A and 4006B) utilizing fiberglass
cloth. Repairs will be accomplished in a
well-ventilated area.

9-14. DEICING SYSTEMS. Pneumatic deicing

systems use rubber deicers, called boots or shoes,
attached to the leading edge of the wing and stabilizers.
The deicers are composed of a series of inflatable
tubes. During operation, the tubes are inflated with
pressurized air, and deflated in an alternating cycle as
shown in figure 9-31. This inflation and deflation causes
the ice to crack and break off. The ice is then carried
away by the airstream.

a. Deicing System Precautions. Exercise the

following precautions to assure maximum service life of
deicer shoes:

• Repair all damage promptly.

• Keep deicer shoes free of oil, gasoline,

paint remover, solvents, and other injurious
substances.

• Clean deicer shoes, using a mild soap, A-A-

50, and water solution not exceeding 180°F
(82°C).

• Do not rest ladders of work stands against

leading edges having deicer shoes in-
stalled. Wrap padding around those por-
tions of work stands which could come in
contact with installed deicer shoes.

• Do not drag fuel or oil servicing hoses over

the deicer shoes.

• Do not walk or lay tools and objects on

upper stretch area of shoes. Deicer shoes,
when installed, are under tension and
therefore readily susceptible to abrasion.
Figure 9-31. Deicer Boot Inflation Cycle
• Protect deicer shoes from abuse.
b. Deicing System Preventive Maintenance.
Preventive maintenance for deicing systems will entail
the following procedures:

DELETED

Change 5 9-31
TM 1-1500-204-23-1

(c) Clean buffed area with a clean cloth com-

pletely dampened with Aliphatic Naphtha.

Aliphatic Naphtha, TT-N-95, is extremely (d) Select a patch of ample size to cover
flammable and toxic to eyes, skin, and respi- damage.
ratory tract. Wear protective gloves and gog-
gles/face shield. Avoid repeated or prolonged (e) Apply one coat of Goodrich 60 cement, or
contact. Use only in well ventilated areas equivalent, to damaged area and patch, and allow to dry
(or use approved respirator as determined thoroughly (5 to 10 minutes).
by local safety/industrial hygiene personnel).
Keep away from open flames, sparks, or other (f) Reactivate both cemented surfaces with a
sources of ignition. cloth dampened with Aliphatic Naphtha, and apply patch
to deicer shoe, starting at edge and working down care-
(1) Thoroughly clean affected Aliphatic Naph- fully to avoid trapping air beneath patch.
tha, TT-N-95.
(g) Allow patch to set 15 minutes, then wipe
patch and surrounding area with Aliphatic Naphtha.

Avoid breathing vapors from cements and sol- (h) Buff and clean a minimum area of ½ inch
vents utilized during this operation. around patch.

(2) Apply a brush coating of sealing area us- (i) Apply a brush coat of sealing compound,
ing compound, PR-1826 B1/2, approximately 1/32 inch PR-1826 B1/2.
thick over clean area.
NOTE
(3) Allow sealing compound to dry until no Weather-checked surfaces and abraded areas
longer tacky. not requiring a patch will be treated as outlined
in paragraph 9-14b.
(4) Rub down sealing compound to remove
brush marks and feather edges using abrasive paper, Repair cuts, tears, and severe scuff damage to
400 grit, Federal Specification P-P-101, or equivalent. tube or stretch area with reinforced (one-way
stretch) neoprene patches. Damage to non-
(5) Remove powdered sealing compound with stretch areas will be repaired with plain neo-
compressed air or a dry, clean cloth. prene patches.

(6) Apply one coat of approved conductive ce- (2) Cold patch limits. Limits for cold patching
ment to entire surface of shoe. are as follows:

c. Deicing System Troubleshooting. A typical (a) Cuts up to one inch on deicer shoes at-
troubleshooting chart for deicing systems is shown in ta- tached with fairing strips.
ble 9-4.
(b) Cuts up to three inches in length on deicer
d. Deicing System Maintenance. Maintenance shoes attached with cement.
of deicer system consists primarily of the care and repair
of deicing shoes and the replacement of defective com- 9-15. FIRE DETECTION AND EXTINGUISHING
ponent parts. The following paragraphs explain general SYSTEMS. Fire detection and extinguishing systems
maintenance for deicing systems. are explained in the following paragraphs.

(1) Patch installation. Install patches using the a. Fire Detection Systems. The fire detection
following procedures: systems are designed to detect the presence of fire
in zones such as engine compartment and combus-
(a) Thoroughly clean affected area, using tion-type heater compartment, and to light a red warning
Aliphatic Naphtha, TT-N-95. light in the pilot’s compartment in event of fire. To detect
fires or overheat conditions, detectors are placed in the
(b) Buff affected area until completely rough- various zones to be monitored. Fires are detected in
ened. aircraft using one or more of the following:

9-32 Change 5
 TM 1-1500-204-23-1

Table 9-4. Troubleshooting Pneumatic Deicing Systems

Trouble Probable cause Remedy

1. Pressure gauge oscillates. a. Faulty lines or connections. Repair or replace lines. Tighten
loose connections.
b. Deicing boots torn or punctured Repair faulty boots.
c. Faulty gauge Replace gauge.
d. Faulty air relief valve Adjust or replace relief valve.
e. Faulty air regulator Adjust or replace regulator.
2. Pressure gauge oscillates; peaks at a. Vacuum check valves installed Reinstall correctly.
a specified pressure while instrument improperly
vacuum gauge shows no reading.
b. Vacuum relief valve improperly Adjust or replace valve as
adjusted or faulty necessary.
c. Faulty lines between pump and Tighten, repair, or replace faulty
gauge lines or connections.
3. Pressure gauge shows no pressure a. Faulty pressure gauge line Repair or replace line.
while vacuum gauge shown normal
reading.
b. Faulty pressure gauge Replace gauge.
c. Pressure relief valve faulty Adjust or replace as necessary.
d. Pressure regulator faulty Adjust or replace as necessary.
4. Cycling period irregular. a. Loose or faulty tubing and Tighten, repair, or replace as
connection necessary.
b. Boots torn on punctured Repair faulty boots.
c. Faulty electronic timer Replace timer.

9-33
TM 1-1500-204-23-1

• Rate-of-temperature rise detectors (3) Continuous-loop system. A continuous-

loop detector or sensing system permits more complete
• Radiation sensing detectors coverage of a fire hazard area than any type of spot-type
temperature detectors. Continuous-loop systems are
• Smoke detectors versions of the thermal switch system. They are over-
heat systems, heat-sensitive units that complete electri-
• Overheat detectors
cal circuits at a certain temperature. There is no rate-of-
• Carbon monoxide detectors heat-rise sensitivity in a continuous-loop system. Two
widely used types of continuous-loop system are the
• Combustible mixture detectors Kidde and the Fenwal systems.
(a) Kidde system. The Kidde continuous-
• Fiber-optic detectors
loop system, as shown in figure 9-33, has two wires
• Flame detectors imbedded in a special ceramic core within an Inconel
tube. One of the two wires in the Kidde sensing system
• Observation by crew members is welded to the case at each end and acts as an internal
ground. The second wire is a hot lead (above ground po-
b. Types of Fire Detection Systems. A fire de- tential) that provides a current signal when the ceramic
tection system should signal the presence of a fire. Units core material changes its resistance with a change in
of the system are installed in locations where there are temperature.
greater possibilities of a fire. Three detector systems in
common use are the thermal switch system, thermocou-
ple system, and the continuous-loop detector system.
(1) Thermal switch system. The thermal
switch system uses a bimetallic thermostat switch or
spot detector similar to that shown in figure 9-32. Each
detector unit consists of a bimetallic thermoswitch.
These thermal switches are heat-sensitive units that
complete electrical circuits at a certain temperature.
If the temperature rises above a set value in any one
section of the circuit, the thermal switch will close,
completing the light circuit to indicate the presence of
a fire or overheat condition.

Figure 9-33. Kidde Sensing Element

Figure 9-32. Thermal Switch

(2) Thermocouple system. The thermocou-
ple is constructed of two dissimilar metals such as
chromel and constantan. The point where these metals
are joined and will be exposed to the heat of a fire is
called a hot junction. There is also a reference junction
enclosed in a dead air space between two insulation
blocks. A metal cage surrounds the thermocouple to
give mechanical protection without hindering the free
movement of air to the hot junction. If there is a fire, the
hot junction will heat more rapidly than the reference
junction. This will complete a circuit from the aircraft
power system to the coil of the slave relay which closes
and completes the circuit to the fire-warning light.

9-34
 TM 1-1500-204-23-1

(b) Fenwal system. The Fenwal system, as NOTE

shown in figure 9-34, uses a single wire surrounded by
a continuous string of ceramic beads in an Inconel tube. Limits on the element diameter, acceptable
The beads in the Fenwal detector are wetted with a eu- dents or kinks, and degree of smoothness of
tectic salt which possesses the characteristic of sud- tubing contour are specified by manufacturers.
denly lowering its electrical resistance as the sensing No attempt should be made to straighten any
element reaches its alarm temperature. acceptable dent or kink, since stresses may be
set up that could cause tubing failure.
c. Maintenance of Fire Detection Systems. In- • Loose nuts or broken safety wire at the end
spect fire detection systems for the following: of the sensing elements.
• Cracked or broken sections caused by NOTE
crushing or squeezing between inspection
plates, cow panels, or engine components. Loose nuts should be re-torqued to the value
specified in the manufacturer’s instructions.
• Abrasion caused by rubbing of element on Some types of sensing element connections
cowling, accessories, or structural mem- require the use of copper crush gaskets. These
bers. gaskets should be replaced any time a connec-
tion is separated.
• Pieces of safety wire or other metal parti-
• Broken or frayed flexible leads, if used.
cles which may short the spot detector ter-
minals. NOTE
• Condition of rubber grommets in mounting The flexible leads is made up of many fine metal
clamps, which may be softened from ex- strands woven into a protective covering sur-
posure to oils, or hardened from excessive rounding the inner insulated wire. Continuous
heat. bending of the cable or rough treatment can
break these fine wires, especially those near the
• Dents and kinks in sensing element sec- connectors. Broken strands can also protrude
tions. into the insulated gasket and short the center
electrode .
• Proper sensing element routing and clamp-
ing.
NOTE
Long unsupported sections may permit exces-
sive vibration which can cause breakage. The
distance between clamps on straight runs is
usually about 8 to 10 inches, and is specified
by each manufacturer. At end connectors, the
first support clamp is usually located about 4 to
6 inches from the end connector fittings. In most
cases, a straight run of 1 inches is maintained
from all connectors before a bend is started, and
an optimum bend radius of 3 inches is normally
Figure 9-34. Fenwal Sensing Element adhered to.

9-35
TM 1-1500-204-23-1

• Rubbing between a cowl brace and a sens- (1) Replace defective control unit with a service-
ing element. able unit.

• Correct grommet installation.

• Thermocouple detector mounting brack-

ets should be repaired or replaced when Do not bend sharply, kink, or twist sensing el-
cracked, corroded, or damaged. ement during installation. Minimum allowance
curve radius is one inch. Damage may other-
d. Troubleshooting of Fire Detection Systems. wise result.
A typical troubleshooting chart for fire detection systems
is shown in table 9-5.

e. Repair or Replacement of Fire Detection Com-

ponents. Repair or replace fire detection components
using the following procedures:

Table 9-5. Troubleshooting of Fire Detection Systems

Trouble Probable cause Remedy

1 Intermittent alarms. a. Short in the detector system wiring Repair or replace defective
. wiring.
b. Kinks and bends in sensing element Repair damaged areas of
sensing element.
2 False alarms. a. Short between loop connections and Repair or replace defective
. control units wiring.
b. Bent areas of sensing loop in contact Repair bent areas of sensing
with hot parts of the engine loop.
c. Short in the sensing loop Replace shorted section of
sensing loop.
d. Moisture in detection system Remove moisture
contamination.
3 Failure to obtain an alarm signal a. Defective test switch or control unit Replace test switch or
. when the test switch is actuated control unit.
b. Lack of electrical power Provide electrical power.
c. Inoperative indicator light Replace indicator light.
d. An opening in sensing element or Repair sensing element or
connecting wiring connecting wiring.

9-36
 TM 1-1500-204-23-1

(2) Replace sensing element only when physi-

cal damage such as chafing, bending, twisting, or break-
ing has occurred. Replace attaching parts when found
to be defective. Repeated or prolonged exposure to high con-
centrations of bromochloromethane (CB) or
decomposition products should be avoided.
CB is a narcotic agent of moderate intensity
but of prolonged duration. It is considered
Bends will not be less than two inches in radius.
less toxic than carbon tetrachloride, methylbro-
mide, or usual products of combustion. Normal
(3) Replace cable detector only when physical precautions should be taken while using bro-
damage such as chafing, bending, twisting, or breaking mochloromethane including use of oxygen
has occurred. Make all bends and routing with fingers masks when available. Injury to personnel may
only. Replace attaching parts when found to be defec- otherwise result.
tive.
Monobromotrifluoromethane (CF3Br) is highly
(4) Replace mounting brackets of thermocouple volatile but is not easily detected by its odor.
detectors when cracked, corroded, or damaged. Re- Although nontoxic, it must be considered to be
place attaching parts when found to be defective. about the same as other freons and carbon
dioxide, causing danger to personnel primar-
NOTE ily by reduction of oxygen available for proper
breathing. The liquid should not be allowed to
When replacing thermocouple detector, note
come into contact with skin, as it may cause
which wire is connected to identified plug termi-
frostbite or low temperature burns.
nal of defective unit, and connect replacement
in the same way.
g. Fire Extinguishing Systems. The fire extin-
guisher system is the one-shot type consisting of one
f. Testing of Fire Detection System. Test fire de-
or more charged containers of bromochloromethane or
tection system using the following procedures:
monobromotrifluoromethane (CB and CF3Br), discharg-
ing tubing, overboard discharge tube, discharge indica-
(1) Test system for proper operation by turning tor, circuit breakers, and control panel switch. The con-
on power supply and placing FIRE DET TEST switch in tainer is charged with monobromotrifluoromethane un-
test position. Red warning light should flash on within der pressure, which is discharged through tubing into
10 seconds. Turn switch and power off. the engine compartments by actuating FIRE EXT switch
to the ON position.
(2) Test required after repair or replacement of
units in fire detector system or when system is inopera- h. Maintenance of Fire Extinguishing Systems.
tive as follows: Maintenance of fire extinguisher system consists of in-
• Replace lamp in warning light, when spection and replacement of defective parts using the
warning light does not flash on. following procedures:

• Polarity, ground, resistance, and conti- (1) Check for specific pressure on pressure
nuity tests are required for systems with gauge as given in applicable aircraft maintenance man-
thermocouple detect or units. ual.

• Resistance and continuity tests are (2) Inspect overboard discharge indicator for
required for systems with sensing ele- evidence of system being discharged due to thermal
ments or cable detector units. expansion.

Change 7 9-37
TM 1-1500-204-23-1

NOTE

Install cartridges in the assigned locations (see

Do not flush system with water. Damage to DA Form 2408-18) to preclude incorrect age life
system may otherwise result. control removals at a later date.
(3) Purge system thoroughly with clean, dry, 9-16. HOIST SYSTEMS. The hoist system which pro-
compressed air immediately after landing when system vides a means of raising and lowering equipment or per-
has been used in flight, or immediately after discharged sonnel during flight or ground operation is of two types:
on the ground. Absorb residual bromochloromethane hydraulic and electric.
remaining on surface areas with dry cloths and clean,
dry, compressed air.
a. Hydraulic Hoist System. Maintenance and
testing procedures for hydraulic hoist systems are ex-
(4) Inspect compartments and components that plained in the following paragraphs.
may have come in contact with extinguishing agent for
possible damage. Replace defective parts.
(1) Maintenance of hydraulic hoist system.
Maintenance of the hydraulic hoist system consists
(5) Inspect rubber materials and insulations of replacement of defective parts using the following
where extinguisher was used. Replace when found procedures:
defective.
(a) Service system with fluid, MIL-H-5606,
(6) Relubricate all lubricated parts exposed to and maintain indicated reservoir level.
extinguishing agent.
(b) Cap all tubing disconnected during re-
(7) Replace overboard discharge indicator disc moval of units to prevent entry of foreign matter.
after system has been discharged.
(c) Replace damaged tubing. Use old tubing
or a piece of string as a pattern in routing new tubing.
Disconnect positive electrical lead on solenoid (d) Reuse fittings of hose and tube assem-
valve before removing container, and do not blies unless damaged.
connect lead until all circuit tests have been
completed and firing switch on control panel is in NOTE
OFF position. Damage to equipment may oth-
erwise result. Clean and thoroughly flush tubing and hose
prior to installation.
(8) Replace discharged container and bonnet
assembly with fully charged assemblies. (e) Replace hoist cable when kinked or when
cable has broken.

(f) Replace micronic filters periodically to as-

Before attempting to perform continuity test of sure delivery of uncontaminated fluid.
the fire extinguishing electric circuit, the extin-
guisher cartridges must be removed to preclude (g) Lubricate hoist as prescribed in the appli-
accidental firing during test. cable aircraft maintenance manual.

(9) Make a visual inspection of the electrical cir- (2) Testing of hydraulic hoist system. Test
cuit wiring for obvious damage. Test the continuity of hydraulic hoist system for operation periodically (and
the entire circuit excluding the fire extinguisher container when a new unit is installed in the system) by perform-
cartridge. ing a functional check using the following procedures:

9-38 Change 2
 TM 1-1500-204-23-1

NOTE The oxygen flows from the charged cylinder through the
high-pressure line to the pressure-reducing valve, which
Use an external hydraulic test unit or the aircraft reduces the pressure to that required at the mask out-
hydraulic system with engine operating. lets. A calibrated orifice in the outlets will control the
amount of oxygen delivered to mask.
(a) Check operation of down-limit switch by
unwinding winch to its limit to assure that winch will stop (2) Pressure-demand system. A simple pres-
when cable is fully unwound. sure-demand oxygen system is shown in figure9-36.
Note that there is a pressure-demand regulator for each
(b) Check operation of up-limit switch by run- crew member, who can adjust the regulator according
ning cable until up-limit switch is actuated. to his requirements.

b. Electrical Hoist System. Maintenance and b. Maintenance of Oxygen Systems. Mainte-

testing procedures for electric hoist systems are ex- nance of oxygen systems is described in the following
plained in the following paragraphs. paragraphs.

(1) Maintenance of electric hoist system. (1) Oxygen leaks . Use soap test to locate
Maintenance of the electric hoist system consists leaks unless individual leaks are large enough for per-
primarily of replacement of defective parts using the sonnel to hear or feel. Apply soap solution, using mild
following procedures: soap, A-A-50, to suspected part using a soft brush and
watch carefully for frothing, bubbling, or growing bub-
(a) Replace hoist cable when kinked or when bles.
cable has been broken strands.

(b) Replace monorail attaching parts when

found to be defective.
Do not allow petroleum base products to come
in contact with oxygen system components, as
(c) Lubricate hoist as prescribed in the appli- an explosion or fire may result.
cable aircraft maintenance manual.

(2) Testing of electric hoist system. Perform

a functional check, to test the electric hoist system for
operation periodically, and when a unit or electrical Drain tubing of all solutions and blow out with
wiring is replaced in the system. oxygen prior to installation in aircraft. Contami-
nation may otherwise result.
9-17. OXYGEN SYSTEMS. Oxygen system types,
maintenance, and servicing is explained in the following (2) Tubing and fittings. Maintenance, repair,
paragraphs. replacement, and installation of oxygen system tubing
is given in TM 1-1500-204-23-2.
a. Oxygen System Types. The design of the
various oxygen system types used in aircraft de- (3) Cylinders. Replace all damaged cylinders.
pends largely on the type of aircraft, its operational No maintenance is authorized on installed low or high
requirements, and, where applicable, the pressurization pressure cylinders.
system. In some aircraft a continuous-flow oxygen
system is installed for both passengers and crew. The NOTE
pressure demand system is widely used as a crew
system, especially on the larger transport aircraft. Many All low pressure oxygen cylinders which carry
aircraft have a combination of both systems which may a maximum charge of 450 psi will be painted
be augmented by portable equipment. yellow. High pressure oxygen cylinders which
carry a maximum of 2000 psi will be painted
(1) Continuous-flow system. The continuous- green.
flow oxygen system is shown in figure 9-35.

9-39
TM 1-1500-204-23-1

Figure 9-35. Continuous-Flow Oxygen System

Figure 9-36. Pressure-Demand Oxygen System

9-40
 TM 1-1500-204-23-1

(4) Check valves. Replace all faulty check (8) Charging after flight. Charge oxygen
valves as complete units. Check valves cannot be system on aircraft that have had all the oxygen supply
repaired. drained during flight within two hours after landing.
When oxygen system is not charged within two hours
after landing, system will be purged.

NOTE
Do not use masking tape to seal openings in
oxygen regulators. Masking tape constitutes a • Do not use lubricant other than antiseize tape,
safety hazard when use on either serviceable or MIL-T-27730, on aircraft oxygen systems.
repairable oxygen equipment.
• Do not use cleaning solutions, or any other so-
(5) Regulators. Do not apply oil or grease to lutions, inside any part of oxygen system when
any part of an oxygen regulator. installed in aircraft.

(6) Flexible hose. Maintain flexible hose using • Do not use any gases other than oxygen in-
the following procedures: side any part of oxygen system when installed
in aircraft.
(a) To remove contamination other than oil
and grease from flexible hose, remove hose and clean c. Servicing of Oxygen Systems. Prior to
with mild soap, A-A-50, and warm water solution; thor- servicing an aircraft oxygen system, personnel shall fa-
oughly rinse with fresh water and thoroughly dry with a miliarize themselves with the system, precautions, and
stream of clean, dried, water-pumped air or nitrogen. instructions for handling gaseous oxygen, operation of
servicing equipment, and potential hazards involved.
Oxygen servicing requires the utmost precautionary
(b) Replace hoses damaged or contam-
measures due to the highly explosive and flammable
inated with oil or grease. Repair and replacement
capabilities of oxygen. All personnel shall heed the
procedures for flexible hose are outlined in TM
following precautionary procedures when servicing:
1-1500-204-23-2.

(c) Examine fittings for tightness.

Only qualified personnel shall be authorized to
(7) Open lines. Plug or cap all open lines and operate equipment for servicing of an aircraft
equipment when opening system for replacement of any oxygen system. Damage to system may oth-
part. When system has been accidentally left open, sys- erwise result.
tem will be purged by one of the following methods:
(1) Aircraft shall not be serviced with oxygen
• In aircraft having filler lines connected when any of the following conditions prevail:
to one end of cylinder, and distribution
lines connected to opposite ends of • Aircraft electrical switches are on.
cylinder, purging will be accomplished
by connecting a service trailer to aircraft • Ground powered equipment is operating
filler valve. With all regulators open, within 50 feet of the servicing area.
pass oxygen through system for at least
30 minutes at a pressure of 50 psi at • Aircraft is being serviced with fuel, oil, or
filler valve. anti-icing fluids.

• In aircraft having filler lines and distribu- • Any combustible materials, fluids, etc.,
tion lines commonly connected at one are evident around oxygen servicing
end of cylinder, purging will be accom- equipment.
plished by filling system with oxygen and
then draining system. This cycle shall
be performed at least three times.

9-41
TM 1-1500-204-23-1

(2) When aircraft is being serviced with oxygen 9-18. RELIEF TUBE SYSTEM. Maintenance of re-
within 50 feet of an area where smoking is permitted, lief tubes primarily consists of cleaning and replacing of
NO SMOKING signs shall be placed at a 50-foot radius parts. Clean or replace parts using the following proce-
around the servicing area. dures:

(3) All aircraft parked outside will be grounded a. To clean and deodorize relief tube systems, a
and bonded, in accordance with TC 3-04.75, to the solution of 1 ½ ounces of MIL-SPEC A-A-1634 general
aerospace ground equipment while servicing oxygen purpose deodorant and 5 gallons of water will be used
systems. to wash area around relief tube exit and relief tube en-
trance.

b. Pour remainder of solution through the tube.

Oxygen equipment shall be kept clean at all When an offensive odor remains, use a stronger solu-
times. No organic matter or flammable sub- tion and reclean until odor is removed.
stance of any nature shall be allowed to con-
tact oxygen. Ensure that all components of the NOTE
systems are free of moisture, oil and grease
at all times. Oxygen is a nonflammable gas; The area of relief tube exhaust will be primed
however, it supports combustion and lowers the with zinc chromate primer, Federal Specifica-
flash ignition point of all combustible materials. tion TT-P-1757, and painted with acid proof lac-
Oxygen shall be handled as a flammable gas. quer, Federal Specification TT-L-54.

(4) To prevent overfilling of tanks, personnel c. Replace deteriorated hose, broken or damaged
shall observe aircraft oxygen system gauges at all times horn, and broken or damaged attaching parts.
during servicing operation.
NOTE
(5) Personnel shall be stationed at the oxygen
servicing unit at all times during servicing operation to Install hose so as to eliminate any residue pock-
shut off unit valves immediately upon receiving a com- ets.
mand from personnel watching aircraft system gauge.
9-19. WINDSHIELD WIPER SYSTEM. Maintenance
(6) Service aircraft from cylinders clearly la- and adjustment of the windshield wiper system is ex-
beled DRY or AVIATOR’S BREATHING OXYGEN. plained in the following paragraphs.
Other Oxygen may have moisture which could cause
flow stoppage at temperatures below freezing. a. Maintenance of Windshield Wiper System.
The maintenance of the windshield wiper system con-
(7) Always use a pressure-reducing device sists primarily of replacement of defective parts, as
when servicing low-pressure oxygen system from follows:
high-pressure bottles.
(1) Replace wiper motor, wiper units, wiper
(8) Fill oxygen system slowly to prevent explo- arms, and flexible cables that are inoperative, cracked,
sion resulting from heat generated by filling too fast. bent or otherwise defective.

(9) An aircraft oxygen system not equipped with (2) Replace wiper blades that are worn, deteri-
shut off devices at cylinders shall be completely dis- orated, or torn, or when rubber has lost its elastic qual-
charged of all pressure prior to removing components. ities.
All electrical power shall be shut off during oxygen dis-
charge operations.

(10) Refer to applicable aircraft maintenance

manual for additional information and maintenance
procedures.

9-42 Change 8
 TM 1-1500-204-23-1

b. Adjustment of Windshield Wiper System.

The windshield wiper system shall be adjusted as fol-
lows:
Degreasing Solvent, MIL-PRF-680, is com-
bustible and toxic to eyes, skin, and respiratory
tract. Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged con-
Do not operate wipers on dry glass. tact. Use only in well ventilated areas (or use
approved respirator as determined by local
(1) Loosen locknut on wiper blade, align blade, safety/industrial hygiene personnel). Keep
and tighten locknut. away from open flames or other sources of
ignition.
(2) Remove locknut from wiper unit shaft, adjust
position of arm on shaft to give full sweep on windshield, (g) Remove grease spots with degreasing
and reinstall locknut. solvent, MIL-PRF-680.

(3) Adjust tension nut at base of wiper arm until (h) Remove blood stains by use of cold wa-
blade exerts 1 ½ to 2 pounds pressure against wind- ter applied with sponge. Remove residue with a 10 per-
shield. cent solution of ammonia hydroxide, MIL-STD-612, or a
paste of cornstarch, Federal Specification N-C-541. Al-
NOTE low treated area to dry. When cornstarch is used, brush
dried material from fabric.
Measure tension at tip of wiper arm in a direction
perpendicular to windshield surface.
(2) Repair. Repair and patch fabric material of
troop seats using repair procedures outlined in para-
9-20. AIRCRAFT SEATS. Maintenance of aircraft graph 9-22.
seats shall be accomplished in accordance with the
procedures explained in the following paragraphs.
(3) Installation and removal. Follow instruc-
tions contained in the applicable aircraft maintenance
a. Troop Seats. Cleaning, repair and installation manual for installation and removal procedures.
and removal procedures for fabric or cotton canvas troop
seats are explained in the following paragraphs.
b. Metal Seats. Cleaning, repair, and installation
and removal procedures are explained in the following
(1) Cleaning. Clean troop seats as follows: paragraphs.
(a) Unfold and place parts face up.

(b) Brush with a firm bristle brush to remove

excess dirt. DELETED

(c) Prepare a cleaning solution of 1 ounce of (1) Cleaning. Clean with clean cloth moistened
anionic synthetic detergent (alkyl benzene sulfonate), with degreasing solvent, MIL-PRF-680.
Federal Specification P-D-410, per gallon of water.
(2) Repair. Patches and reinforcement repairs
(d) Work up heavy suds by repeatedly to metal seats will be accomplished in accordance with
squeezing of a sponge saturated with detergent solu- repair procedures in TM 1-1500-204-23-10.
tion. Apply heavy suds to soiled areas.
(3) Installation and removal. Follow instruc-
(e) Scrub soiled areas briskly, using a firm tions contained in the applicable aircraft maintenance
bristle brush or heavy cloth. Wipe off with a damp cloth. manual for installation and removal procedures.

(f) Allow treated area to dry. Brush to raise

nap.

Change 5 9-43
TM 1-1500-204-23-1

c. Upholstered Seats. Cleaning, repair, and in- The patch should be sized to extend 1.0 inch
stallation and removal procedures are explained in the in all directions to the damaged area and in-
following paragraphs. clude 0.50 inch of material to fold under to
finish all the edges of the patch. The patch
(1) Cleaning. Clean upholstered seats by using should be located on the underside of the dam-
cleaning materials and methods as prescribed in para- age area with the folded edges to the inside.
graph 9-20a. Zig-zag sew the damage area into the patch,
followed by a minimum of two (2) rows of stitch-
(2) Repair. Repair small rips or tears with a ing around the patch using 6-9 stitches per
sewed or unsewed patch. Attach unsewed patches with inch.
adhesive, Federal Specification MMM-A-1617. NOTE
A 24 month service life pertains only to those
(3) Installation and removal. For instructions
covers which are used in an energy attenuation
installation and removal, refer to the applicable mainte-
application.
nance manual for particular aircraft.
• Replace the original nylon spall shield, or use
d. Raschel Knit Seat Covers. Raschel knit seat
new ballistic nylon MIL-C-12369 for replace-
cover maintenance limits are listed below:
ment. Apply a thin even coat of contact adhe-
sive EC 1300L (FSCM 04963) to the tile sur-
• Deterioration or discoloration which indicates face. Allow adhesive to dry until tacky. Care-
a strength decrease to the point where it affects fully mate the spall shield to the tile, working it
the integrity of the seat(s) is not allowed. on by hand pressure. Fit the nylon snugly over
the fiberglass patch (or patches). Do not wrap
• Tears, cuts, or holes greater than 2.5 inch in
the spall shield over the edge of the panel.
length or diameter are not allowed; the seat
Tears in the spall shield shall not exceed 3
should be replaced
inches. Any unbonded area of the spall shield,
• Tears, cuts, or holes less than 2.5 inch in (as evidenced by bulges), shall not exceed a
length can be repaired. Repair is not allowed diameter of 1 inch.
for seat covers with holes, cuts, or tears in
• Seat covers made of raschel knit nylon cloth
raschel kit material that are located close to the
shall have a service life of 24 months. Seat
seams of the adjoining panels and do not al-
covers that are not marked with an installation
low sufficient space for the darning procedure.
date shall be assumed to have the same date
Repair should be used as a temporary mea-
as the day of acceptance of the aircraft. Re-
sure until new seat covers or back covers can
placement covers shall be marked with con-
be installed. In the fine-mesh duck cloth sur-
trasting ink conforming to MIL-I-6903. The size
rounding the raschel knit material, tears, cuts
of marking shall be of sufficient size and loca-
and holes up to 2.5 inches in length can be re-
tion so that it can easily be read. The following
paired. A different method for repairing is re-
is an example of marking installation date: 7
quired and is as follows:
Mar 88
Tears, cuts or holes less than 0.5 inch in length
may be repaired by stitching which extends 0.5 e. Polyester Fabric Seat Covers (UH-60).
inch into the sound material surrounding the Cleaning, repair, and installation and removal proce-
damaged area. dures for polyester fabric seat covers are explained in
the following paragraphs.
Tears, cuts or holes of up to 1.0 inch in length
may be repaired with the use of a patch made (1) Cleaning. Clean the polyester fabric seat
of the same material as the seat cover. Lo- and back using the following procedures:
cate on the underside of the damaged area and (a) Brush fabric with firm bristle brush remov-
sew a zig-zag stitch over the tear area and into ing excess dirt.
patch extending 0.5 inch into the sound mate-
rial surrounding the damaged area. (b) Use enough liquid to allow complete im-
mersion of the seat cover to be washed.
Tears, cuts, or holes of 1.0 to 2.5 inches in
length may be repaired with the use of a patch (c) Mix 3 ounces of low strength laundry
made of the same material as the seat cover. soap, Federal Specification P-S-1792, to each gallon
of water. Synthetic detergent is permissible as an
alternative.

9-44 Change 2
 TM 1-1500-204-23-1

NOTE 9-21. AIRCRAFT LITTERS. Litters installed in Army

aircraft shall be installed and removed as described in
The water temperature should not exceed the following paragraphs.
100°F (37°C).
a. Installation. Install Litters using litter kits pro-
(d) Immerse one cover at a time in the soap vided with each aircraft. Refer to the applicable aircraft
solution, let stand for 20-25 minutes, and hand wash for maintenance manual for specific installation procedure.
5 minutes.
b. Removal. Upon completion of mission involv-
(e) Rinse cover in clean water until all soap ing litters, remove from aircraft and return to supplying
is removed. agency. Stow litter kit in original container in aircraft
NOTE when applicable.
If machine washed, use complete wash and 9-22. PROTECTIVE COVERS. The instructions con-
rinse cycles. tained below are applicable to all types of aircraft pro-
tective covers and shields used by the Army.
(f) Spread covers on a clean surface out of
direct sunlight to dry. a. Installation and Removal Precautions. In-
stallation and removal precautions for the protective
(2) Repair. Repair polyester fabric covers using covers are as follows:
the following procedures:
• Protective covers shall be installed to
(a) Inspect for cuts, tears, punctures, burns protect airframe components which are
and broken stitches. Any damage less than 2-½ inches affected by extreme weather conditions.
long x 1 inch wide in the seat bottom may be repaired.
Replace seat bottoms with damage greater than 2-½ • Covers shall be installed when aircraft is to
inches long x 1 inch wide. remain in an exposed area for any extended
length of time, or when snow or ice is antic-
NOTE ipated.
Seat backs do not have a damage size limit for
repair. • To keep out dust, rain, and foreign matter,
protective shields, such as intake duct and
(b) All seats will be repaired using polyester exhaust covers, shall be installed to cover
thread, Specification Federal V.T. 285 and cloth openings and passages in the aircraft struc-
polyester (P/N SS9512) as required. ture and engine nacelle which leads to inter-
nal components of aircraft.
(c) Repairs will be accomplished using the • Do not drag covers over sharp objects;
details in figure 9-37. prevent contact with ground when installing
and removing.
(d) Damage that is close to the edge of the
seat cover which has insufficient space to allow a com- • Spread wet covers out to dry before folding
plete patch pattern will not be repaired. and storing.

(3) Installation and removal. For instructions • When installing and removing covers, do
on installation and removal, refer to the applicable main- not allow attaching buckles to scratch or
tenance manual for the particular aircraft. mar plexiglass sections of aircraft.

9-45
TM 1-1500-204-23-1

NOTES
1 ALL DIMENSIONS IN INCHES
2 STITCHING TO BE IN ACCORDANCE
WITH DDD-S-751 5 TO 8 STITCHES
PER INCH DEPENDING UPON
WEIGHT OF MATERIAL USE
FEWER STITCHES PER INCH
FOR HEAVIER MATERIAL
3 INSERT TO BE SAME MATERIAL
AND WEIGHT AS ORIGINAL
4 USE THREAD VT285 COLOR
TO MATCH COLOR OF
ORIGINAL MATERIAL

Figure 9-37. Repair Pattern for Polyester Cloth.

9-46
 TM 1-1500-204-23-1

b. Maintenance of Protective Covers. Cleaning, 1 Repair punctured, snagged, or torn

repair, waterproofing, and storage of protective covers areas by sewing in place a patch of
are explained in the following paragraphs. material equal to basic material in
weight, quality, and color.
(1) Cleaning. Protective covers contaminated
with salts from the atmosphere, specifically chlorides 2 Reinforce and darn punctures and
(in marine areas) and sulphur compounds (in industrial small holes (½ inch or less).
areas), can promote corrosion of aircraft skins. Grease,
oil, or dirt can mar or discolor plexiglass portions of 3 Trim and turn under frayed edges to
the aircraft. Therefore, only clean covers will be used. make a neat and durable repair.
Clean protective covers using the following procedures:
4 Use circular patches on small holes
NOTE and rectangular patches on larger
holes, irregular snags, or tears.
To increase life expectancy, protect covers
against rain, wind, snow, sand, and mildew 5 Mend a cluster of holes with one
when not installed on aircraft. suitable patch, after first removing
damaged area and turning under all
(a) Remove all possible ropes and wooden edges.
attaching parts.
6 Provide best possible water drainage
(b) Tape or wrap all attaching parts, such as by extending patch seams diago-
buckles, snaps, hooks, and D-rings to prevent tearing nally from centerline of cover section
and snagging of covers during soaking or washing. whenever possible.
(c) Brush soiled section with firm bristle 7 Do not extend patches over more
brush to remove excessive soil. than one section of cover (seam to
seam).
(d) Select a container that will hold enough
liquid to allow complete immersion of cover to be 8 Restitch all open seams. Stitch pat-
washed. tern and type thread will follow as
near as possible the type stitch and
(e) Mix soap solution containing 3 ounces of thread used in original construction of
low strength laundry soap, Federal Specification P-S- item being repaired.
1792, to each gallon of water. Synthetic detergents are
permissible when available. (b) Edge damage. Repair edge damage as
follows:
NOTE

The temperature of water should not exceed 1 Repair damaged areas along edge of
100°F (37°C). covers where grommets or attaching
points are located by folding a piece
of material equal to the basic mate-
(f) Immerse one cover at a time in soap solu-
rial over damaged area by sewing in
tion for a period not to exceed 30 minutes.
place.
(g) Rinse over in clean water until all soap
2 Replace corner areas where attach-
has disappeared.
ing points are located by sewing on a
patch composed of three thicknesses
(h) Spread covers on a clean surface to dry. of material equal to basic material.
(2) Repair. Make prompt repairs to aircraft pro- 3 Replace any worn or missing web-
tective covers to prolong service life. Inspect for dam- bing keepers, defective elastic web-
age immediately after use and make repairs using the bing, or reinforcement patches.
following paragraphs.

(a) Puncture, snagged, or torn areas. Repair

punctured, snagged or torn areas as follows:

9-47
TM 1-1500-204-23-1

(c) Attaching equipment damage. Repair (a) Fold covers neatly to facilitate easier and
attaching equipment damage as follows. faster installation when covers are needed.

1 Repair, when practicable, or replace (b) Store covers in a dry place on a platform
all damaged attaching equipment or on slats of wood. Never store covers on ground or
such as straps, buckles, webbing, concrete.
keepers, cords, cables, cable fittings,
grommets, etc. 9-23. ARMOR PLATING. The repair instructions that
follow are limited to composite armor composed of a ce-
2 Dip ends of all new webbing in a mix- ramic facing bonded to a fiberglass reinforced plastic
ture of 50 percent paraffin, Federal backing. The ceramic facing is covered with a flexible
Specification VV-W-95, and 50 per- spall shield to protect the crew members from ballistic
cent beeswax, Federal Specification fragments. A rubber molding is also provided on the
C-B-191. edges of some panels for crew protection. These repair
procedures were developed with the objective of match-
3 Dip ends of sash cords in shellac, ing, to a high degree, the original strength and ballistic
Federal Specification TT-S-271. properties of the undamaged armor panel, with a min-
imum increase in weight. Extending the service life of
(3) Waterproofing. Restore water, mildew, and armor panels will facilitate the mission capabilities of or-
weather resistant qualities of a protective cover by coat- ganizational units by the effective use of material assets.
ing with water repellent textile finish compound as fol- The ceramic facing may consist of one of the following
lows: materials:

• Aluminum Oxide (Al2O3)

• Boron Carbide (B4C)

Solvents contained in the compounds are highly
flammable and toxic; therefore all work shall be • Silicon Carbide (SiC)
accomplished in an open area away from any
flame. a. Armor Plating Inspection and Repair Defini-
tions. Table 9-6 gives definitions relative to inspection
(a) Stir compound thoroughly until uniform and repair criteria.
mixture is obtained.
b. General Inspection of Armor Plating. Radio-
(b) Spread cover out completely on a clean graphic inspection of the assembled armor panel is the
flat surface, with inside of cover down. primary method used for nondestructive testing in deter-
mining the extent and location of internal damage. The
radiographic skills and equipment required for this type
of testing, while available at Depot installations, are not
available to Army field units. Therefore, for field units,
Solvents contained in compound may tend to a visual inspection of the panels must be made, which
irritate skin; therefore, prolonged contact shall requires removal of the nylon spall shield. Remove the
be avoided. edge molding and peel off the nylon spall shield. Exer-
cise care when removing the spall shield to avoid dam-
(c) Apply moderate application of compound age to the cloth. Use the following inspection proce-
to outside of cover with a brush or spray. dures:

(d) Apply compound well into seams, as they

are particularly susceptible to mildew and leakage.
Handle armor panels with care. Ceramic tile is
(e) Dry cover thoroughly until odor of com- brittle and cracks easily.
pound has completely disappeared.

(4) Storage. Store protective covers as follows:

9-48
 TM 1-1500-204-23-1

Table 9-6. Armor Plating Definitions.

Terms Definitions
Panel Each individual removal unit or module of the
total assembled armor protective system.
Delamination Any area where the fiberglass ply or plies have
become detached from the binding resign in the
reinforced plastic backing.
Backing The ballistic energy absorber and structural
support system for the brittle ceramic tile. The
backing is a composite of fiberglass lamination
impregnated with plastic resign.
Spall Shield A cover on the ceramic tile to protect crew
members from flying fragments during a ballistic
impact. The spall shield is made of nylon cloth
MIL-C-12369.

(1) Inspect for the following damages which NOTE

cannot be repaired. In the following substeps (a)and
(b), the allowable deviation is zero; therefore the panel To check for unbonded tile on armor having mul-
must be scraped. In the Note following substep (c) an tiple tile sections, lightly tap the ceramic surface
acceptance tolerance is specified, therefore, do not using a coin. Any area that has a lack of bond
scrap panels that are within the allowable tolerance. between the tile and plastic backing should re-
Send panel to a higher level of maintenance for repair. spond with a dull thud, as opposed to the higher
pitched sound of a well bonded area. How-
(a) Inspect all panels for ballistic damage. Do ever, the distinction between the bonded and
not repair armor panels with any ballistic damage (direct unbonded area will not always be clearly evi-
hit). dent.

(b) Inspect for cracked resign or ridges in the NOTE

backing that show evidence of a structural failure.
To determine a characteristic sound, compare
NOTE with a well-bonded area, such as along a panel
edge. Press firmly by hand all over the tile sur-
This damage will be matched by a tile crack face, observing any tile movement on release of
generally paralleling the failure line in the back- hand pressure. Outline any unbonded area on
ing. This damage may occur at a weaker re- the face of the tile for reference. A 100 percent
duced sections of the panel, such as the area bond between tile and backing is not required
around the head. Accidental blows from tools for ballistic efficiency. Do not make allowance
or hard objects, and the use of armor panels as for any additional support of the tile by the spall
handholds, are usually the cause of this type of shield. Do not repair armor panels having a total
damage. Do not repair armor panels with any unbonded area in excess of 20 percent for each
cracked resin or ridges in the backing. tile section. For monolithic armor (one piece
cast tile), the tile bond as a whole should be ad-
(c) Inspect the panel for unbonded tiles. equate.

9-49
TM 1-1500-204-23-1

(2) Refer to the repair procedures in paragraph Although catalysts are used to control the curing rate of
9-23 d for inspection of damage and for damage limita- resins, they reduce the pot life of a mixture formulation,
tions other than those specified. If the panel is damaged such as DTA and EPON. Do not use any curing agent
beyond the limits specified, it cannot be repaired. accelerators. Since water is an accelerator, avoid any
contact of the mixture formulation with water.

NOTE

Aliphatic Naphtha, TT-N-95, is extremely • As the room temperature decreases the resin
flammable and toxic to eyes, skin, and respi- curing rate time falls rapid. The DTA curing
ratory tract. Wear protective gloves and gog- agent may be applied at a temperature as low
gles/face shield. Avoid repeated or prolonged as 55°F (13°C), although the time to reach a
contact. Use only in well ventilated areas given stage of cure is at least double that re-
(or use approved respirator as determined quired at normal room temperature.
by local safety/industrial hygiene personnel).
Keep away from open flames, sparks, or other • The viscosity of the resin may be too high for
sources of ignition. some methods of application. Add methyl ethyl
ketone, TT-M-261, up to a maximum of five per-
c. Adhesives, Resins, and Solvents for Repair of cent by weight of the total solution content, to
Armor. The following paragraphs explain adhesives, lower viscosity.
resins, and solvents used for repair of armor.
(3) Solvents. For solvents and cleaning solu-
(1) Adhesives. For adhesives, follow manufac- tions, observe all of the usual precautions for ventilation
turer instructions concerning storage, agitation, mixing, to prevent the accumulation of toxic vapors and to avoid
thinning, temperature, range, fire and health hazards, a fire hazard.
plus contamination by moisture and dust. The adhesive
used for repair can be applied to the fraying surfaces by (4) Instructions for Pro-Seal 890 sealant . In-
any convenient means that will give a smooth, uniform structions are as follows:
spread of the adhesive. Use methods such as a brush,
a hand roller, an extrusion gun and squeegee. Clean all NOTE
tools immediately after each use with Aliphatic Naphtha,
TT-N-95. Do not let adhesive polymerize (cure) before • Bonding material Pro-Seal 890 consists of two
cleaning. parts: Pro-Seal 890 Sealant and Pro-Seal 890A
Curing Agent .
NOTE
• Both Pro-Seal 890 and its curing Agent Pro-
Use Polysulfide Sealing Compound, PR-1826 Seal 890A should be used as received. Do not
B1/2, Class A-2 or B-2 for adhesive. Pro-Seal thin with solvent.
890 (FSCM 83527) is a qualified product meet-
ing or exceeding the requirements of PR-1826 • Curing agent Pro-Seal 890A contains no
B1/2. Use Pro-Seal 890, Class B-2 for ap- solvent to assure a minimum amount of shrink-
plication by squeegee or extrusion gun. Use age when mixed with Pro-Seal 890 Sealant.
Pro-Seal 890BT, Class A-2 for application by Pro-Seal 890A contains an oxidizing com-
brush or hand roller. pound, therefore avoid prolonged contact with
the skin. Wash hands thoroughly before eating
(2) Resins. Many tertiary amines, phenolic ma- or smoking.
terials, alcohols and water catalysts accelerate the re-
action between the Diethylene Triamine (DTA) curing
agent and EPON resin.

9-50 Change 5
 TM 1-1500-204-23-1

(a) Open curing agent Pro-Seal 890A and Do not repair armor panels where a crack (or
thoroughly mix it in the container until it becomes a cracks) wider than 1/16 if an inch is found. To-
smooth paste. tal allowable defects are three or less cracks,
chips, or spalls in any 2-inch square area.
(b) Thoroughly mix 10 parts of Pro-Seal
890A to 100 parts of Pro-Seal 890 by weight, or 8.4
parts of Pro-Seal 890A to 100 parts of Pro-Seal 890 by (b) Repair cracked tile by bonding a 1/8 inch
volume. thick sheet of fiberglass, type GEE, MIL-P-18177, over
the crack (or Cracks) overlapping the damaged area by
(c) Carefully fold the material upon itself and three (3) inches on each side, using Polysulfide Sealant
blend for a period of at least five minutes. This will give Pro-Seal 890 (FSCM 83527).
a satisfactory mix.
NOTE (c) Bevel all edges of the fiberglass patch ¼
inch deep and 30 degrees from the top surface so the
Avoid violent agitation in order to beat as little air nylon spa shield will fit smoothly over the patch.
into mixture as possible. Also, frictional heat de-
veloped from violent agitation may reduce work NOTE
life of the material.
For ceramic having raised edges at the joints,
(5) Curing requirements for Pro-Seal 890 one side of the patch may be cut short of the
sealant (2 cure option). Requirements are as follows: 3 inch overlap requirement. If the crack ex-
tends through a raised edge on the tile, shape
• Mixed, uncured Pro-Seal 890 sealant the patch, by undercutting, to fit over the raised
material (Class A-2 or B-2) requires 72 edge. Use good judgment in determining this,
hours at room temperature for a full bearing in mind that the patch is to restore struc-
cure. tural integrity of the panel. When patching along
a panel edge, cut patch to fit the edge boundary
• If the production schedule is not flexible along periphery of the tile.
enough to allow for the long-time room
temperature cure, accelerated step cur-
ing conditions may be employed to fully
cure the sealant material in four hours
at elevated temperatures. The step cur- Aliphatic Naphtha, TT-N-95, is extremely
ing conditions are two hours at 120°F flammable and toxic to eyes, skin, and respi-
(49°C), followed by an additional two ratory tract. Wear protective gloves and gog-
hours at 158°F (70°C). This means that gles/face shield. Avoid repeated or prolonged
you should use two ovens set at the two contact. Use only in well ventilated areas
different temperatures specified to fully (or use approved respirator as determined
cure the uncured material under accel- by local safety/industrial hygiene personnel).
erated conditions. Keep away from open flames, sparks, or other
sources of ignition.
d. Repair of Armor Plating. Specific repairs and
inspections for armor plating are described in the follow- (d) Remove existing sealant residue from the
ing paragraphs. tile surface by using Aliphatic Naphtha, TT-N-95.
(1) Repair and inspection of cracked tile. Re- (e) Lightly abrade the fiberglass patch and
pair and inspection procedures are as follows: ceramic surface surrounding the cracked area where the
patch (or patches) is to be bonded.
(a) Inspect for cracked tiles.
(f) Clean the abraded ceramic and patch
NOTE surface using a clean cloth moistened with Aliphatic
Naphtha, TT-N-95. To obtain satisfactory adhesion,
Multiple cracks converging at an angle of 15
apply sealant only to a clean dry surface, free of oil and
degrees or less are not repairable. You may
grease.
repair cracks occurring in the ceramic tile 1/16
of an inch or less in width, provided that the
backing is not damaged beyond repair.

Change 5 9-51
TM 1-1500-204-23-1

NOTE NOTE

Do not use reclaimed solvents when preparing • Do not repair armor panels where spalled ar-
a surface for bonding. eas or chips have a total area greater than 1
square inch or a depth exceeding 1/10 of the
(g) Mix Pro-Seal sealant according to para- thickness of the ceramic material.
graph 9-23c(4).
• Total allowable defects are 3 or less cracks,
(h) Apply sealant to the ceramic surface, and chips, or spalls in any 2-inch square area. Edge
press the fiberglass patch over the crack (or cracks) to chips or spalling are acceptable without limit
be repaired. within the ¾-inch edge boundary of the tile
around the periphery of the armor panel.
(i) Apply metal clamps or weights to the patch
to apply contact pressure equal to about five pounds per (c) Repair spalled areas or chips occurring in
square inch. the ceramic, if they do not exceed the limits as specified,
by applying Polysulfide Sealant Pro-Seal 890.
(j) Place pieces of 1/8 inch fiberglass of ¼
inch plywood pads under the clamps to distribute the (d) Fill the chipped or spalled areas with
clamping force. sealant, smooth flush with the ceramic surface and
apply a 1/8 inch thick fiberglass patch. The fiberglass
NOTE patch should overlap the chipped or spalled areas by
three (3) inches on each side.
Do not use rigid pads, as these will concentrate
the clamping force on the point of contact and (e) Bevel all edges of the fiberglass patch ¼
may crack the ceramic tile. Maintenance activ- inch deep and 30 degrees from the top surface so that
ities having the necessary equipment may use the nylon spall shield will fit smoothly over the patch.
the vacuum bag method for clamping the patch
to the tile surface. The vacuum bag process is
used for both fabrication and repair of glass fab-
ric reinforced plastic sheets . The process con-
sists of applying pressure by vacuum and then Aliphatic Naphtha, TT-N-95, is extremely
curing by infrared heat heat lamp or oven. An flammable and toxic to eyes, skin, and respi-
autoclave is also used to apply heat and pres- ratory tract. Wear protective gloves and gog-
sure for curing. gles/face shield. Avoid repeated or prolonged
contact. Use only in well ventilated areas
(k) Cure Pro-Seal sealant according to para- (or use approved respirator as determined
graph 9-23c(5). by local safety/industrial hygiene personnel).
Keep away from open flames, sparks, or other
(2) Repair and inspection of spalled or sources of ignition.
chipped tile. Repair and inspection procedures are
as follows: NOTE

(a) Inspect for spalled or chipped tiles. For ceramic having raised edges at the joints,
one side of the patch may be cut short of the
three inch overlap requirement. If the crack ex-
(b) Repair spalled areas or chips in the ce-
tends through a raised edge on the raised edge.
ramic tile, except at the tile joints that do not exceed 1
When patching along a panel edge, cute patch
square inch, and whose depth (at any point) does not
to fit the edge boundary along periphery of the
exceed 1/10 of the thickness of the ceramic material.
tile.

(f) Remove existing sealant residue from the

tile surface by using Aliphatic Naphtha, TT-N-95.

(g) Lightly abrade the fiberglass patch, the

ceramic surface surrounding the spalled or chipped area
where the patch (or patches) are to be bonded, and the
inside surface of the chipped or spalled area.

9-52 Change 5
 TM 1-1500-204-23-1

NOTE

A delamination 3 inches or less in length may

Aliphatic Naphtha, TT-N-95, is extremely be repaired. No repairs can be made if a de-
flammable and toxic to eyes, skin, and respi- lamination if longer than 3 inches or if panel has
ratory tract. Wear protective gloves and gog- more than one delamination.
gles/face shield. Avoid repeated or prolonged
contact. Use only in well ventilated areas (b) Remove dirt and grease from the delam-
(or use approved respirator as determined inated cavity before repairing as follows:
by local safety/industrial hygiene personnel).
Keep away from open flames, sparks, or other 1 Inject Aliphatic Naphtha, TT-N-95,
sources of ignition. into cavity with a syringe. Let solution
soak for a few minutes to loosen the
(h) Clean the abraded ceramic surface, in- dirt and grease.
cluding the fiberglass patch and the chipped or spalled
surface, using a clean cloth moistened with Aliphatic 2 Draw out the contaminated naphtha
Naphtha, TT-N-95. To obtain satisfactory adhesion, ap- with the syringe, or position the panel
ply only to a clean dry surface, free of oil and grease. to allow the naphtha to flow out by
gravity. Repeat the procedure until
NOTE the cavity is clean.

(i) Mix Pro-Seal sealant according to para- 3 Volatize the naphtha using an elec-
graph 9-23c(4). tric hot air gun, or vacuum nozzle di-
rected into the cavity. Continue pro-
(j) Apply Sealant mixture to the ceramic sur- cedure for 10 to 15 minutes. Do not
face, but first fill all spalled or chipped areas with sealant use compressed air because oil and
and spread flush with the ceramic surface. dirt in the air may contaminate the
cavity.
(k) Press the fiberglass patch (or patches)
over the filled area to be repaired. (c) Repair delamination of fiberglass plies
along the edges of the backing by filling the voids with
(l) Attach metal clamps or weights to the epoxy resin using a DTA curing agent. Mix 100 parts by
patch to apply contact pressure equal to about five weight of EPON 828, MIL-R-9300 (FSCM 36131) with
pounds per square inch. 10 parts by weight of DTA O-D-1271 as follows:

(m) Place pieces of 1/8 inch fiberglass of ¼ 1 Inject the resin with a syringe until the
inch plywood pads under the clamps to distribute the cavity is filled, then brush the edge
clamping force. surface smooth.

NOTE 2 Attach metal clamps to the repaired

area to rebond the fiberglass plies.
Do not use rigid pads, as these will concentrate
the clamping force on the point of contact and 3 Place pieces of 1/8 inch fiberglass
may crack the ceramic tile. Maintenance activ- or ¼ inch plywood pads under the
ities having the necessary equipment may use clamps to distribute the clamping
the vacuum bag methods. force.
(n) Cure Pro-Seal sealant according to para- NOTE
graph 9-23c(5).
Do not use rigid pads, as these will concentrate
(3) Repair and inspection of delaminated the clamping force on the point of contact and
edges of backing. Repair and inspection procedures may crack the ceramic tile.
are as follows:
(4) Repair and inspection of internal delami-
(a) Inspect edges of the backing for delami- nation of backing. Repair and inspection procedures
nation of the fiberglass layers. are as follows:

Change 5 9-53
TM 1-1500-204-23-1

(a) Inspect panels for internal deliminations. (e) Attach metal clamps or brace the panel in
You can find the location and size of any internal delam- a fixture to apply the required high contact pressure to
ination by lightly tapping the fiberglass reinforced plastic seal the filled area. Use care to distribute the contact
backing using a coin or small hammer. pressure to prevent damage to the ceramic tile.

NOTE (f) Cure the panel at room temperature for

five days.
• The tapping sound will be a clear metallic ring
over well-bonded areas, and a dull thudding NOTE
sound over delaminated areas. Trace the out-
line of and delaminated area with chalk for ref- • Maintenance activities desiring to repair inter-
erence during repair. nal delaminations must have the required tools
and fixtures to assure a tight relamination.
• Internal delamination up to 4 inches in diam-
eter are acceptable without repair. Although a • If the delamination cavity is filled with resin
ballistic degradation does occur from a delami- without rebonding the fiberglass plies, the repair
nation of fiberglass plies, excessive resin in the will have reduced ballistic protection.
delamination cavity has a greater degrading ef-
fect. Excessive resin promotes ballistic shear- (5) Repair and inspection of minor scars and
ing as opposed to bulging of the fiberglass back- fraying of backing. Repair and inspection procedures
ing. Do not repair armor panels with any internal are as follows:
delamination in excess of 4 inches in diameter
or with more than one area of internal delami- (a) Inspect panel for scars or surface abra-
nation. sion, and for fraying along edges of the backing.
(b) Repair internal delaminations by using a NOTE
resign and curing agent mixed as specified in paragraph
9-23 d(3)(c). After a time, fraying will occur on some perma-
nent, exposed edges of the panel having no pro-
(c) Drill a small hole at each end of the void tective edge molding. You may repair frayed
(marked during inspection). edges, but only to edges normally having no
protective molding.
(d) Slowly inject resin using a syringe until
void is filled and epoxy discharges from opposite hole.
See figure 9-38. Additional holes may be needed if air
entrapment occurs when injecting the resin.

Figure 9-38. Delaminated Repair

9-54
 TM 1-1500-204-23-1

(c) Repair cuts or gouges not exceeding

three layers of fiberglass by first removing successive
Aliphatic Naphtha, TT-N-95, is extremely layers of damaged laminate in approximately oval
flammable and toxic to eyes, skin, and respi- patches (round corner rectangular patches are permis-
ratory tract. Wear protective gloves and gog- sible).
gles/face shield. Avoid repeated or prolonged
contact. Use only in well ventilated areas NOTE
(or use approved respirator as determined
Patches must form a step pattern as shown in
by local safety/industrial hygiene personnel).
figure 9-39. Steps should be at least ¼ to ½
Keep away from open flames, sparks, or other
inch long. Use a cutting tool with a controlled
sources of ignition.
cutting depth to facilitate the cutout and to avoid
possible damage to the layers underneath.
(b) Repair scars, scratches, or surface abra-
sion not penetrating through the facing, or fraying of the
(d) Remove these sections by peeling from
edges of the backing by first cleaning the damaged or
the center and working carefully back to the desired
frayed surface thoroughly and carefully using a clean
perimeter of the cutout. Cut through the overlaying ply
cloth moistened with Aliphatic Naphtha, TT-N-95 (or
in a series of cuts.
other approved cleaning agent).
(c) Lightly sand the damaged surface using NOTE
No. 280 grit abrasive cloth. Clean the surface thor-
oughly using Aliphatic Naphtha. Remove moisture and Exercise care not to peel back or to rupture the
solvents completely to prevent inhibiting the curing of adhesion of the lamination layers beyond the
the resin . cutout perimeter.
(d) Apply one or two coats (depending on (e) Scrape each step and wipe clean with a
severity of the abrasion or fraying) of epoxy resin using cloth moistened with Aliphatic Naphtha, TT-N-95.
DTA curing agent. Mix 100 parts by weight of Epon
828-MIL-R-9300 (FSCM 36131) with 10 parts by weight (f) Cut pieces of fiberglass cloth, type 181, Cl
of DTA O-D-1271. Brush the surface smooth. Methyl 2, MIL-C-9084 to extract size, with the weave direction
ethyl ketone may be added to lower viscosity of the such that they will overlay the original layup.
solution for brushing using a maximum of 5 percent by
weight.
(g) Use the wet layup technique. Place the
(e) Over this coated surface, apply a sheet first ply of precut cloth on a clean layup table. Spread
of cellophane L-C-110, or polyvinyl alcohol (PVA) film 45 to 50 percent of resin by weight on the cloth, using a
extending 2 or 3 inches beyond the surface. Cellophane squeegee to thoroughly impregnate all of the fabric.
or polyvinyl alcohol film will prevent exposure to the air,
and will provide a smooth bubble-free surface for the (h) Layup the resin impregnated cloth in the
resin to cure. previously prepared cutout, being careful not to entrap
any air under the fabric. Repeat the same procedure
(f) Tape the cellophane or PVA film in place
with the next ply.
and work out all air bubbles and excessive resin by hand
or by using a rubber squeegee.
(i) Place the last ply dry in the cutout after first
(g) Cure at room temperature for 24 hours. coating the surface of the previous ply with resin.
After the resin has cured or set, remove the cellophane
or PVA film for finishing. (j) Replace each piece of fabric being careful
to maintain the wet resin content (by weight) between
(6) Repair and inspection of cuts and gouges 45-50 percent. Use resin and curing agent as specified
in backing. Repair and inspection procedures are as in paragraph 9-23d(3)(c)
follows:
(k) Cover the repair with cellophane L-C-110
(a) Inspect for cuts and gouges in the backing or polyvinyl alcohol (PVA) film and press down to smooth
using special care to determine extent of the damage. the patch and to expel air bubbles.

(b) Count the number of fiberglass plies that (l) Cure at room temperature for 24 hours.
have been damaged as accurately as possible. Mark After resign has cured or set, remove cellophane or PVA
the number on the backing next to the damaged area. film for finishing.

Change 5 9-55
TM 1-1500-204-23-1

Figure 9-39. Gouge Repair

(m) Sand smooth all repaired areas after cur-

ing using No. 320-400 grit abrasive cloth.
Aliphatic Naphtha, TT-N-95, is extremely
(7) Repair and inspection of threaded inserts flammable and toxic to eyes, skin, and respi-
in backing. Repair and inspection procedures are as ratory tract. Wear protective gloves and gog-
follows: gles/face shield. Avoid repeated or prolonged
(a) Inspect panel for loose inserts or dam- contact. Use only in well ventilated areas
aged threads. (or use approved respirator as determined
by local safety/industrial hygiene personnel).
NOTE Keep away from open flames, sparks, or other
Inserts in a composite fiberglass-plastic type of sources of ignition.
backing have a tendency to work loose. It is NOTE
important to replace any missing insert as the
heavy armor panels are severely strained dur- Metalset A4 resin cement is furnished as two
ing a shock loading, such as a hard landing. compounds, Part A (resin) and Part B (hard-
ener). Thoroughly mix Part A and Part B in a
(b) Repair damaged insert threads, where 1 to 1 ratio by weight or volume. Allow bond-
possible, using the proper sized tap to chase threads. ing compound to cure at room temperature for
24 hours. For accelerated curing cure bond-
(c) Where an insert is loose, drill two small
ing compound at 150°F (66°C) for two hours.
holes, 180 degrees apart, in the fiberglass backing next
Excess Metalset A4 must be removed before it
to the insert. Angle the holes toward the bottom of the
hardens. Remove excess resin with Aliphatic
insert.
Naphtha, TT-N-95.
(d) Inject bonding compound, Metalset A4
(e) Replace rubber edge molding after abrad-
(FSCM 90414) with a syringe into one hole. Fill around
ing the inside surface using a fine wire wheel (0.004 inch
insert until compound discharges from second hole.
diameter wire) or abrasive cloth.

9-56 Change 5
 TM 1-1500-204-23-1

webbing, nets, rope, cables, or fittings. Use snaps,

hooks, clamps, buckles or other acceptable fasteners.
Install tensioning devices or other means to provide a
Aliphatic Naphtha, TT-N-95, is extremely method of tightening and adjusting restraint system.
flammable and toxic to eyes, skin, and respi- Provide covers or guards to prevent damage to or jam-
ratory tract. Wear protective gloves and gog- ming of aircraft equipment, structure, or control cables.
gles/face shield. Avoid repeated or prolonged Inspect and repair in accordance with the applicable
contact. Use only in well ventilated areas maintenance manual.
(or use approved respirator as determined
by local safety/industrial hygiene personnel). 9-25. VIBRATION ISOLATORS. Vibration isolators
Keep away from open flames, sparks, or other are shock absorbing mountings which absorb vibrations
sources of ignition. or movements of a component. They are utilized with
armament equipment, electronic equipment, photo-
(f) Wipe with a cloth moistened with Aliphatic graphic equipment, instruments, instrument panels,
Naphtha, TT-N-95. and other like equipment requiring shock mounting.

(g) Apply a sufficient amount of contact ad- a. Type of Vibration Isolators. Vibration isola-
hesive 1300L to cover the inside surface of the rubber tors are commonly classified in three types: open-type,
and the mating surface. closed-type, and combined vibration isolator mounting
base type.
(h) Allow adhesive to dry until tacky.
(1) Open-type. Open-type vibration isolators
(i) Carefully fit and press the molding over the are those on which the shock absorbing material is ex-
edge of the panel. posed, and are usually so constructed that the load is
supported on rubber in shear (A and B, figure 9-40) or
(j) Clean dirt and dust accumulation from the compression (C, figure 9-40).
repaired panel using general purpose detergent. Do not
use methyl ethyl ketone for cleaning the fiberglass back- (2) Closed-type. Closed-type vibration isola-
ing. tors are those on which the shock absorbing material
is enclosed by a metal cup or housing. The shock ab-
sorbing material is usually a coil spring, rubber, or metal
mesh in compression, or a combination of these mate-
rials as shown in figure 9-41.
Prolonged contact of the fiberglass to methyl
ethyl ketone or acetone will result in deteriora-
(3) Combined vibration isolator mounting
tion of the resin.
base type. Combined vibration isolator mounting
base type vibration isolators are formed by combining
(k) Rinse the washed area with clear water resilient material such as sponge rubber, metal mesh
and dry panel with a soft cloth. Then permit panel to dry pads, or coil springs with a mounting base and support-
out thoroughly. ing structure as shown in figure 9-42.
(l) Touch up repaired areas of spall shield b. Installation of Vibration Isolators. Installation
and fiberglass backing with acrylic lacquer, MIL-L-81352 of vibration isolators should be accomplished in such a
. manner as to allow free movement of mounted equip-
ment with adequate clearance around brackets, piping
(m) Apply a base coat of epoxy primer, MIL- lines, and other items of equipment. Accomplish the fol-
PRF-23377. Feather the primer coating onto to sur- lowing procedures when installing vibration isolators:
rounding color coat.
(1) Measure vertical and horizontal clearance
(n) Allow the primer to air dry for a minimum between equipment and nearest supporting structure.
of 30 minutes.
NOTE
(o) Apply two coats of acrylic lacquer to
match the original finish color as applicable. A vertical and horizontal clearance of 1/16 inch
shall be maintained. Maintain adequate dis-
9-24. CARGO TIEDOWN EQUIPMENT. Cargo tance between mounted equipment and nearest
tiedown equipment devices may be assembled from object (bracket, pipe, line, structure, etc.).

Change 5 9-57
TM 1-1500-204-23-1

(2) Move equipment to extreme positions in ev- or instrument panel), and nearest support structure (iso-
ery direction to ensure that retaining fasteners are se- lator mounting cup, mounting base, or aircraft structure)
cure and the isolators have not sagged. with vibration isolators with any vertical or horizontal
clearances of less than 1/16 inch.
NOTE
Prior to any attempt to install vibration isolators, (2) Move equipment or instrument panel to ex-
the high, or low side, must be found. Each treme positions in every direction to determine if isola-
isolator has a low side and a high, or load side. tors have sagged, or retaining rivets or holddown screws
in some instances, the words LOAD SIDE will are loose.
be stamped in the high side of the isolator to
facilitate identification. (a) When elastic rubber parts of open-type vi-
bration isolators are stretched to their extreme position,
c. Inspection of Vibration Isolators. To prevent examine rubber for cracks, or separation of rubber to
unsatisfactory isolation and eliminate damage, vibration metal bond. Replace isolators with any of these condi-
isolators shall be inspected and replaced in accordance tions visible.
with the applicable phase maintenance inspection
checklist. The following are general inspection proce- (b) When equipment on combined vibration
dures for all types of vibration isolators: isolator mounting base is moved to extreme positions
in all directions, examine sponge rubber or metal mesh
(1) Using a standard thickness gauge or 6 inch pads for deterioration and permanent packing. Replace
scale, measure vertical and horizontal clearance be- vibration isolators with cracked or deformed pads which
tween isolated load (equipment case, mounting base, seriously affect isolation efficiency of mounting system.

Figure 9-40. Open-Type Vibration Isolators

9-58
 TM 1-1500-204-23-1

Figure 9-41. Closed-Type Vibration Isolators

9-59
TM 1-1500-204-23-1

Figure 9-42. Combined Vibration Isolator Mounting Base

9-26. ELASTIC SHOCK CORD ASSEMBLIES. NOTE

Elastic shock cord assemblies are explained in the
following paragraphs. Section of cord shipped to service activities
shall have a duplicate tag affixed to provide
a. Inspection and Testing. Inspection and test- information for reinspection data.
ing of elastic shock cord assemblies are described in
the following paragraphs. Cords in stock at all activities other than
depots shall be visually inspected for
(1) Inspection. All cords installed in aircraft irregularities in diameter or other evi-
shall be visually inspected at each phase maintenance dence of deterioration and to see that
inspection. Any cord that shows irregularity in diameter serviceable parts tag is attached as
must be replaced. Cords found to be over five years specified.
old will not be considered serviceable. Observe the
following inspection requirements: Cords that fail to meet test requirements
shall not be installed on aircraft, but will
• Cords in stock shall be inspected and be made available for use on ground
tested every six months as specified be- equipment or for other uses.
low. At the time a test is made, a ser-
viceable parts tag shall be affixed to the Cord requiring reinspection will be
spool or cord as follows: retested and retagged if facilities are
available. If facilities are not available,
INSPECTED cord shall be returned to depot for rein-
DATE spection.
ACCORDING TO
TM 1-1500-204-23-1 Cords not suitable nor required for
TO BE REINSPECTED AND ground equipment or other uses shall
RETESTED be administratively condemned or con-
6 MONTHS FROM DATE HEREON dition condemned.

9-60
 TM 1-1500-204-23-1

(2) Testing. Cords requiring testing shall be (g) Reject cords which elongate more than
tested when facilities are available. When facilities are 100 percent during test.
not available, return cords to depot for testing. Elon-
gation testing should be accomplished in the following (h) Reject cords which have gauge marks
manner: more than 6 ¼ inches apart 10 minutes after pressure
is released.
(a) Test bungee or endless ring type cord as
a complete unit using suitable jigs or spools and test load (i) After testing, fill in and attach an Accept-
specified in table 9-7. able or Serviceable Tag (DD Form 1574) to cord with a
note:
(b) Jigs or spools for stretching shock ab-
sorber cords should be smooth and not less than 1 ½ To be reinspected and retested 6 months from date
inches in diameter to prevent damaging cords during hereon.
testing.
b. Fabrication Requirements. Elastic shock
(c) Prepare straight and elastic exerciser cord used for fabrication of assemblies shall not be
cords for testing by marking 6-inch gauge lengths on over 20 quarters (5 years) old from date of manufac-
one side of cord. Use soft lead pencil for marking. ture. Date of manufacture of elastic shock cord shall
be determined from table 9-8. Date of manufacture is
(d) Mark bungee cords with 6-inch gauge indicated by colored threads in the cotton braid. The
marks penciled on opposite sides of ring. first two colored threads indicate the year of manufac-
ture and the third colored thread indicates the quarter.
(e) Attach cord to be tested to suitable jigs or Replace cord using the following procedures:
spools. Apply specified test pressure slowly.
(1) Cut the elastic shock cord square with a
(f) After test load has been applied, remove knife or other sharp cutting tool.
cord from rig and measure between gauge marks.

Table 9-7. Test Loads

Cord Diameter Inches Load pounds

Straight cord 1/4 13

3/8 80
1/2 155
5/8 225
3/4 360

Endless ring bungee 3/8 155

7/16 235
1/2 315
9/16 380
5/8 450
11/16 585
3/4 720
113/16 1000

Elastic Exerciser 3/16 5

5/16 7

9-61
TM 1-1500-204-23-1

Table 9-8. Color Coding (3) Stretch elastic shock cord to 2 ¼ times its
original free length.
Year Identification
NOTE
1984 — Yellow
— Stretch fixtures used to elongate elastic shock
1985 Black
cord will be capable of securely holding ends
1986 — Green of cord without slippage. When elastic shock
cord is stretched to twice its original free length,
1987 — Red stretch fixture shall not damage cord ends.
1988 — Blue
(4) Dip or brush cut ends of elastic shock cord
1989 — Yellow with a coat of sealant MIL-S-4383, and allow to air-dry.
1990 — Black
NOTE
1991 — Green
— Coating should be heavy enough to prevent rav-
1992 Red eling of cotton braid.
1993 — Blue
(5) Locate lockrings approximately ½ inch from
Quarter Identification ends of elastic shock cord; however, do not extend ends
January Red of cord outside body of terminal fastener.
February (6) Stretch elastic shock cord 50 percent in area
March of lockring or splice location prior to crimping lockring in
place or serving elastic cord.
April Blue
May (7) Crimp lock rings securely in place to form a
continuous ring around elastic shock cord.
June
July Green (8) Accomplish serving of elastic shock cord us-
ing the following items:
August
September
• Elastic cord, MIL-C-5651.

October Yellow • Cotton cord, Style A, No. 10 (Use for

serving elastic shock cord ½-inch and
November smaller in diameter.)
December
• Nylon Cord, MIL-C-5040, Type I (Use
for serving elastic shock cord larger than
NOTE ½-inch diameter.)
For succeeding years and quarters, this cycle NOTE
repeats.
Minimum serving lengths are specified in table
9-9.
(2) Wrap cord with masking tape prior to cutting
to prevent raveling of cotton braid during subsequent
fabrication or handling operations.

9-62
 TM 1-1500-204-23-1

Table 9-9. Minimum Serving Length (4) Measure back from each end of marked fin-
ished assembly length a distance equal to lockring di-
Serving length mension specified in table 9-10, and mark this dimen-
Elastic cord diameter (Inches) (Inches) sion.
¼ 1½
Table 9-10. Lockring Locating Dimensions
3/8 2
½ 2½ Cord size 3/8 inch ½ inch 5/8 inch
5/8 3 Lockring 1.5 inch 2.0 inch 2.25
Locating dim. inches
¾ 4
1 4 (5) Install end fittings back to back on elastic
shock cord.
c. Identification. Colored threads in the outer (6) Clamp elastic shock cord in a stretch fixture
cover are used to indicate date of manufacture. The in such a manner that markings for finished assembly
color code for threads is given in table 9-8. Bungee and length and lockring locations are approximately equal
shock absorber cords have two threads to indicate year distances between stretch fixture jaws.
and one to indicate quarter. Elastic exerciser cords
have three threads to indicate year and one for quarter. (7) Stretch elastic shock cord until distance be-
Elastic shock cord, used in some compass mounts, is tween cord markings has increased 50 percent.
covered with a solid black braid with no colored thread
to indicate date of manufacture. Although these cords
(8) Crimp lockrings on cord at marked locations.
do not have a limited shelf life, they must pass the
Crimp each ring until ring ends are in contact with each
elongation test before installation.
other.
d. Fabrication Procedures. Fabricate elastic
(9) Remove elastic shock cord from stretch fix-
shock cord assemblies using the following procedures.
ture and cut elastic shock cord approximately ¾ inch be-
yond lockrings.
(1) Cut elastic shock cord a minimum of 4
inches longer than required finished assembly length. NOTE
(2) Wrap ends of cut elastic shock cord with After cutting elastic shock cord, ends will shrink
masking tape to prevent raveling of cotton braid. approximately ¼ inch.

(3) Center mark required finished assembly (10) Dip or brush cut ends of elastic shock cord
length on elastic shock cord as shown in figure 9-43. with a coat of sealant, MIL-S-4383, and allow to air-dry.
Coating should be heavy enough to prevent raveling of
cotton braid.

(11) Reinstall assembly in stretch fixture, and

pull until finished assembly length has increased 50 per-
cent. Ensure that there is no slippage of lockrings or end
fittings.

Figure 9-43. Marking Elastic Shock Cord

9-63
TM 1-1500-204-23-1

e. Serving Elastic Shock Cord. Serve elastic (7) Continue serving elastic shock cord as spec-
shock cord using the following procedures: ified above until required length of serving has been ap-
plied.
(1) Secure adjacent sections of elastic shock
cord in stretch fixture and mark minimum length of cord NOTE
to be served. Minimum serving lengths are specified in
table 9-9. While serving, keep tail end of loop outside of
half hitches for a distance of half the length of
(2) Stretch elastic shock cords until marked the required serving. Keep it under serving for
serving length has increased 100 percent. Maintain this reminder of required distance as shown in figure
length during entire serving operation. 9-45.

(3) Use a piece of serving cord of sufficient (8) When the required length of elastic shock
length to form a loop extending a minimum of 1 inch cord has been served, put end of serving cord through
past mark used to designate one end of elongated loop and pull tail end until both ends have been pulled
serving area. through. Cut ends of serving cord as close as practical
to serving wraps.
(4) Form a tail extending a minimum of 6-inches
past mark used to designate other end of elongated f. Process Control. The following procedures are
area, as shown in figure 9-44. used for elastic shock cord process control:

(5) Place loop on top of elastic shock cords over (1) Accomplish periodic checks of storage area
area to be served. to assure requirements of paragraph 9-26b are complied
with.
NOTE
(2) Maintain control of elastic shock cord as
Types of serving cord are specified in paragraph specified in TM 1-1500-204-23-6.
9-26b, step (8) .
(3) Crimp lockrings securely in place with ends
(6) Hold loop firmly on top of adjacent sections of ring in contact with each other.
of elastic shock cord and wrap serving cord around elas-
tic shock cord. Make wraps over loop using a half hitch
knot in serving cord at completion of each wrap. Pull
serving cord tight.

Figure 9-45. Serving Elastic Shock Cord

Figure 9-44. Preparation for Serving Shock Cord

9-64
 TM 1-1500-204-23-1

NOTE • Locate storage area where elastic shock

cord and assemblies shall be free of contact
Slight marking on ring caused by crimping tool with oil, grease, solvent, fumes, direct sun-
shall not be cause for rejection. Cotton braid light, or local heat concentrations. Avoid
caught between crimped ends of lockring will storage adjacent to steam pipes, space
not be cause for rejection providing no elastic heaters, or like conditions.
bands in shock cord are pinched or cut.
• Do not store items containing chemicals
(4) Assure that minimum of ½ inch of elastic harmful to rubber products near elastic
shock cord extends beyond last wrap of serving cord. shock cord and assemblies.

(5) Test finished elastic shock cord assemblies • Store elastic shock cord and assemblies
as outlined in paragraph 9-26d, step (11). from storage areas for manufacture or de-
livery on the basis of the oldest material be-
g. Storage of Elastic Shock Cords. In addition to ing used first. This assures that no cord
the general storage requirements for rubber items in TM shall spend an excessive time in storage
1-1500-204-23-6, the following practices shall be em- and thus lessen its active service life.
ployed during storage of shock absorbers and elastic
exerciser cords: • Dispense elastic shock cord and assem-
blies from storage areas for manufacture or
• Store cords so they shall not be subject to delivery on the basis of the oldest material
stresses. being used first. This assures that no cord
shall spend an excessive time in storage
• Keep stocks of cord at a minimum, but con- and thus lessen its active service life.
sistent with operating requirements.

• Maintain temperature of storage area be-

tween 32 and 80°F (0 and 27°C) when pos-
sible. During summer months, keep elastic
shock cord and assemblies in the coolest
part of the storage area.

9-65/(9-66 blank)
 TM 1-1500-204-23-1

CHAPTER 10
ARCTIC, DESERT, AND TROPIC MAINTENANCE

10-1. GENERAL. Arctic, desert, and tropic mainte-

nance, inspections, and operations are explained in the
following paragraphs.
Do not permit air from heaters with temperature
in excess of 251°F (122°C) to blast against ig-
10-2. ARCTIC MAINTENANCE. The following para-
nition harness, flexible hose, self-sealing tanks,
graphs contain the basic principles and procedures
or other rubberized or fabric materials. Damage
which are essential for efficient utilization of aircraft,
may otherwise result.
equipment, and personnel in arctic areas. The opera-
tion of aircraft in arctic regions is seriously handicapped
because of the effect of the elements on both personnel (1) Preheat requirements. Engine preheat is
and equipment. With a decrease in temperature, an normally required only on reciprocating engines. Jet en-
increase in time required to perform duties is inflicted gines do not require preheat unless the available auxil-
due to reduced flexibility of packings and rubber parts, iary power unit is not sufficient to overcome additional
higher viscosity of lubricants, and binding of metal parts starter loads. Preheat requirements can be consider-
due to contraction. General procedures for all aircraft ably reduced by following proper oil dilution procedures.
are discussed within these paragraphs. For specific
problems on a particular aircraft or piece of equipment, (2) Preheat for starting. At low temperature,
refer to the applicable maintenance manual. apply heat to engine as a starting aid. Reduce starter
loads by preheating engine, thereby reducing oil viscos-
a. Precautions. Maintenance personnel shall ob- ity. Generally, preheat will not be required if temperature
serve the following precautions as a guide to successful is above 0°F (-18°C) and engine oil has been properly
performance of duty in severe weather: diluted.

(1) Exercise care when stepping or walking on (3) Preheat time. Preheat time required to pre-
snow or frost-covered or very cold surfaces. Wearing pare an engine for starting depends on outside air tem-
proper shoes will aid in walking on slippery surfaces and perature, size of engine, heater output, and velocity and
reduce the possibility of injuries from slipping. direction of wind. Also, when oil dilution, method of pre-
heat application, or use of covers and nose shields are
inefficiently applied, the required preheat time will be
(2) Exercise caution when touching very cold
lengthened.
metal with bare hands; moisture on hands will tend to
freeze skin to metal. When practical, wear gloves and
cover metal tool handles. (4) Preheat application. Apply heat to both the
power and accessory sections until cylinder heat, tem-
perature reaches 68°F (20°C). Do not rely entirely upon
(3) Do not exert excessive torque or tension on
temperature gauge as readings may be misleading be-
bolts, nuts, cables, or similar items when making repairs
cause of thermocouple being located in path of heater
on equipment that has been exposed to extreme cold.
blast. Where heater supply is limited, concentrate heat
These items tend to freeze or snap as metal expands
on rear accessory section, particularly main oil drain, oil
upon warming.
lines, and oil sump, with second priority going to nose
gear, propeller hub, and power section.
b. Preheating. The following paragraphs explain
general procedures for preheating aircraft and engines.

10-1
TM 1-1500-204-23-1

(5) Preheat for accessories. At temperature Brush off loose snow or frost. Remove remaining ice by
below -22°F (-30°C), apply heat to batteries, feathering spraying or brushing on a coat of anti-icing and deicing-
pumps, master brake cylinder, and actuating cylinders. defrosting fluid, MIL-A-8243. Work from upper surfaces
Aircraft with constant speed drives for alternators should downward to prevent accumulation of ice on previously
have drives heated. cleared surfaces.

(6) Heater placement. Prevent possible heat (3) When rapid frosting occurs after initial re-
loss during preheat period by placing heaters as close moval, apply a coat of defrosting fluid to retard accu-
as possible to aircraft, but avoid areas under fuel and mulation of frost before taxiing. Also apply a coat of de-
oil drains, vents, or supplies. Inspect heater ducts for frosting fluid after the last flight of the day to help retard
leaks. Cover heater and ducts with noncombustible can- further accumulation of ice, snow, or frost.
vas covers. Provide adequate fire bottles in flight area.
(4) Inspect control surfaces for freedom of oper-
ation. Sudden temperature drops will cause ice to form
on the inside of the surfaces as well as on the outside.
When evident that ice has formed on the inside restrict-
Do not apply heat directly against plastic or plex- ing control surface movement, remove by application of
iglas windshields or windows. Directly applied heat.
heat will cause crazing, cracking, and discol-
oration. Remove existing snow deposits before (5) Inspect windows and windshields for cracks.
heating crew compartment. When cabin heat is To prevent cracking, open all windows before removing
applied on the ground with temperatures below aircraft from heated hanger.
freezing, the snow will melt and cause accumu-
lation of ice on top of fuselage and windshields.
(6) Inspect fuel and oil tank caps and vents
and crank-case breathers for presence of ice, snow, or
(7) Preheat of flight compartment. Appy heat frozen condensate. Plugged lines or vents can cause
to flight compartment and cabin to ensure operation of collapsing fuel tanks and swelling of oil tanks.
instruments and equipment, reduce windshield frosting,
soften canopy seals, and increase crew comfort. Heater
(7) Inspect wing and fuselage drains and vents
ducts may also be positioned so as to direct heated air
for ice and snow. Thaw clogged drains or vents.
toward any valves found to be sticking. Preheat vacuum
pumps in aircraft employing vacuum-driven instruments
to ensure low viscosity of oil in and around pumps and (8) Inspect fuel and oil tank sumps for ice.
to prevent pump drive shaft from shearing. Where water condensate has frozen, heat to permit
drainage.
c. Preflight. The following procedures and in-
spections shall be accomplished during preflight for (9) Inspect hydraulic reservoirs for evidence of
aircraft operating in arctic conditions: freezing; if evident, apply heat to thaw.

(1) During severe weather, delay removal of en- (10) Inspect cylinder struts and hydraulic pis-
gine covers, propeller covers, flight compartment cov- tons for accumulation of dirt and ice. Ice and grit which
ers, and miscellaneous covers until just prior to engine will damage cylinder strut packings shall be removed.
start. Leave wing and empennage covers in place until Pistons shall be wiped with a clean cloth saturated in
just prior to taxiing. hydraulic fluid, MIL-H-5606.

(11) Using an auxiliary power source, check ra-

dios and electrically operated controls and equipment
for proper operation.
Exercise care to prevent flow of melted ice into
areas where freezing would cause restricted (12) Inspect exposed limit switches and micro-
movement of flight controls and restricted flow switches for presence of ice or snow and for proper op-
of air through vents. Where water flows toward eration.
any of these areas, it shall be mopped up im-
mediately.

(2) Inspect entire aircraft for snow, frost, or

ice. Any deposit can cause loss of lift and treacherous
stalling characteristics.

10-2
 TM 1-1500-204-23-1

(13) Inspect hydraulic accumulators, landing

gear struts, and tires for proper inflation. Air pressures
will drop due to a temperature drop.
Rapid oxidation and fire can occur when
NOTE glyco-water solutions come in contact with a
short across bare or defective insulated silver or
Exposure of aircraft to low temperatures will silver-coated electrical circuits such as wiring,
cause contraction of metals and hardening of switches, and circuit breakers which carry posi-
rubber seals. Frequent inspections for leakage tive direct current (dc), such as electronic black
and looseness of connections is necessary to boxes.
prevent leakage.
NOTE
d. Anti-Icing, Deicing, and Defrosting. A protec-
tive coating of unheated, undiluted, anti-icing and de- The fluid shall be homogenous and free of sed-
icing-defrosting fluid will prevent frozen accumulations iment and abrasive. A slight waxy separation
from forming on aircraft surfaces if applied before freez- in the fluid shall be no cause for rejection if the
ing conditions begin and as often as necessary during separation is dispersable by several seconds
the precipitation. Any frost or thin layer of ice that does of moderate agitation. Fluid shall remain dis-
form can be removed easily by application of additional persed for at least 24 hours.
fluid. A protective coating of fluid applied before instal-
lation of covers will permit easy removal with a minimum (2) Fluid application. The following para-
sticking of covers. graphs describe methods and equipment used to apply
anti-icing, deicing, and defrosting fluids.

When handling and applying glycol-water prod-

ucts, wear eye, hand, and body protection. Special care must be taken by personnel to pre-
Avoid inhaling vapors and skin contact. Follow vent slipping and falling when walking on wing
Material Safety Data Sheet procedures for indi- surfaces coated with deicing fluid. Otherwise
vidual product use. Injury may otherwise result. death or injury may result.

(1) Types of fluid. Anti-icing, deicing, and de- (a) Spray method. If hangars, covers, or
frosting fluid characteristics are explained in the follow- equipment for heating fluid-water solutions are unavail-
ing paragraphs. able, the preventive spray method will be used to main-
tain standby and alert aircraft in a state of readiness.
(a) Ethylene/propylene glycol. Anti-icing The preventive spray method is application of cold, undi-
and deicing-defrosting fluid, specification MIL-A-8243B, luted fluid on surface to be protected in a quantity to wet
is basically a mixture of ethylene glycol and propylene the area thoroughly without excessive drainage.
glycol and is recommended for preventing formation and
removing deposits of frost, ice, and snow on exterior (b) Spray pattern. Suitable spray equip-
aircraft surfaces on the ground in temperatures rang- ment should be used, as application of fluid is done
ing from -65 to 32°F (-54 to 0°C). Ethylene glycol and best by spraying surfaces. Spray should not be applied
propylene glycol are formulated with intrinsic corrosion in a solid stream, but be fine enough to prevent waste.
inhibitor, as prescribed in MIL-A-8243B. A fan-shaped pattern is recommended.

(b) Glycol-water. Glycol-water anti-icing (c) Spray equipment. Cleaning or other de-
and deicing-defrosting fluids, including MIL-A-8243 contaminating equipment may be modified to spray de-
anti-icing fluid, are not recommended for use around icing fluids . Spray guns on this equipment can be used
aircraft electronic equipment which employs silver or as they are, but better spray coverage can be obtained if
silver coated electrical/electronic circuitry. they are modified slightly. A common garden hose noz-
zle will give satisfactory result in accumulation removal
if the solid stream is used. This nozzle also can be used
to apply a protective coating of fluid if a fine conical spray
is used.

10-3
TM 1-1500-204-23-1

(d) Spray nozzles. The three nozzles shown (f) Support equipment. Use of mainte-
in figure 10-1 may be fabricated in any base shop and nance stands and work platforms is recommended to
used with equipment in the preceding paragraph (c) with position personnel safely near wing and tail surfaces
good results. Each is explained in the following para- during application of fluid.
graphs.
e. Prevention and Removal of Snow, Ice, and
1 Bent tube nozzle. The bent tube noz- Frost Deposits. The following paragraphs contain
zle is made by drilling approximately methods for the prevention and removal of snow, ice,
60 holes along the longitudinal axis and frost deposits.
through one side of an aluminum,
brass, or steel tube. Holes are (1) Prevention of deposits. The following
0.043-inch diameter. Tube is capped paragraphs explain the prevention of snow, ice, and
and bent in a tube bender to give frost deposits.
about a 90-degree fan spray.
(a) Snow deposit prevention. If snow is ex-
2 Pipe nipple nozzle. The pipe nip- pected, wing and tail covers should be used. Deicing
ple nozzle consists of a one-inch pipe fluid should not be used for protective coating if snow is
nipple with 0.0512-inch holes drilled predicted, except in conjunction with installation of cov-
radially around 90 degrees from outer ers. If attempts are made to use the fluid to prevent
edge. snow accumulation, a frozen deposit will be encoun-
tered which is difficult to remove. The fluid is diluted by
3 Pipe cap nozzle. The pipe cap noz-
the melting snow to form a slush which freezes in place.
zle is hardest to fabricate. It con-
Use of covers after coating aircraft surfaces with fluid will
sists of a ¾- or one-inch pipe cap
prevent snow from forming directly on aircraft and per-
with 0.0312-inch drilled holes in cen-
mit easy removal of covers. If covers are unavailable,
ter and 0.0469-inch drilled holes to-
the best method of preventing heavy snow accumula-
ward edges, all radiating from a point
tion is constant removal by brushing or sweeping during
in base of cap.
the snowfall.
(e) Alternate application method. Cold de-
icing fluid may be applied with a mop, broom, or soft
bristle brush if spray equipment is unavailable.

Figure 10-1. Types of Spray Nozzles

10-4
 TM 1-1500-204-23-1

(b) Ice deposit prevention. Deicing fluid

will protect aircraft surfaces as long as it remains on the (a) Snow removal. Deicing fluids should not
surfaces. However, freezing rain will tend to wash sur- be used to remove heavy snow accumulation. Snow ab-
faces clean of fluid, as well as dilute the fluid to the point sorbs wasteful amounts of fluid to form a slush which
at which ice will form. The amount of protection afforded is difficult to remove and eventually will refreeze. The
by the fluid depends on the amount of freezing rain. The slush will get into control surface hinges and freeze,
following steps should be taken if ice caused by freezing causing additional difficulty. Snow will be removed by
rain is expected: brushing or sweeping or by moving the covers. Usu-
ally after snow removal, a layer of rough ice remains.
1 On aircraft for which covers are avail- This frozen crust can be removed with hot, diluted, de-
able, a coating of fluid applied be- icing fluid. In an emergency when aircraft must get off
fore covers are installed will prevent ground as quickly as possible, thin layers of snow can
covers from freezing on aircraft sur- be removed with hot, diluted, deicing fluid. If sufficient
faces and make removal of covers fluid is used, the combination of heat from fluid and force
much easier. However, care should of the stream will permit removal of slush, as it is formed
be taken to ensure that only a min- without refreezing. Quantity of heated fluid required for
imum amount of rain is allowed to snow removal is prohibitive. Remove snow, water and
blow under covers. Otherwise, dilu- ice from aircraft fuel filler cap wells before removing fuel
tion of fluid will allow freezing to oc- filler cap. Only one filler cap should be removed at a
cur. time, and it should be replaced immediately after servic-
ing is completed.
2 On larger aircraft for which covers
are unavailable, the best method of (b) Ice and frost removal. If hangars and
prevention is to keep the surfaces covers cannot be used to prevent frozen formations on
wet with fluid. As long as this fluid aircraft, but equipment is available for heating fluid-wa-
remains on the surface, protection ter solutions, removal of frozen formations by hot, di-
is afforded. Since rain eventually luted, deicing fluid will be used in place of preventive
will dilute the fluid and render it inef- spraying. Accumulations should be allowed to form and
fective for preventing ice formation, then be removed just after each precipitation or just be-
protection must be maintained during fore each flight, whichever is most practicable or com-
precipitation by continual spraying of patible with operational mission of the aircraft.
fluid. If weather conditions are such
that it is impossible to prevent ice f. Preventive Maintenance. Accomplish the fol-
formation, removal should be accom- lowing preventive maintenance procedures:
plished. (1) Avoid parking aircraft in wet or slushy areas.
(c) Frost deposit prevention. A satisfactory (2) Use caution when towing aircraft in ex-
procedure for protection of aircraft from frost is the appli- tremely low temperatures to prevent damage to hy-
cation of a layer of unheated, undiluted, deicing fluid to draulic seals which would result in strut leakage.
aircraft surfaces after the last flight of the day or as close (3) Inspect oil and fuel drains and crankcase
to midnight as possible, whichever is later. This should breathers for ice and frost. Remove any existing frost
permit early morning departure without further fluid ap- or ice.
plication. The length of time that an aircraft will be pro- (4) If layovers are to be over 4 hours and tem-
tected by a single coat of fluid depends on the climatic perature is below -20°F (-29°C), remove battery and
conditions. store in a warm place.
(2) Removal of deposits. The following para- (5) Drain oil system when there is no provision
graphs explain the removal of snow, ice, and frost de- available for preheating oil and a long layover period is
posits. anticipated.
(6) When temperature rises above freezing dur-
ing a long layover, drain fuel and oil tank sumps of water
before temperature drops.
Extreme care shall be taken to prevent dam- (7) Install protective covers and shields to pro-
age to aircraft. Sharp instruments, such as tect aircraft from accumulation of snow, frost, or ice.
picks, knives, or screwdrivers, will not be used
to loosen ice formation.

10-5
TM 1-1500-204-23-1

(8) Partly open canopy when parking aircraft for

the night, or provide some other opening to prevent ac-
cumulation of frost on windows. During thawing operation, no aircraft will be
parked within a 100-foot radius of operation.
(9) Clean dirt, ice, and grit from landing gear Damage to equipment may otherwise result.
struts and hydraulic pistons. Wipe struts with a clean
cloth saturated in hydraulic fluid, MIL-H-5606. Inspect (b) Dig pit a minimum of 3 feet deep and wide
struts for proper inflation. enough to accomodate a 3-foot length of log or similar
object.
(10) Inspect tires for proper inflation.
(c) Connect rope, insert log or similar object
(11) Install or remove snow- and ice-grip tires and fill pit with gravel and snow.
to comply with change of seasons. Use of snow and ice
grip tires on clear, hard surfaced runways reduces the 10-3. DESERT MAINTENANCE. The following para-
life and effectiveness of the tires. graphs contain the basic principles and procedures
which are essential for efficient utilization of aircraft,
(12) In emergency arctic conditions, tie down equipment, and personnel in desert areas. In the desert,
aircraft using trees or the arctic-type mooring anchor aircraft can be protected from deterioration problems by
shown in figure 10-2. The following procedures can be using protective covers, preventive maintenance, and
used to construct an arctic-type rnooring: maintaining regular inspections. These paragraphs are
not considered as a substitute for detailed maintenance
(a) Thaw ground with fire where pit is to be and operating instructions, but as a supplement to each
dug. aircraft operation and maintenance manual.

Figure 10-2. Arctic-Type Mooring

10-6
 TM 1-1500-204-23-1

a. Deterioration Factors. Deterioration problems Aircraft tires can easily be damaged in rocky desert ter-
result from sand and dust, high day temperatures, tem- rain.
perature fluctuations, ultraviolet radiation, and terrain.
Considerations for each problem are explained in the b. Precautions. Maintenance personnel will ob-
following paragraphs. serve the following precautions as a guide to successful
performance of duty under desert conditions:
(1) Sand and dust. The large quantities of
loose sand and dust create serious erosion problems for
rotor blades, propellers, turbine engine compressors,
windshields and other exposed surfaces of the aircraft. Severe burns can result when bare skin touches
While sitting on the ground, the aircraft is exposed to metal parts of aircraft or equipment.
blowing sand and dust from frequent desert windstorms
and sand and dust clouds created by vehicular traffic Exercise caution when touching aircraft sur-
and operation of other aircraft nearby. Sand and dust faces or metal tools that have been exposed
particles collect on all surfaces of the aircraft and will to the sun. Wear gloves and use mats or pad,
penetrate almost any crack or crevice to accumulate when practical, to prevent burns or blisters.
inside the aircraft. Electronic gear and optical equip-
ment are very susceptible to sand and dust. Weapons Use extreme care when handling engine fuel at
are particularly susceptible since many parts are often temperatures above 120°F (49°C), to prevent
covered with a light coat of lubricant. possible sparks and explosion. Open gasoline
drums with bronze or other non-sparking tools.
(2) High day temperature. In the desert, heat Electronic gear and optics must be shielded
creates serious problems for people and equipment. from direct sunlight and/or otherwise cooled for
The temperature inside a parked aircraft which has efficient operation.
been closed up to keep the sand and dust out can reach
temperatures much higher than outside temperatures.
c. Inspection and Maintenance. The following
Extreme heat can cause the failsafe device in electronic
procedures are for the inspection and maintenance of
gear to shut the equipment off. High temperatures can
aircraft operating in desert conditions:
cause lubricants to break down, distort seals and gas-
kets, and result in increased leaking problems. Other NOTE
problems due to high temperatures include softening
of plastics, high stress on pressurized containers, and Aircraft should be cleaned daily. Frequent use
shortened battery life. of a vacuum cleaner will prevent accumulation
of sand and dust in aircraft. Pay particular at-
(3) Temperature fluctuations. Daytime tem- tention to abrasion/erosion problems during in-
peratures can reach over 100°F (38°C), while night time spections.
temperatures could reach freezing (or close to it). The
condensation resulting from this extreme temperature (1) Inspect bungee cords, seals, tires, etc., fre-
variation contributes to increased corrosion. quently for blisters and other signs of deterioration.

(4) Ultraviolet radiation. The abundant desert (2) Inspect vibration isolators every two weeks
sunlight produces a high level of ultraviolet radiation and replace where cracking or permanent set is exces-
which can cause unprotected plastic components to sive.
become very brittle and easily cracked. Ultraviolet ra-
diation also accelerates deterioration of nylon webbing (3) Keep a chart showing engine oil consump-
used in seats and restraint systems. tion. A sharp rise on the chart will indicate faulty or in-
efficient engine operation. An inefficient engine should
(5) Terrain. The terrain causes problems with not be continually operated. It is better to correct the
moving aircraft and associated support equipment on trouble so the engine will operate at peak performance.
the ground. Sand can bog a vehicle or aircraft down to
the axles. A condition known as Cap Rock is often en- (4) Inspect, clean, or replace filters at regular
countered. The terrain appears rocky, however, the sub- intervals. Sand and dust quickly choke fuel and oil filters
strate will not support weight and a vehicle can sink up and air cleaners. Keep an adequate reserve stock of
to the frame when attempting to travel over Cap Rock. cleaners and filters.

10-7
TM 1-1500-204-23-1

(5) Keep parachute pack flaps sealed and cov- NOTE

ered when not in use. Seals must be removed before
takeoff. Ensure that all weather stripping on doors, pan-
els, covers, etc., is serviceable and that these
(6) Inspect and clean flags, control hinges pul- items are adjusted to make proper contact with
leys, bearings, worm gears, cowl slides, landing gear, sealing surface.
and tail wheel assemblies regularly to arrest corrosive
action. (2) Leave canopy partly open, except during
dust or rain storms, to permit circulation of air within the
(7) Inspect aircraft regularly for adequate lubri- flight compartment.
cation, leakage, contaminated hydraulic fluid, specific
cable tension, and condition of materials, such as rub- NOTE
ber and hydraulic equipment. Excess lubricant must be
wiped off all exposed bearing surfaces, joints, fittings, Ensure that sealant installed around windows,
components, and fuselage. seams, chin bubbles, and sheet metal repairs
is serviceable.
(8) Carefully smooth pitted propellers (if not be-
yond permissible limits) with a fine file and emery cloth. (3) Install protective covers and dust excluder
Remove all rough burrs and ragged edges around pits plugs on all engine openings, vents, air intakes, exhaust
at frequent intervals. outlets, breathers, propeller hubs and feathering domes,
cowls, and other vital openings to prevent entry of sand
(9) Inspect dead air spaces in wings, fuselage, and dust. Keep aircraft pointed into wind when not being
and tail group at regular intervals for accumulation of serviced or prepared for flight.
sand. Remove accumulated sand to prevent a weight
and balance change of aircraft. (4) Run up engine on a hard surface, as shown
in figure 10-3, such as a landing mat, or sand and dust-
(10) Clean engines, where possible, with a free area, to prevent sand blasting, rotor blade, pro-
high-pressure spray gun filled with appropriate cleaning peller, fuselage, and tail surfaces. Landing/taxi area
fluid . should be located as far as possible from maintenance
area and allow as much space between aircraft as tac-
tically feasible.
(11) Clean instrument filters thoroughly at regu-
lar intervals. Replace wornout filters promptly.
(5) Never taxi aircraft under its own power un-
less necessary. This will aid preventing pitting of the
(12) Clean oil and gasoline tanks periodically,
rotor blade, propeller, fuselage, and tail surfaces. Tow
as sand accumulates in corners, seams, and bottom of
aircraft, using proper tow fittings. Do not move aircraft
tanks.
over desert crust or hardpan any more than necessary.
(13) Clean metal parts not in use carefully,
(6) Keep pitot heads and gyro instrument ven-
cover with grease, and either wrap or store away from
turi covered when not in use.
sand and dust.
(7) Make all possible ground checks before
(14) Clean plexiglass surfaces with clean water.
starting engine. Inspect controls for freedom of move-
Do not rub plexiglass surfaces during cleaning nor use
ment to ensure no binding is caused by sand.
plexiglass cleaning kit.
(8) Do not run up aircraft in such a manner as
d. Preventive Maintenance. Accomplish the fol-
to damage other aircraft or injure personnel by blown
lowing preventive maintenance procedures:
sand. Engine should never be run on ground longer than
necessary. Use ground guides to prevent landing gear
(1) Protect aircraft from excessive surface tem- from resting on sharp rocks while parking aircraft.
peratures by covering with canvas or native matting.
Use protective covers as soon as possible prior to op-
(9) Do all shop (bench) repairs in enclosed shel-
eration. Covers over plexiglass should be installed so
ter. Never use sand-encrusted tools on aircraft.
that they do not touch the surface of the glass. Barrier
material may be installed for this purpose.

10-8
 TM 1-1500-204-23-1

Figure 10-3. Construction of Hard Stands

10-9
TM 1-1500-204-23-1

(10) When possible, accomplish repairs and (1) Treat corrosion-affected area.
servicing during early morning hours, or in late after-
noon, evening, and night, when heat is less intense. (2) Prevent rot, mildew, and mold by keeping
Desert camouflage netting can be used for shade. fabrics, rubber, and other susceptible items as dry as
possible. Clean fabrics in aircraft daily. The effects of
(11) Ground aircraft, funnel, and fuel nozzle dur- moisture and fungus on fabrics are listed in table 10-1.
ing refueling operation. Accomplish filling of gasoline
from cans, using a filter funnel that fits snugly into tank (3) Operate all heat-producing electrical equip-
opening. Exercise every precaution to exclude sand ment daily to remove moisture. When this procedure is
from gasoline and oil during servicing operations. not practical, dry equipment using a ground heater or by
placing in sun.
(12) Where possible, service oil system directly
from can to oil tank, without using an intermediate mea- (4) Wash aircraft often, and lubricate moving
suring can. parts when aircraft is exposed to salt-laden air or mud.

(13) Keep lubricants and gasoline drums cov-

ered, and where possible, maintain storage temperature
below 120°F (49°C).
Before drilling holes, ensure that the aircraft will
(14) Use polarized sunglasses during sunlight not be weakened structurally and the operating
hours. characteristics will not be adversely affected.
Damage may otherwise result.
(15) Use eye protection in blowing sand/dust.
Extra measures should be used to secure aircraft and (5) Keep all drain holes clear of obstructions,
shelter. and drill holes where necessary in wings, fuselage, en-
closed equipment, etc., (when approved by the mainte-
nance officer), to facilitate draining where a noticeable
(16) Ensure voltage regulators are properly set
accumulation of water is observed.
during all temperature changes.
(6) Leave canopy windows or doors open when
(17) Tape all opening or seams around win-
aircraft is parked in sun to permit air circulation within
dows, chin bubbles, seldom used access panels, etc.,
flight compartment. Protect windshields and windows
being sure not to inhibit or restrict airflow required for
from sun by covering with canvas.
cooling, or increase Infrared (IR) signature. An entry is
required on DA Form 2408-13 in the aircraft log book
after tape has been installed. Use tape MIL-T-21595 (7) Blow out brakes frequently with compressed
Type I. air when operating from muddy or dusty fields to prevent
damage to brake disks.
10-4. TROPIC MAINTENANCE. The following para-
graphs contain basic principles and procedures essen- (8) To prevent rust, wipe control cables daily
tial for efficient utilization of aircraft equipment and per- with an oily rag.
sonnel in tropic areas. Factors having deteriorating in-
fluence on fabrics in tropic areas can be categorized (9) Check battery every third day to maintain
as high humidity, high temperatures, salt-laden air, and proper electrolyte level.
sunshine. These factors create corrosion, rot, mildew,
and mold. Preventing these deteriorating effects to en- (10) Every 25 hours, dip paper air filter car-
sure safety and proper operation requires constant, reg- tridges in leaded gasoline and dry thoroughly.
ular inspections and preventive maintenance measures.
This paragraph is not to be considered as a substitute (11) Drain all fuel traps and strainers immedi-
for detailed maintenance and operating instruction, but ately prior to flight.
as a supplement to each aircraft operation and mainte-
nance manual. (12) While aircraft is on ground, avoid excessive
water in fuel systems by keeping fuel tanks completely
a. Inspection and Preventive Maintenance. filled.
Proper cleaning, packaging, and storing ensures longer
life and serviceability of aircraft and equipment. The
following practices should be used as a guide:

10-10
 TM 1-1500-204-23-1

Table 10-1. Part and Fabrics Affected by Moisture and Fungi

Part or fabric Effects of moisture and fungi

Cotton, Linen, Paper, and Cellulose Derivatives: Insulation, Insulating and dielectric properties are lost
coverings, webbing, belting, laminations, dielectrics, etc. or impaired by moisture, causing arcing,
flash-overs and cross talk. Fungi causes rot
and complete destruction.
Fiber: Terminal strips and insulators. Moisture causes electrical leakage paths to
form, in turn, causing flash-overs, cross talk,
and loss of insulating properties. Fiber terminal
strips and insulators are destroyed by fungi.
Fiber: Washers, supports, etc. Moisture causes swelling which, in turn,
causes supports to misalign, resulting in
binding of supported parts. Washers are
destroyed by fungi.
Glass: Lenses, windows, etc. Fungi grow on organic dust, insect tracks,
insect feces, dead insects, etc. Dead mites
and fungus growth on glass obscures visibility
and corrodes nearby metal parts.
Laminated Plastics: Terminal strips and boards, switchboard Moisture causes electrical leakage paths to
panels, etc., tube sockets and coil forms, and connectors. form, in turn, causing flash-overs, cross talk,
and loss of insulating properties. Delamination
occurs and fungi grow on surfaces and around
edges. Extreme temperature changes cause
expansion and contraction.
Leathers: Straps, cases, gaskets, etc. Fungus destroys tanning and protective
materials, causing rotting due to moisture
bacteria fungi
Metals High temperature and moisture vapor cause
rapid corrosion. Fungus and bacterial growth
produce acids and other products which speed
corrosion, etching of surfaces, and oxidation.
This interferes with the operation of moving
parts, screws, etc. and causes dust between
terminals, capacitor plates, air condensers,
etc; thus causing noise, loss in sensitivity, and
arc-overs.
Metals: Two or more. Different metals which have different potentials
when moisture is present cause electrolysis,
thus causing formation of salts and beep
etching of surfaces as one metal is plated onto
the other. This happens at riveted and bolted
joints, bearings, slides, and screw threads.

10-11
TM 1-1500-204-23-1

Table 10-1. Part and Fabrics Affected by Moisture and Fungi — Continued

Part or fabric Effects of moisture and fungi

Molded Plastics: Terminal strips and boards, switchboard Machined, sawed, or ground edges or surfaces
panels, connectors, etc., and tube sockets and coil forms. are supporters of fungi, causing shorts and
flash-overs. Fungus growth reduces resistance
between parts mounted on plastic to such an
extent that the item is useless.
Soldered joints Excessive soldering flux on terminal boards
holds moisture, which speeds up corrosion
and growth of fungi. Soldering irons should not
come in contact with wire insulation.
Wax: For impregnation Fungus-inhibiting waxes which are not clean
support fungi, thus causing destruction
of insulating and protective qualities and
permitting entrance of moisture which destroys
parts and unbalances electrical circuit.
Wood: Cases, houses and housings, plastics fillers, masts, etc. Moisture and fungi cause dry rot, swelling, and
delamination.

(13) Run up reciprocating engines at least once (16) Inspect canvas or duct covers for wear, torn
every third day. seams, stains, fungi, etc.

(14) Operate gas turbine engines at least once b. Parts and Fabrics Affected by Moisture and
every seven days for approximately 10 minutes at flight Fungi. Parts and fabrics affected by moisture and
idle. fungi are shown in table 10-1.

(15) Inspect webbing for wear and fungi.

10-12
 TM 1-1500-204-23-1

CHAPTER 11
AVIATION LIFE SUPPORT EQUIPMENT MAINTENANCE

11-1. GENERAL. Organizing Aviation Life Support 11-4. PERSONNEL. Maintenance of ALSE will be
Equipment (ALSE) servicing facilities is based on many performed only by school-trained, qualified personnel,
factors, such as the number of aircrew members as- either military or civilian personnel trained in accordance
signed, and the type and quantity of equipment. With with paragraph 11-19 may inspect first aid kit. General
this in mind, the ALSE maintenance shop should be purpose, panel mounted, NSN 6545-01-599-5586, for
tailored to the needs of the aviation unit, activity or fa- aircraft. Also maintenance personnel must be gradu-
cility. The minimum standards for the ALSE facility and ates of the U.S. Army 600-Q2 or 600-H2, U.S. Air Force
equipment contained in this Technical Manual (TM) are C3AABR92230-000, U.S. Navy LSE C-602-2010, or
not mandatory requirements, but are standards which other courses of instruction approved by U.S. Army
can be used for planning purposes. Local Commanders Aviation Logistics School (USAALS), Ft. Eustis, VA.
are authorized to deviate from these standards when- USAALS has responsibility for training ALSE mainte-
ever circumstances cannot be reasonably obtained. nance personnel. Refresher courses do not qualify
It will be the responsibility of the local Commander to personnel to service ALSE.
be certain that any deviation permitted will not foster
unsafe or unsanitary practices, recognizing that ALSE 11-5. PUBLICATIONS. ALSE consists of equipment
has specific areas of supporting the user in hostile unique to aviation needs while flying or in a survival con-
conditions i.e., high altitude, in water, land survival, etc. dition. This equipment covers several Federal Supply
This equipment must perform to standards the first time classifications i.e., Clothing 8415, Flotation Equipment
upon being activated for use. These standards will not 4220, Aircraft Air-Conditioning, Heating and Pressuriz-
be compromised. ing 1660, etc. Each stock classification is initially as-
signed to a command to manage i.e., stock classification
11-2. ADMINISTRATION. Administration of the unit 1660 is assigned to the Air Force Logistics Command
Life Support Program must have the Commander’s ap- while 4220 is assigned to Naval Sea Systems Com-
proval. The unit Training Officer must provide schedul- mand. Army Technical Manuals are assigned numbers
ing time and training for ALSE. Included should be Code by basic series and stock classification i.e., (TM 1-1500,
of Conduct/Survival, Evasion, Resistance, and Escape 1 signifies aviation while 1500 signifies general aviation
(SERE) Training in accordance with AR 528-28. The manuals). Because the management responsibility is
unit Aviation ALSE Officer must not only supervise the fragmented between many managers, which includes
ALSE technician’s work, but also the training of the unit engineering and maintenance, all ALSE items cannot be
aircrew personnel in the care and use of ALSE, and combined into a single TM. The following paragraphs will
survival training. The ALSE technician will inspect, re- described the ALSE items and then reference the repair
pair/replace, and service the equipment in accordance manuals for that item.
with the applicable Technical Manuals (TMs), Technical
Orders (TOs), and Naval Air Manuals (NAVAIRs), and 11-6. ADMINISTRATION AREA. The ALSE adminis-
maintain the required forms and records as well as su- tration area should have a desk and chair, bookcase file
pervise the ALSE training performed by aircrew person- cabinet, and enough chairs for the efficient use of the
nel. area. A library containing the necessary Army Regula-
tions (ARs) and the applicable TMs, TOs, and NAVAIRs
11-3. SAFETY. The ALSE maintenance area will for the ALSE being used by the unit/units being ser-
comply with all Army safety regulations and unit Stand- viced. Included should be a PC or laptop with access
ing Operation Procedures (SOP). The area will have all to LOGSA publications web site. ALSE maintenance
regulatory signs i.e., NO SMOKING, EXIT, OXYGEN, forms will be maintained and used in accordance with
etc., conspicuously posted. Horseplay will not be tol- DA PAM 738-751. Visual boards relating to ALSE main-
erated or permitted in the area at any time. Personal tenance scheduling shall be located near the desk of the
safety equipment will be used while working/servicing individual assigned to that particular equipment for quick
ALSE i.e., goggles, face shield, apron, gloves, etc. Fire reference, (Refer to TC 3-04.72). Loitering of personnel
extinguishers will be located as needed by type and level in the ALSE area will not be permitted. Loitering
weight. It is recommended an extinguisher be located fosters horseplay and other unsafe actions by person-
in each of the work, storage, and administrative areas. nel.

Change 10 11-1
TM 1-1500-204-23-1

11-7. MAINTENANCE AREA. The ALSE mainte- of health and food service regulations, food will not be
nance area consists of work, storage, and fitting areas. stored in refrigerators.
Access to a classroom adjacent to or in close proxim-
ity of the life support area is desired for lectures and 11-10. FITTING AREA CRITERIA. The fitting area
instructions on the equipment being used and survival will be well-lighted and have enough space so person-
conditions. The shop should contain not less than nel may be fitted with clothing and equipment being as-
1,000 square feet of usable area that is environmentally signed to them, i.e. survival vest, flight clothing, flight
controlled within a range of +60°F (15.6°C) to 75°F helmet, parachute harness, etc.
(23.8°C) and have a potable water source i.e., hot and
cold water. The area will be protected from pilferage, 11-11. TOOLS AND SPECIAL REPAIR EQUIPMENT.
dampness, fire, dust, insects, rodents, direct sunlight, All ALSE items will be serviced and repaired in accor-
and be free from uncontrolled foot and vehicle traffic. dance with applicable TM/TO. The required and autho-
To ensure that all ALSE is maintained in a high state of rized tools and special repair equipment are found in the
readiness through inspecting, cleaning, fitting, testing, Repair Parts and Special Tools List (RPSTL) of the ap-
adjusting, and repairing, all maintenance will be in plicable TM/TO.
accordance with the applicable TM, TO, or NAVAIR. For
additional information refer to TC 3-04.72. Table 11-1 11-12. TRAINING EQUIPMENT. Most equipment
lists recommended test equipment for the ALSE work used for training can be returned to service, providing
area. the equipment is serviceable and can pass all inspec-
tion criteria for that item, before it is returned to service.
11-8. WORK AREA CRITERIA. The work area will The exceptions are as follows:
have bench surfaces free from rough or abrasive mate-
rials, splinter-free tops with a nonporous surface. The • All flotation equipment — these are to be
area is to be well-lighted with accessible electrical out- marked FOR TRAINING ONLY in accordance
lets to all bench and desk areas. Cabinets and work with TM 1-1680-377-13&P.
benches/tables with locks should be used for securing
test equipment, tools, and supplies. Units that have oxy- • Sleeping bags — either those packed inside a
gen equipment will have an area set aside for oxygen 12" by 12" by 1" hard fiberglass container or
maintenance that will have hot and cold running water, the new vacuum packed soft plastic package.
stainless steel sinks, and floors that are sealed and pro-
tected from spills. The area will be restricted to ALSE • DELETED
personnel only. Units supporting flotation equipment
will have a moisture and oil-free source of low-pres- 11-13. TEMPORARY STORAGE OF LIFE SUPPORT
sure, high-volume air and a vacuum source. A vac- EQUIPMENT. Equipment being stored is subject to dry
uum cleaner may be used; however, the vacuum cleaner rot, rodent damage, mildew and other contamination. It
must not be used for cleaning at any time, because dirt is important for the area to be environmentally controlled
and dust must not be induced into the flotation cells. The as well as secured from pilferage.
floor of the work shop will be sealed and coated to pre-
vent chemical spills from penetrating the floor surface. a. Survival Kits. Survival kits to be in temporary
The work area will have hot and cold running water for storage will:
cleaning equipment as well as a wash area. Cleanliness
is very important in maintaining the equipment. Smok-
• Be inspected, repaired, and if needed,
cleaned.
ing, eating or drinking should not be permitted in the
area. • Have components replaced if necessary.
11-9. STORAGE AREA CRITERIA. The storage • Have matches and pyrotechnics removed
area will be well-ventilated, out of direct sunlight, and and stored in accordance with post policy
well-lighted. The storage area will have storage shelves for units operating within a military base, or
and cabinets that provide security for the stored equip- local policy for those units not operating on
ment and be free from dust, moisture, fire, insects, and a military base.
rodents. The floor is to be sealed and covered with a
dust-free flooring material. A refrigerator will be used to • Have kits appropriately tagged with annota-
store batteries used in life support equipment; because tions about items not in the kit being stored.

11-2
 TM 1-1500-204-23-1

Table 11-1. Test Equipment

Nomenclature NSN
Multimeter, AN/PSM-45 6625-01-139-2512
Test set, AN/PRM-32A 6625-01-013-9900
Test set, AN/R/TS-24 6625-01-128-8588
Test set, strobe 6625-01-085-9669
Test set, TS-2530A/UR 6625-00-238-0223
For flotation equipment
Cleaner, vacuum (not for cleaning purposes) 7910-00-550-9123
C02 Transfer unit 3655-00-288-0309
Manometer 6685-00-526-5323
Scale, dial and beam 6670-00-255-0239
Separator, oil and water 4920-00-242-4100
For oxygen equipment
Parts kit, oxygen mask repair 1660-00-672-3945
Regulator 1660-00-700-9776
Tester, oxygen mask, MQ-1A 1660-01-097-0441
Tester, oxygen regulator 4920-00-128-8584

NOTE

Storage cabinets or workbenches/tables with storage shelves/drawers that can be secured with locks
should be used for securing test equipment, tools, equipment, and supplies. The storage cabinets, work-
benches/tables will be marked to identify the tools, equipment, supplies and test equipment contained
within them.

• Be stored on shelved well-ventilated and • Have radios removed from vest. Battery
out of direct sunlight. will be removed from the radio and put into
refrigerated storage.
b. Survival Vests. Survival vests to be put in tem-
porary storage will: • Have the light marker distress removed
from the vest and the battery from the light
• Be inspected, repaired, and if needed, marker removed and put into refrigerated
cleaned. storage.

• Have components replaced if necessary. • Have vest appropriately tagged and items
not in vest annotated on the tag. The vest
• Have signal kits, personnel distress re- will be hung on a hanger for storage, out of
moved and stored in accordance with post direct sunlight.
policy if unit is operating from a military
base, or local policy if unit is operating off a
military base.

11-3
TM 1-1500-204-23-1

c. Flotation Equipment. Flotation equipment to Included are two types of survival vest kits; the SRU-
be put into storage will be stored in accordance with TM 21/P is used by all aircrew personnel except OV-1 air-
1-1680-377-13&P/TO 14S-1-102. crews who wear the vest designed for the OV-1 aircraft.
Both types of vests come in two sizes; the median chest
d. Pyrotechnics. Pyrotechnics will be stored in size is 37 inches, and that determines which size is to
accordance with post policy, if unit is operating on a mil- be used by the wearer. The survival kits contain items
itary post, or in accordance with local policy if unit oper- to support the aircrew personnel in a particular environ-
ates off a military base. ment, i.e., land, either Hot or Cold Climate, or Overwa-
ter. The Overwater kit contains a one man liferaft. This
e. Oxygen Equipment. Oxygen equipment is the only kit that contains flotation equipment. The
to be put into storage in accordance with TM survival vests ensure the individual will have a limited
55-1660-245-13/TO 15X-1-1. amount of survival equipment. The vests are a supple-
ment to the survival kits. Individual under-arm flotation
f. New Equipment. All newly assigned ALSE equipment is available to those aircrew personnel who
equipment prior to storage will be inspected upon fly overwater and is worn with the vest. AR 95-1 regu-
receipt from supply/individual turn-in, and prior to is- late the use of survival equipment for Army aircraft and
sue/reissue, and then in accordance with applicable aircrews. Table 11-3 gives references for survival kits.
TM/TO for that piece of equipment.
a. Inspection. Inspection of the survival kits will
11-14. FLIGHT CLOTHING. Flight clothing consists be in accordance with TM 1-1680-377-13&P, Army Air-
of flight coveralls, nomex flight jackets, nomex or leather craft Survival Kit Maintenance Manual.
flight gloves, anti-exposure suits, flight helmet, and air-
crew body armor. Nylon flight jackets are no longer au- b. Repair. Repair/replacement will be in accor-
thorized for flight duty use. dance with TM 55-1680-317-23&P. Most survival items
will be required to be replaced rather than repaired.
a. Inspection. Inspection of flight clothing, anti- This is due to the nature of packaging for the particular
exposure suits, flight helmet, and aircrew body armor item or the shelf life.
will be in accordance with the applicable TM, TO, or
NAVAIR. c. Cleaning. Clean survival kits using the follow-
ing procedures:
b. Repair. Repair will be in accordance with TM
10-8400-201-23, General Repair Procedure for Clothing (1) Clean the canvas inner or outer cases using
and Inspection Equipment. The applicable TM/TO, for procedures in TM 10-8400-201-23 for lightweight load
the item to be repaired, will be the damage repair criteria carrying equipment.
guidance.
(2) Clean the AMSS per TM 1-1680-377-13&P.
c. Cleaning. Cleaning will be done in accordance
with the applicable TM/TO. Clothing will not be returned (3) Empty the contents of all pockets of the sur-
to unit supply, Repairable Exchange (RX) point, or sal- vival vest and remove any flotation equipment. Wash
vage points needing to be cleaned. Cleaning of all flight the empty vest using soap and warm water. Rinse with
clothing is the responsibility of the aircrew member. The clean, warm water. Put vest on a hanger and air dry out
ALSE technician will instruct the users in the proper use of direct sunlight. The vest may be machine washed us-
and care of flight clothing. Table 11-2 gives references ing a delicate wash cycle.
for flight clothing.

11-15. SURVIVAL KITS. Survival kits currently are is-

sued only to individual aircrew personnel and only for
the climatic zone they will be operating in. The current
survival kit is the AMSS kit information located in TM
1-1680-377-13&P. Individual under-arm flotation equip-
ment is available to those aircrew personnel who fly over
water and is worn with the vest. AR 95-1 regulate the
use of survival equipment for Army aircraft and aircrews.

11-4 Change 9
 TM 1-1500-204-23-1

Table 11-2. References for Flight Clothing

Publication Description
TM 10-8400-201-23 Organizational and Direct Support Maintenance Manual:
GeneralRepair Procedures for Clothing and Individual Equipment
TM 10-8400-202-13 Maintenance Instructions for NOMEX Flight Gear Coveralls Types
CWU-27/P and CWU-28P; Gloves, Type GS-FRP-2; Jacket Flyer’s,
Summer, Type CWU-35/P and Winter, Type CWU-45/P Hood,
Flyers (CWU-17/P Jacket); Trousers, Flyer’s Extreme Cold Weather
CWJ-18/P (TO 14P3-1-112)
TM 10-8415-206-12&P Operator’s and Organizational Maintenance Manual Including Repair
Parts and Special Tools List for Helmet, Flyer’s, Protective, Model
SPH-4 Regular and X-Tra Large
TM 10-8470-202-13 Operation and Service Instructions for Ground and Aircrew Body
Armor (TO 14P3-1-102)
TM 10-8475-200-13 Use, Inspection, Fitting, and Maintenance Instructions for
Anti-Exposure Assembly. Type CWU-21/P (TO 14P3-5-81)
TM 10-8475-202-13 Operation, Service and Maintenance Instructions for Quick Donning
Anti-Exposure Flying Coverall, Type CWU-16/P TO 14P3-5-61
TM 10-227 Fitting of Army Uniforms and Footwear
Deleted
FM 10-267 General Repair for Clothing and Textiles
FM 21-15 Care and Use of Individual Clothing and Equipment
CTA 50-900 Clothing and Individual Equipment
FED STD 757 Stitches, Seams, and Stitching
TC 3-04.72 Maintaining Aviation Life Support Equipment (ALSE): Maintenance
Program

11-16. FLOTATION EQUIPMENT. Flotation equip- Any and all flotation equipment used for training will not
ment consists of underarm flotation bladders (life be used as serviceable equipment for survival kits or
preservers), one man liferafts, seven man liferafts and issued for individual use in lieu of serviceable flotation
20 man multi-place liferafts. All flotation equipment equipment. There will be no waivers for this policy.
contains an air bladder or air chambers, an inflation de- Flotation equipment used for training equipment will be
vice, inflating gas (usually CO2) in cylinders of varying visibly marked FOR TRAINING ONLY in accordance
sizes and capacities to fit the particular piece of flotation with TM 1-1680-377-13&P/TO 14S-1-102. Table 11-5
equipment, and a topping off valve to replenish lost gas gives references for flotation equipment.
or to relieve excess pressure. The device will either
be an oral inflation tube or a hand pump in the case
of multi-place rafts. The type and quantity of flotation
equipment will depend on the type of aircraft being
flown and the number of aircrew and passengers on
board (refer to table 11-4, Liferafts for Aircraft.)

Change 9 11-5
TM 1-1500-204-23-1

Table 11-3. References for Survival Kits

Publication Description
TM 9-1370-203-20&P Organizational Maintenance Manual for Military Pyrotechnics
TM 10-8400-201-23 General Repair Procedures for Clothing and Individual Equipment
TM 55-1680-316-10 Operator’s Manual for Rigid Seat Survival Kit and Survival Vest for
OV-1 Aircrews
TM 55-1680-317-23&P Maintenance Manual for Army Aircraft Survival Kits
TM 55-1680-322-12 Operation and Service for Distress Marker Light, P/N SDU-5/E
TM 55-1680-348-10 Survival Kit, Cold Climate, Individual
TM 55-1680-349-10 Operator’s Manual for Survival Kit, Hot Climate
TM 55-1680-350-10 Operator’s Manual for Survival Kit Overwater, Individual
TM 55-1680-351-10 Operator’s Manual for SRU-21/P Army Vest
TC 3-04.72 Maintaining Aviation Life Support Equipment (ALSE): Maintenance
Program
Deleted
FM 10-267 General Repair for Clothing and Textiles
FM 10-1269 Repair of Canvas and Webbing
FM 21-15 Care and Use of Individual Clothing and Equipment
FED STD 757 Stitches, Seams and Stitching
DA PAM 738-751 Functional Users Manual for the Army Maintenance Management
System-Aviation (TAMMS-A)
TB 9-1300-385 Munitions Suspended or Restricted
TB 740-10 Quality Control Depot Storage Standards. Appendix M Medical
Supplies.
DOD Medical Catalog VOL I, VOL II, VOL III MCRL I, II, III
DOD 5154.4S DOD Ammunition and Explosives Safety Standards
SB8-75-SERIES Army Medical Department Supply Information 8-75-1 thru 8-75-35
SB11-6 FSC Class 6135; Dry Battery Supply Data
SB11-30 FSC Class 6135; Dry Battery Management Data

11-6 Change 9
 TM 1-1500-204-23-1

Table 11-3. References for Survival Kits — Continued

Publication Description
SB742-1370-94-721 Signal, Smoke and Illumination, Marine MK13, MOD O Surveillance
Function Test

a. Precautions. Comply with the following pre- (4) Do not step on any part of liferaft while wear-
cautions when handling or accomplishing maintenance ing shoes when accomplishing inspections or repairs.
on liferafts:
b. Stowage in Aircraft. Liferafts shall be stowed
(1) Prevent hydrocarbons, such as gasoline, oil, in aircraft as follows:
or grease from contacting liferaft materials.

(2) Do not drop or throw liferafts, as damage to

liferaft or accessories may occur. Do not sit or place equipment or tools on liferafts
stowed in aircraft. Keep the liferaft free of oil,
(3) Do not step or sit on packed liferafts, or place grease, and other rubber deteriorating agents.
weights or items on liferafts which are not required. Damage to liferaft may otherwise result.

Change 2 11-7
TM 1-1500-204-23-1

Table 11-4. Liferafts for Aircraft

Aircraft Maxi-
mum
num- Authorized Op-
ber on Authorized optional Authorized tional
board liferaft one- liferaft liferaft liferaft
Type Model Crew Pax Total man 7-man 10-12 man 20-man

U-21 A,D,F,H,J 2 6 8 8 1 1
RU-21 A,B,C,D 2 6 8 8 1 1

AH-64 A 2 0 2 2

C-12 A,C,D 1
CH-47 A,B,C, D 3 33 36 2

OH-6 A 1 3 4 4
OH-58 A,C 1 3 4 4
OH-58 D 2 0 2 2

UH-60 A 3 14 17 17 2
T-42 A 1 3 4 4 1

NOTE
Underarm flotation devices must be worn by all persons on board all Army Aircraft
flying over water. This requirement complies with AR 95-1.
(1) Prior to stowing liferaft assemblies in air- (4) Heavy multi-place liferafts are to be carried,
craft, inspect liferaft compartment or stowage area to not dragged over floor areas.
ensure freedom from oil, dust, water, sharp protruding c. Inspection. All flotation equipment will be in-
edges, or any foreign substances or articles that could spected in accordance with TM 1-1680-377-13&P/TO
cause damage to the liferaft. 14S-1-102.
(2) Refer to aircraft manuals for proper installa- d. Repair. All repairs of flotation equipment will
tion and location within the particular aircraft. be in accordance with TM 1-1680-377-13&P/TO 14S-
(3) Leave liferaft assemblies stowed in fuselage 1-102. The flotation maintenance facility will conform to
(not in compartment) in the carrying cases. Stow auxil- the requirements of the same TM/TO.
iary kit in same manner.

11-8 Change 9
 TM 1-1500-204-23-1

Table 11-5. References for Flotation Equipment

Publication Description
TM 55-1680-321-12 Inspection, Maintenance and Disposition Instructions, Desalter Kit,
Type MK-2
TO 14S-1-102 Maintenance Instructions with Parts Breakdown USAF Flotation
Equipment
TM 1-1680-377-13&P Interactive Electronic Technical Manual (IETM) for Air Warrior
TC 3-04.72 Maintaining Aviation Life Support Equipment (ALSE): Maintenance
Program

Table 11-6. References for Oxygen Equipment

Publication Description
TM 55-1660-245-13 Maintenance Instructions:
TO 15X-1-1 Oxygen Equipment
NAVAIR 03-50-1
TM 1-1680-377-13&P/TO 14S-1-102 Maintenance Instructions with Parts Breakdown USAF Flotation
Equipment
TM 55-1660-247-12 Operation, Fitting, Inspection and Maintenance Instructions for
TO 15X-3-6-1 MBU-12/P Pressure-demand Oxygen Mask.
TM 55-6695-217-13 Operation and Maintenance Instructions for Tester, Oxygen Mask,
Headset, Microphone and Flash Goggles Type MQ-1A
Deleted

e. Cleaning. All cleaning of flotation equipment A clean environment is required to service personal oxy-
will be in accordance with TM 1-1680-377-13&P and TO gen equipment, masks-regulators-oxygen bottles, etc.
14S-1-102. The mask, because it is on the users face, if not properly
serviced, could cause facial skin, throat, and lung prob-
11-17. OXYGEN EQUIPMENT. Oxygen equipment lems, or at worst, no oxygen flow when needed causing
for ALSE consists of that equipment not a permanent/ hypoxia and possible death. Table 11-6 gives references
integral part of the aircraft/aircraft airframe. Oxygen to for oxygen equipment.
be used is Oxygen, Breathing, Aviator’s, MIL-0-27210.
The cylinder is color-coded with a green top, white a. Inspection. Inspection of all oxygen equipment
band, green band and a green body in accordance will be in accordance with the applicable TM/TO.
with MIL-STD-101. There are several types of oxygen.
Aviation oxygen is dry compared to the wet medical b. Repair. Repair of all oxygen equipment will be
oxygen . Dry oxygen for aviation is required because in accordance with the applicable TM/TO/NAVAIR. The
of high altitude and low temperatures. Medical oxygen, maintenance facility will conform to the requirements of
which is wet, can freeze causing malfunction of oxygen TM 55-1660-245-13/TO 15X-1-1/NAVAIR 03-50-1, a tri-
equipment and oxygen masks. The handling of oxygen service manual for oxygen and some oxygen equipment
demands the safe handling, care, and attention to maintenance including the requirements for the oxygen
details. Refer to TM 55-1660-245-13 and TO 15X-1-1. maintenance area.
There are many restrictions to servicing oxygen equip-
ment; all must be adhered to.

Change 9 11-9
TM 1-1500-204-23-1

c. Cleaning. Cleaning of oxygen equipment will Kits will be installed in aircraft locations indicated in
be in accordance with the applicable manual for that the applicable aircraft maintenance technical manual.
piece of oxygen equipment. When the required quantity of first aid kits, for troop
transport mission(s) is in excess of the provisions for
11-18. SIGNALING DEVICES. Signaling devices are installation of the kits, the additional kits will be carried
flares, whistles, reflections from shining surfaces (mir- on board as loose equipment. Upon completion of
rors, plexiglass from doors or windows etc.), smoke, ra- mission(s), the additional first aid kit(s) will be removed
dios, sea dye, cloth, vegetation, and rocks. The use of and turned in.
these items are found in FM 3-05.70 Survival Manual
or AFM 64-5 Survival Manual or the applicable survival c. Identification. There are two configurations of
radio TM/TO. Caution must be used with flares and fire authorized first aid kits with different NSNs for use on
signals. Table 11-7 gives references for signaling de- aircraft . The older design case as shown in figure 11-1
vices. is marked with a red cross and the words First Aid Kit,
General Purpose, and NSN 6545-00-919-6650 appear
a. Inspection. Inspection will be accomplished in on the outer fabric case and will be used until unit stocks
accordance with the applicable TM/TO/NAVAIR. are replaced with the newer design and updated com-
ponents. The newer configuration first aid kit case looks
b. Repair. Repairs, if any, will be accomplished in identical to the older kit with the exception of NSN 6545
accordance with the applicable TM/TO/NAVAIR. -01-599-5586 appearing on the fabric of the case. The
components of the new first aid kit (NSN 6545-01-599-
c. Cleaning. Cleaning will be accomplished in ac- 5586) are different than the old first aid kit (NSN 6545-
cordance with the applicable TM/TO/NAVAIR. 00-919-6650). The old first aid kit and its components
can no longer be ordered.
11-19. FIRST AID KITS. This section establishes the
responsibility and procedures for installation and inspec- d. Protection of Contents. The first aid kit will be
tion, and furnishes information regarding source of sup- closed and sealed when carried in aircraft. Serviceable
ply of approved First Aid Kit, General Purpose, Panel kits will always be tagged with a DD Form 1574 (Ser-
Mounted, NSN 6545-01-599-5586, for aircraft. This kit viceable Tag-Materiel) as shown in figure 11-3, properly
provides first aid essentials for use by flight crews and completed and attached. This will be the responsibility
passengers sustaining injuries due to combat, accident, of designated personnel.
malfunctioning of equipment, or survival conditions.
NOTE
NOTE
This seal will be broken on installed first aid
This publication will be used as authority to iden- kits only when the contents are to be used for
tify and inspect first aid kits for Army aircraft. first aid treatment of an injury. When the seal
Other references in this chapter are used only has been broken, it will be annotated on DA
for purposes specified. Form 2408-13-1 /DA Form 2408-1-E DA Form
2408-13-1-E (Aircraft Inspection and Mainte-
a. Basis of Issue. The property book officer for nance Record).
authorized activities will submit requests for first aid kits
to the supporting medical supply officer, based on one e. Controlled Substances. All narcotics and non-
per crew compartment in Army aircraft; and one for each narcotic controlled substances have been deleted from
five passenger seats/capacity or fraction thereof. this medical kit. Controlled substances are normally not
included in the medical kit. Amphetamines will not be
b. First Aid Kit Installation. Maintenance per- added to medical kits under any circumstances.
sonnel will insure that serviceable first aid kits are in-
stalled in aircraft, as specified in the applicable -10 man-
ual. The absence of required serviceable first aid kits
from an aircraft combined with the inability of securing
and installing required kits prior to flight shall warrant
placing the aircraft in a limited (one kit in crew com-
partment and one kit for each five passenger seats in-
stalled or fraction thereof) operable status, IAW DA PAM
738-751.

11-10 Change 9
 TM 1-1500-204-23-1

Table 11-7. References for Signaling Devices

Publication Description
TM 9-1300-200 Ammunition, General
Deleted
TM 9-1300-214 Military Explosive
TM 9-1300-250 Ammunition Maintenance
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
TM 11-5820-800-13&P Operator’s Aviation Unit and Intermediate Maintenance Manual
Including Repair Parts and Special Tools List for Radio Set AN/PR C90
Deleted
Deleted
TM 11-6625-2632-14 Operator’s Organizational, Direct Support and General Support
Maintenance Manual Including Depot Maintenance Repair Parts and
Special Tools List for Radio Test Set AN/PRM-32
TM 11-6625-2632-14-1 Operator’s, Organizational, Direct Support and General Support
Maintenance Manual Radio Set AN/PRM-32A

Change 9 11-11
TM 1-1500-204-23-1

Table 11-7. References for Signaling Devices — Continued

Publication Description
TM 11-6625-2632-24P-1 Organizational, Direct Support, and General Support Maintenance
Repair Parts and Special Tools List for Radio Test Set AN/PRM-32A
SB11-6 FSC Class 6135; Primary Battery Supply Data
Deleted
SB742-1370-94-721 Signal, Smoke and Illumination Marine: AN-MK 13, MOD O (L275)
Ammunition Surveillance Surveillance Procedures
TM 1-1680-377-13&P Interactive Electronic Technical Manual (IETM) For Air Warrior
TM 55-1680-322-12 Operator’s and Service, Distress Marker, Light, SDU-5/E

Figure 11-1. First Aid Kit, Airplane (Older Configuration)

11-12 Change 9
 TM 1-1500-204-23-1

Figure 11-2. First Aid Kit, General Purpose (Newer Configuration)

Figure 11-3. Serviceable Tag-Materiel (DD Form 1574) (Yellow)

11-13
TM 1-1500-204-23-1

f. Inspection. Inspections of first aid kits by ALSE 5 Ensure that items are inspected in ac-
medical personnel, or other certified personnel are de- cordance with the following inspec-
scribed in the following paragraphs. tion tests.

(1) Inspection by ALSE, medical or other cer- a Replace bandages, dressings,

tified personnel. First aid kits will be inspected for ser- and compresses when there is
viceability and completeness upon receipt. Inspecting evidence of mildew, mold, dry
personnel will annotate the DD Form 1574 with the date rot, discoloration, or when in-
of the shortest expiration dated item contained in the kit. structions are illegible.
This date will be used to schedule the next inspection
due, or when: b Replace adhesive tape when the
adhesive mass separates from
• Suspension of the kit, or an item within the backing fabric upon unwind-
the kit, is announced by the support- ing (unwinding shall consist of
ing medical supply officer, the US Army not less than six inches nor more
Medical Materiel Agency, or the Medical than seven inches of length from
Supply Bulletin (SB8-75-SERIES). the starting end) or when the ad-
hesive mass is not uniform.
• The kit is turned in by using activities.
Using activities will ensure that the kit c Deleted.
is removed for inspection and quality
assurance prior to the next inspection d Deleted.
due/overage date or immediately upon
receiving notice from the supporting
e Deleted.
medical supply officer of an applicable
item suspension. Personnel may be
medical, ALSE, TIs or safety personnel f Ensure that a list of contents is
as authorized in writing by the unit com- included in the kit. Local repro-
mander. duction of the listing, Table 11-8
is authorized.
(a) Inspection procedures. ALSE medical
or certified personnel shall accomplish the following in- g Ensure that component items
spection procedures: of first aid kit that are deleted
through normal supply actions
are replaced or withdrawn from
1 Ensure kit is properly marked using
the appropriate material condition the kit. It is not necessary to
tags and labels listed in paragraph recall the kit in use to effect re-
5-3. placement of deleted items un-
less otherwise specified.
2 Replace all expiration dated items NOTE
with less than 12 months shelf/ser-
vice life whenever possible. The Using activities may use the inspection codes
NEXT INSPECTION DUE DATE an- identified in DLAM 4155.5, Quality Control,
notated on the serviceability tag will Depot Serviceability Standards manual, for
be that of the item that has the short- additional assistance in the identification of
est expiration date or one year after serviceable/non-serviceable medical material
the inspection which ever comes first. contained in the first aid kit.
3 Ensure that the kit contains no (2) Inspection by maintenance personnel.
Schedule II controlled medical items Installed First Aid Kit will be inspected by maintenance
unless a current MACOM authoriza- personnel at the Preventive Maintenance Daily inspec-
tion is on file. tion as prescribed in the applicable aircraft Preventive
Maintenance Daily (PMD) inspection checklist.
4 Ensure that contents of the kit are
complete and serviceable.

11-14 Change 8
 TM 1-1500-204-23-1

NOTE
g. Sealing. The following paragraphs describe
If a seal has been broken, and no kit is imme- the materials and procedures used to seal first aid kits.
diately available, a circled red X status symbol
will be entered in block 16 and a statement en- (1) Materials. Requisition the following materi-
tered in Part I, Fault Information Section of DA als through normal supply channels:
Form 2408-13-1/DA Form 2408-13-1-E (Aircraft
Inspection and Maintenance Record) restricting • Seal, lead, 3/8-inch-diameter, 1/8-
the aircraft to a specified number of passengers inch-thick, with 5-½-inch 27 AWG
until a serviceable kit is installed. Kits on which single-crimped copper wire, NSN
seal has been broken will be turned in to desig- 5340-00-391-4240.
nated ALSE personnel for a replacement kit.
• Flat-head pin, NSN 5315-00-989-7631.
When kit is due for an inspection or kit is con-
sidered unserviceable due to missing or illegible • Seal, anti-pilferage, NSN 5340-00-779-
materiel condition tag, torn case, broken seal, or 3516 (alternate seal).
(on older design) incomplete side pocket con-
tents, etc., inspector will remove DD Form 1574 • Seal, anti-pilferage, NSN 5340-01-004-
(Serviceable Tag-Materiel) and retag kit with DD 9387 (alternate seal).
Form 1577-2 Unserviceable (Repairable) Tag-
Materiel, as shown in figure 11-4. • Copper wire, NSN 5340-00-391-4240.

Figure 11-4. Unserviceable (Repairable) Tag-Material (DD Form 1577-2) (Green)

Change 4 11-15
TM 1-1500-204-23-1

NOTE (d) Continue by passing free end of wire

through one of the holes in seal and pull wire so that
If copper wire, NSN 5340-00-391-4240, seal is held tightly against end of pin.
is not available, use copper wire, NSN
6145-00-234-4991, and lead seal NSN (e) Proceed, by passing end of wire through
5340-00-598-3417. Use press seal NSN hole of materiel condition tag.
5120-00-221-1668 for crimping the lead seal.
(f) Position tag along with wire, approxi-
(2) Sealing procedures. Accomplish the fol- mately one inch away from seal, continue by passing
lowing procedures when sealing first aid kits: the free end of wire through one of the holes in the lead
seal.
(a) Complete DD Form 1574 in accordance
with DA PAM 738-751. (g) Extend wire so that both wires from tag to
seal are even, then take free end of wire, and pass it
NOTE through hole in materiel condition tag again.
The inspection DUE DATE will be no longer than
(h) Crimp seal, then twist materiel condition
the first item with an expiration period. That
tag three or four times. This will create a loop that will
date will become the DUE DATE for the next
hold tag in position.
inspection.

Supplies of Materiel Condition Tags will be req- (i) After completing the resealing action, po-
uisitioned through normal publication channels. sition tag to the double edge of fabric, as shown in figure
11-5, with a minimum of two staples from a standard of-
(b) Reseal kit by closing zipper and placing fice type stapler. This action is intended to reduce the
slide fastener tab in down and locked position, and in- inadvertent loss of the tag due to wind movement when
stall flat-head pin into slide fastener loop. operating aircraft with door/windows open.

(c) Slip free end of sealing wire through hole

in end of flat-head pin already installed in loop and pull
wire through until lead seal is against end of pin.

Figure 11-5. Properly Attached Flat-Head Pin, Lead Seal, and Identification Tag

11-16 Change 1
 TM 1-1500-204-23-1

NOTE (c) Using the instructions from paragraph g

for the sealing and tagging of the kits.
Only one strand of 27 AWG is to be put through
the lead seal. Using more than a single strand (d) Describing what effects outdated or con-
of 27 AWG wire could make the breaking of the taminated components would have on an injured or
seal more difficult and hinder ready accessibility wounded person.
to the first aid components.
(2) Certification. Upon successfully complet-
Any slack in wire between lead seal and end of ing the course of instruction, will be noted on a mem-
pin is to be avoided; however, do not place pin orandum from the certifying individual to the unit com-
under such extreme tension that the possibility mander concerned.
of accidental breakage is increased.
NOTE
h. Replacement of Components. A kit will be
considered unserviceable after the expiration date of the Under no circumstances will personnel, other
first item that expires within the kit, or when the DD than ALSE qualified, authorized under the guid-
Form 1574 tag is missing, or the seal is missing. The ance of this paragraph, maintain other ALSE
kit will be retagged with a DD Form 1577-2 tag and the equipment including those first aid kits in sur-
inspector will annotate in Reason for Repairable Condi- vival kits in accordance with AR 95-1.
tion block, Inspection Due, per paragraph 11-19f or the
applicable aircraft maintenance manual. Kits requiring 11-20. NUCLEAR, BIOLOGICAL, AND CHEMICAL
replacement of items will be reconstituted by authorized EQUIPMENT. Unit chemical personnel are supposed
unit ALSE/Certified personnel in accordance with the list to support training and maintenance of all Nuclear,
of items contained inside each kit and with DOD Medical Biological, and Chemical (NBC) equipment. If the ALSE
Catalog. Replenishment items will be requested from technician has been assigned this task, particularly
the supporting medical supply officer. the aircrew members equipment, the ALSE technician
should become very proficient in the care, use, in-
i. First Aid Kit Components. First aid kit items spection, repair or replacement of NBC equipment and
required are listed in table 11-8 and references in table train the aircrew-members in the care and use of their
11-9. NBC equipment. NBC equipment consists basically of
the following: a breathing apparatus, mask with filters
j. Inspection Training Procedures. Only those to eliminate airborne chemicals, protective clothing to
personnel medically trained (MOS 91B,C or 91Q) and protect the individuals from airborne chemicals, cooling
qualified, or ALSE school trained (with an ASI of Q2 apparatus to cool the individuals body while wearing
or H2), may certify and instruct other unit personnel in the protective clothing, and warning devices to alert
the inspection of first aid kit, general purpose, panel personnel of contamination by chemicals of the air in the
mounted, aircraft. ALSE personnel school trained, with immediate vicinity, or dangerous radiation levels in the
an ASI of Q2, will not be subject to retraining at the unit area. Table 11-10 gives references for NBC equipment.
level. Only certified ALSE, medical or other certified per-
sonnel will be appointed on unit orders by the Comman- a. Inspection. Inspections will be accomplished
der, to perform inspections on the first aid kit, general in accordance with the applicable TM, TO, NAVAIR for
purpose aircraft. the particular item involved.

(1) Training. Training will consist of the follow- b. Repair. Repairs will be accomplished in accor-
ing using an aircraft first aid kit: dance with the applicable TM, TO, or NAVAIR for the
item at the authorized maintenance level.
(a) Using the instruction from paragraph f for
inspection procedures. c. Cleaning. Cleaning will be accomplished in ac-
cordance with the applicable TM, TO or NAVAIR for the
(b) Using the instructions from paragraph f particular item needing to be cleaned.
and TB 740-10, Appendix M, for the replacement of time
expired components of the first aid kit.

Change 10 11-17
TM 1-1500-204-23-1

Table 11-8. First Aid Kit Components

Shelf life
Stock No. Nomenclature Unit Quantity (months)
LOCATION 2 CONTENTS (Lower Pocket)
6545-00-912- CASE MEDICAL INSTRUMENT AND EA 1 Conditional
9860 SUPPLY SET POLYAMIDE NYLON OLIVE

LOCATION 1 CONTENTS (Upper Pocket)

6515-01-532- SEAL CHEST COMBAT CASUALTY 6 IN. EA 2 36 mo
8019 F/USE ON THE BATTLEFIELD
6515-01-529- NASAL TRUMPET 28FR STERLIE EA 2 60 mo
1187
6515-01-598- SCISSORS BANDAGE 7.25 IN LG ANG TO EA 1 Conditional
9737 HDL 1.50 IN CUT LG BLUNT PTS CRS
6515-01-541- NEEDLE DECOMPRESSION DEVICE 14 GA EA 2 36 mo
0635 BY 3.25 IN
6510-00-597- BANDAGE ADH 75X3 IN FLESH/CLEAR EA 12 36 mo
7469 STER DRESS AFFIXED TO PLAS ADH 100s
6510-00-201- BANDAGE MUSLIN OLIVE DRAB 37X37X52 EA 3 84 mo
1755 IN TRIANGULAR WITH SAFETY PINS
6510-00-926- ADHESIVE TAPE SURGICAL POROUS ROLL 1 60 mo
8883 WOVEN 2 IN X 10 YD 6S
6510-01-503- BANDAGE GAUZE COTTON 6 PLY WHITE ROLL 1 36 mo
2117 4.5 IN WIDE 4.1 YDS LONG
6510-01-562- BANDAGE GAUZE IMPREGNATED 3 IN X 4 EA 1 36 mo
3325 YD KAOLIN HEMOSTATIC QUIK CLOT
6510-01-492- BANDAGE KIT ELASTIC EA 1 60 mo
2275
6515-01-521- TOURNIQUET NONPNEUMATIC COMBAT EA 1 Conditional
7976 APPLICATION ONE-HANDED 30.5 IN LG
6515-01-525- GLOVE PATIENT EXAMINING & EA 6 Conditional
1975 TREATMENT SZ X-LARGE LATEX/POWDER
FREE

11-18 Change 8
 TM 1-1500-204-23-1

Table 11-9. References for First Aid Kits

Publication Description
DOD Medical Catalog VOL I, Identification/Management Data
VOL II, Sets, Kits, and Outfits
VOL III, MCRL I, II, & III
SB8-75-SERIES Army Medical Department Supply Information 8-75-1 thru 8-75-33
TB 740-10 Quality Control Depot Storage Standards, Appendix M, Medical
Supplies

Table 11-10. References for Nuclear, Biological, and Chemical Equipment

Publication Description
TM 3-4230-216-10 Operator’s Manual for Decontaminating Kit, Skin M258A1, and Training
Aid Skin Decontaminating M581A
TM 3-4240-280-10 Operator’s Manual for Mask Chemical-Biological: Aircraft ABC-M24
and Accessories Mask Chemical-Biological, Tank M24/M24A1 and
Accessories
Deleted
TM 3-4240-312-12&P Aviation Unit Maintenance, Chemical-Biological Mask: Aircrew M43
TM 55-1660-248-12 Operation and Maintenance Instructions Aircrew
Chem-Defense Ensemble
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted

Change 9 11-19
TM 1-1500-204-23-1

11-21. RESTRAINT EQUIPMENT. Restraint equip- (1) Installation inspection. Visually inspect
ment, as used in this section, includes safety lap belts, all restraint equipment prior to installation. Seat belt
shoulder harnesses, and other fabric devices used in latches shall be inspected for fingertip clearance in
Army aircraft for personnel restraint purposes. Restraint accordance with the following procedures:
equipment is to be installed as directed in the applicable
maintenance manual. On all pilot/copilot and crewman (a) Inspect each seat belt latch by using a
seat belts, the safety belt release handle should point steel scale to measure the clearance distance between
to the left. the inside face of the top of the grip and the top of the
wedding, as shown in figure 11-6.
NOTE
(b) If the distance measured above is less
Seat belts will not be replaced for cosmetic rea- than the thickness of gloved fingers (minimum 0.8 inch)
sons. alter latch using the following procedures:
a. Inspection. All personnel restraint equipment 1 Open latch so that sides may be
is to be visually inspected at time of installation and at placed in vise equipped with alu-
specified intervals thereafter. Inspections are explained minum or brass protective plates on
in the following paragraphs. jaws.
• New Restraint Equipment. Perform daily
2 Squeeze sides of latch handle to-
inspection for new seat belt latches
gether using constant, even vise
(MS3488(AS)) also inspect for fingertip
pressure until jaws are approximately
access.
1 ¾ inches apart. Latch will deform
• New Assemblies of Restraint Equipment. upward and inward, as shown in fig-
This equipment requires no inspection dur- ure 11-12.
ing depot storage.
3 Repeat as necessary to obtain
• Seat belt latch (MS3488(AS)). Inspect for 7/8-inch clearance dimension due to
fingertip clearance. Inspect each seat belt spring back of metal.
latch by using a steel scale to measure the
clearance distance between the inside face 4 Perform visual inspection for cracks.
of the top of the grip and the top of the web-
bing, as shown in figure 11-6. 5 Check operation of latch and detent
for complete lock and release.

Deleted

Figure 11-6. Measuring Fingertip Clearance

11-20 Change 9
 TM 1-1500-204-23-1

NOTE • Fraying of the exterior surface of the

webbing, causing separation or rup-
When new nylon webbing is installed, it will be ture of yarns sufficient to obscure the
flexed by pulling it across or around a metal bar identity of any yarn exceeding 20 per-
approximately ¼ inch in diameter. This action is cent of the width or 2 inches in length,
accomplished by holding each end of the new shall render the webbing unservice-
webbing and pulling it in a back and forth mo- able. Fuzzing of the exterior surface
tion. This will assist in making the webbing pli- caused by broken individual filaments
able by breaking down the finishing glaze that in the yarns is not cause for rejection.
is applied to new nylon fabric. Repeat the back
and forth motion until the glaze on the fabric is NOTE
broken down to such an extent that the belt or
harness can be readily adjusted. The flexing Fuzzing of the exterior surface caused by bro-
procedure will be accomplished on both sides ken individual filaments in the yarns is not cause
of the webbing. for rejection.

(2) Daily inspection. Perform the daily inspec- • Discoloration of webbing caused by
tion using the following procedures: contact with strong caustic soaps, or
acid shall be reason for removal from
(a) Check seat belt shoulder harness, re- service. Webbing discoloration re-
straint harness, inertia reel strap webbing for: sulting from contact with metal arti-
cles and hardware is not cause for re-
• Deterioration resulting from contact moval.
with foreign matter, (i.e. acid, pe-
troleum based products, strong caus- NOTE
tic soaps) shall be cause for removal
from service. Surface mold or mildew Webbing discolored or soiled by grease, oil, avi-
may be removed by washing. If no ation fuels and hydraulic fluids shall be cleaned,
deterioration is evident after washing, I.A.W. paragraph d , c . Fading of webbing by
webbing shall be considered service- subjection to sunlight is an unreliable indicator
able. of deterioration and shall not be cause alone for
webbing rejection.
NOTE
Surface mold or mildew may be removed by (b) Any metal restraint hardware which is
washing. If no deterioration is evident after corroded or defective in operation shall be inspected for
washing, webbing shall be considered service- operational use and replaced if found to be substandard
able. or excessively damaged. Missing or unserviceable
adjuster webbing retarder springs and loose or missing
• Cuts of the webbing caused by a bolts will be replaced.
sharp-edged instrument or object
that severs the vertical or horizontal (c) Check buckle mechanisms for ease of
yarns of the webbing, shall be reason locking and releasing. When locked, the latch should
for removal. not have a tendency to release inadvertently, nor should
it be excessively difficult to release.
• Broken stitches identified by missing,
skipped, torn or ruptured threads in (d) Pilot/troop type belts, check for freedom
the stitch pattern. Stitching may be of movement of the link within the mated hook and guide
repaired and will not be cause for re- bar. The link shall not bind in any position (i.e. pivot and
jection. hook tip) within its operating limits.

Change 9 11-21
TM 1-1500-204-23-1

(e) Inertia reels, check for damage, security,

positive locking and unlocking, manual lock-unlock con- NOTE
trol for proper operation.
Surface mold or mildew may be removed by
(f) Examine restraint system attaching points washing if not deterioration is evident after
to aircraft. Check for loose bolts, deformity, corrosion or washing, webbing shall be considered service-
sharp and jagged edges which may damage webbing. able.
(1) Prepare a concentrated soap and hot water
b. Repair. Broken or missing stitches can be re- solution, using laundry soap chips, Federal Specification
paired using a sewing machine in accordance with the P-S-1792, or equivalent. Cool the solution not to exceed
following repair requirements: 100°F (38°C), prior to application.
(2) Dampen an approved clean brush, such as
• If five or more stitches are broken or loose NSN 7920-00-244-7431, with the soap solution and rub
within one linear inch, restitching is re- lightly over the affected surface area.
quired. (3) Rinse the webbing thoroughly with clear,
lukewarm water.
NOTE
(4) Place webbing in open air or a drying room
When restitching safety belts, restraint harness, to dry.
hoist operators harness, gunners harness,
NOTE
stitch directly over the original stitching and
follow the original stitch pattern as closely as Do not expose the wet webbing to freezing tem-
possible. peratures or to direct sunlight during cleaning,
drying, or storage. Redying or painting is pro-
• Only one repair per stitch pattern is autho- hibited.
rized. Restitching should be accomplished
with thread which matches the color of the (5) After cleaning visually inspect in accordance
original stitching, when possible. Restitch- with paragraph a.
ing should be locked by over stitching each
end of the stitch formation by ½ inch. All
stitching shall be with nylon thread conform-
ing to Spec V-T-295, thread size, stitching
pattern and stitches per inch shall be I.A.W. Improper cleaning or drying of the harness re-
original construction. straints and buckle can weaken them, reduce
their effectiveness and can result in serious per-
• Restitching should be locked by over stitch- sonal injury or death.
ing each end of the stitch formation by ½
inch. NOTE
• All stitching shall be with nylon thread Belts utilized in aircraft conducting salt water
conforming to Spec V-T-295, thread size, pick-up training shall be washed in fresh wa-
stitching pattern and stitches per inch shall ter and corrosion preventive compound (MIL-
be in accordance with original construction. C-81309, NSN 8030-00-938-1947) shall be ap-
plied to metal components.
c. Cleaning. Cleaning of personnel restraint
equipment will be accomplished when webbing is soiled d. Replacement. Equipment determined to be
using the following procedures: unserviceable by visual inspection will be replaced.
Unserviceable equipment will be disposed of through
normal disposal channels to the nearest property
disposal activity. The following personnel restraint
equipment having dacron or nylon webbing is to be
Do not use a bleach. Bleach may cause web- replaced if determined to be unserviceable.
bing to deteriorate. No cleaning is authorized
to inertia webbing strap. Acids or caustic soaps • Safety lap belts (crew or troop)
will cause deterioration of the polymer webbing.
Polymer webbing should only be cleaned with • Shoulder harness (crew or troop)
mild soap (soap, laundry (CAGEC 881348) P/N
P-S-1792 • Safety belt tiedown straps

11-22 Change 7
 TM 1-1500-204-23-1

• Personnel restraining harness (gunner and (a) For shoulder harness webbing adjuster,
hoist operator) P/N MS22007, use spring, P/N 65D34083-7 and the fol-
lowing procedures:
• Safety belts (airline type)
• Inertia reel strap (webbed strap only) 1 Hook one end of webbing retarder
spring around flat end of knurled lock-
• Leg restraints ing bar as shown in figure 11-7.
• Litter straps 2 Cut a 16-inch length of type 1 nylon
NOTE cord, and tie the loose ends together
to form a loop in the cord.
Safety belts will not be replaced for cosmetic
reasons. 3 Insert the nylon cord loop through the
Safety belts having cotton webbing are to be slot of the adjuster plate, and hook
removed from service. loop over the webbing retarder spring
hook end.
Replace loose, missing, or damaged bolts,
nuts, washer, and shims in the anchoring 4 Pull the nylon cord through adjuster
points. plate slot and around the bar.
(1) Spring webbing retarder. Replace spring
webbing retarder used in shoulder harness and seat belt
webbing adjusters as follows:

Figure 11-7. Shoulder Harness Webbing Retarder Spring Installation

11-23
TM 1-1500-204-23-1

5 Press the locking bar back with the 2 Hook one end of webbing retarder
left thumb, leaving enough space to spring around flat end of knurled lock-
slide the loop through adjuster plate ing bar. Work other end of spring
slot once the hook end of the retarder around opposite flat end of knurled
spring has engaged on the locking bar as shown in figure 11-8.
bar.
3 Insert center section of webbing re-
6 Pull the nylon cord over the knurled tarder spring into adjuster plate tab
locking bar to disengage the cord release, (fig 11-8).
from the retarder spring.
4 Replace adjuster webbing in adjuster
7 Work the center of the webbing re- plate. Ensure that webbing is cen-
tarder spring into the adjuster plate tered on adjuster plate knurled bar
pull tab slot. and can be adjusted as desired.

8 Ensure that shoulder harness web- (2) Installation or replacement of snap safety
bing is centered on adjuster plate pin. Install or replace snap safety pin on personnel
locking bar and can be adjusted, (fig. restraint harness as follows:
11-7 ).
(a) Secure the snap (MS22042-1) in a vise,
(b) For seat belt webbing adjuster P/N and ensure that the snap guard is not contained within
MS22004-1 NSN 1680-00-876-0971 use spring P/N the jaws.
62B4407 NSN 1680-00-975-2987 and the following
procedures: (b) Drill a 3/32-inch diameter hole through
both sides of snap guard as shown in figure 11-9.
1 For ease in replacing webbing re- Remove all metal burrs and filings from the snap.
tarder spring, remove adjustment
webbing from adjuster plate. Spring
can be replaced without removal of
seat belt from aircraft.

Figure 11-8. Seat belt webbing retarder spring installation

11-24
 TM 1-1500-204-23-1

(c) Cut a five-inch length of 0.080-inch diam-

eter corrosion-resistant wire (NSN 9505-00-892-4616),
and construct a safety pin as shown in figure 11-10.
(d) Cut a 15-inch length of type III nylon
cord (NSN 4020-00-246-0688). Remove the inner core
threads and sear the ends of the cord .
(e) Pass half of the cord length through the
safety pin loop. Tie a square knot up against the loop.
Tie another square knot about 4-½ inches from previ-
ously tied knots.
(f) Pass one loose end of the cord through
the snap where the webbing is attached. Tie the two Figure 11-10. Snap Hook Safety Pin Construction
cord ends together with a square knot as shown in figure Details
11-11. Tie an overhand knot in each loose end of cord.

11-22. PERSONNEL PARACHUTE AND

PARACHUTE HARNESS. Inspection criteria, proce-
dures, and report for the personnel parachute assembly
and parachute harness are explained in the following
paragraphs.

a. Inspection Criteria. Any of the equipment

listed below which is in use, installed in aircraft as extra
equipment, located in an aviation unit ready-for-use
facility, or in the possession of aircraft crew members
will be inspected on a routine basis every 30 days
and prior to issue for use. When an aviation unit is
not conveniently located, E.G. on same installation
as their supporting parachute packing activity, desig-
nated parachute inspectors will check and ensure that
shelf/service life items are withdrawn from use at the
end of their service life in accordance with TB 43-0002-4
and will sign the required document to support turn-in
of expired items.

Figure 11-11. Safety Pin Retaining Cord Secured

to Snap Hook

Figure 11-9. Snap Hook Safety Guard Drill Details

Change 1 11-25
TM 1-1500-204-23-1

Figure 11-12. Seat Belt Latch Modification

11-26
 TM 1-1500-204-23-1

NOTE An emergency-type personnel parachute which has ex-

ceeded 120 days since the last pack will be considered
• Aircrew members who preform flight duties unserviceable. Process for repack according to step (j).
away from home station or assigned unit will en- After determining the last pack date, return the form to
sure that individual emergency type parachutes the log record and survival manual pocket.
and harnesses are inspected every 30 days by
qualified parachute inspectors. However, if a NOTE
situation occurs which precludes inspection due
to a lack of qualified parachute inspection, per- An emergency type chest parachute has two
sonnel, parachutes and harnesses may con- parachute log records. One log record is lo-
tinue to be used until arrival at a facility which cated on the parachute pack, and the other is
can satisfy the inspection criteria, as soon as found on the harness. Each of these log records
practical. In no case will the 30 day inspection shall be maintained. On an emergency type
requirement exceed 60 days. back parachute, the log record may be located
either on the pack right wing flap or on the pack
• Unit commanders/aviation life support person- bottom sTIFFener panel.
nel will ensure that individual emergency type
parachutes, I. E. seat, back, chest, or ejec- (b) Deleted
tion seat type including drogue chutes and har-
nesses when separate from the parachute, I. E. (c) Without opening the pack, visually check
chest harnesses and ejection seat harnesses, external condition of pack and harness for defects or
including seat belts, when integrated into the deterioration of webbing, canvas fabric, or stitching, and
harness parachute system, will be inspected ev- broken or loose tacking.
ery 30 days by an individual qualified to perform
30-day parachute inspections. These person- (d) Check metal components for cracks or
nel will have been trained in parachute inspec- rust. Check ripcord housing for dents or breaks.
tion methods by a qualified parachute rigger.
This training will be documented in individual (e) Deleted
training folders and designated as parachute in-
spectors on unit orders by the aviation unit com- (f) Inspect ripcord grip pocket to ensure the
mander. ripcord grip is secure and the grip protrudes enough to
allow immediate accessibility. Ensure that removal of
• Generic Description of Equipment
ripcord is not obstructed by misplaced stitching or tack-
(1). Parachutes, personnel, emergency ing and that harness chest strap on back parachute is
type: back, chest and seat types. not routed through ripcord grip.

(2). Parachutes, personnel and drogue, (g) Ensure that each pack opening spring
ejection seat type. band is connected. Check the elasticity of each band.

(3). Harnesses, personnel parachute, used (h) Open ripcord protector flap and inspect
with above parachutes. ripcord pins for proper seating in the pack release cones.
Ensure that pins are not bent or corroded. On back of
b. Inspection Procedures. Inspection proce- personnel parachute, each ripcord pin shall extend ¾
dures for personnel parachute assemblies are explained inch beyond pack release cone (measuring from top of
in the following paragraphs. pin to eye of cone).

(1) Personnel parachute assemblies. In-

spection procedures for emergency type personnel
parachute assemblies including back, seat, and chest
types are as follows:

(a) Remove DA Form 3912 from assembly

log record and survival manual pocket. Check record
for date of last pack.

Change 9 11-27
TM 1-1500-204-23-1

(i) On back personnel parachute, grasp har- (2) Enter inspection date in date column.
ness webbing at a point on the lift web above the ripcord
grip pocket. Pull against the weight of pack assembly to (3) Make checkmark in routine inspection col-
ensure the ripcord pins will not move from the preposi- umn.
tioned location given in (h) above.
(4) Repeat the number entered previously in the
(j) If after completing steps (a) thru (i) above, jumped or dropped columns.
it is determined conditions exist which require repair,
repack, or more extensive inspection, prepare DD Form (5) Enter signature in the inspector’s name col-
1577-2 as shown in DA PAM 738-751. Attach form to the umn.
the item. The item then shall be segregated from ser-
viceable items by a physical barrier and evacuated to a (6) Enter designation of the unit to which inspec-
parachute maintenance facility. An emergency type per- tor is assigned in the unit column.
sonnel parachute which is considered serviceable will
have the inspection recorded as described in paragraph NOTE
c, and the parachute will be returned to service. The 30-day routine inspection requires record-
ing on DA Form 3912.
(2) Deleted
11-23. CONSOLIDATED LIST OF ALSE REFER-
c. Inspection Report. Record and report inspec- ENCES. Table 11-11 gives a list of references to be
tion MK-J5 ejection seat personnel parachute harness used as a guide only. Do not maintain manuals that do
onDA Form 2407 in accordance with DA PAM 738-751. not pertain to the units Life Support Equipment autho-
Further inspection record will be made on the individual rized and on hand. Department of the Army PAM 25-30
parachute harness DA Form 3912 as follows: should be consulted frequently for the latest changes or
revisions of the references listed in table 11-11 and for
(1) Open DA Form 3912 to page, entitled jump new publications covered in this section. Instructions
inspection and repack data, for the routine inspection for establishing and maintaining a library are found in
entry accomplishment. DA PAM 310-13.

11-28 Change 9
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References

Publication Description
Army Regulations (AR)
AR 25-400-2 The Modern Army Record Keeping Systems (Marks)
AR 32-15 Classification and Inspection
AR 40-5 Preventive Medicine
AR 40-8 Temporary Flying Restrictions Due to Exogenous Factors
AR 40-61 Medical Logistics Policies and Procedures
AR 40-501 Standards of Medical Fitness
AR 40-656 Veterinary Surveillance Inspection of Subsistence
AR 40-657 Veterinary Medical Food Inspection and Laboratory Service
AR 40-660 DOD Hazardous Food and NON Prescription Drug Recall System
AR 95-1 Army Aviation Flight Regulations
Deleted
AR 190-11 Physical Security of Arms, Ammunition, and Explosives
AR 310-70 Equipment Interservicing of Technical Manuals and Related Technology
AR 340-1 Records Management Program
AR 528-28 Code of Conduct/Survival, Evasion, Resistance, and Escape (SERE)
Training
AR 385-32 Protective Clothing and Equipment
AR 385-64 Ammunition and Explosives Safety Standards
AR 385-95 Army Aviation Accident Prevention
AR 700-89 Identification, Control, and Utilization of Shelf Life Items
AR 710-1 Centralized Inventory Management of the Army Supply System
AR 710-2 Supply Policy Below the Wholesale Level
AR 725-50 Requisitioning, Receipt, and Issue System

11-29
TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Army Regulations (AR) — CONT
AR 750-1 Army Material Maintenance Policies
AR 750-32 Airdrop, Parachute Recovery and Aircraft Personnel Escape Systems
AR 755-1 Reporting, Utilization, and Redistribution of Installation USAMC, and
Overseas Command Excess Property
AR 755-2 Disposal of Excess, Surplus, Foreign Excess, Captured and Unwanted
Material
Department of Defense Publications (DOD Pub)
DOD 4160.21-M Defense Utilization and Disposal Manual
DOD 5154.4S DOD Ammunition and Explosives Safety Standards
Defense Logistics Agency
DLAM 4155.5 Quality Control Depot Serviceabilty Standards (Medical Supplies), Appendix
M
Medical Catalog Containing VOL I, VOL II, VOL III.

NOTE

Department of Defense Customer Assistance Program call Autovon

284-7871. They will mail copies.
FED STD 757 Stitches, Seams, and Stitching
Technical Manual (TM)
TM 1-1680-377-13&P, -1 thru -10 Interactive Electronic Technical Manual (IETM) For Air Warrior
TM 3-4230-216-10 Operator’s Manual for Decontaminating Kit Skin: M25H1 and Training Aid,
Skin Decontaminating: M58A1
Deleted
TM 5-803-4 Planning of Army Aviation Facilities
TM 5-4220-201-12 Operator’s and Organizational, Maintenance, Life Preserver, Underarm,
Parachutist (B-7)

11-30 Change 9
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Technical Manual (TM) (Cont)
Deleted
TM 9-1290-333-15 Operators, Organizational, Direct Support, General Support, and Depot
Maintenance Manual (Including Repair Parts and Special Tools List)
Compass Magnetic Unmounted M2
Deleted
Deleted
TM 9-1370-206-10 Operator’s Manual: Pyrotechnic Signals
TM 9-4940-461-15P Operator’s Organizational, DS, GS, and Depot Maintenance Repair Parts
and Special Tools List for Separator Oil and Water, Spray Gun, Wall MTD
TM 10-1670-1 Survival and Emergency Use of the Parachutes (AFP 64-15)
TM 10-1670-250-20 Organizational Maintenance Manual (Including Repair Parts and Special
Tools List): Parachute System Used w/Martin Baker MK-J5D Ejection Seat
TM 10-1670-213-10 Operator’s Manual for Parachute Personnel, Types 28 Foot Diameter,
Back; 28 Foot Diameter, Chest; NB-8 Back and Martin Baker Ejection Seat
Harnesses
TM 10-1670-251-12 Operator’s and Organizational Maintenance Manual (Including, Repair
Parts and Special Tool List): Lowering Device, Cargo and Personnel, 500
LB Capacity
TM 10-1670-262-12 Operator’s and Organizational Maintenance Manual (Including, Repair Parts
and Special Tools List): For Personnel Stabo Extracts on System and Cargo
and Personnel Lowering Anchor Device
TM 10-3530-202-24 Organizational and Field Maintenance Manual: Sewing Machines for the
Repair of Parachutes and Allied Equipment
TM 10-8400-201-23 Organizational and Direct Support Maintenance Manual: General Repair
Procedures for Clothing and Individual Equipment
TM 10-8415-206-12&P Operator’s and Organizational Maintenance Manual (Including Repair Parts
and Special Tools List): For Helmet, Flyer’s Protective, Model SPH-4 Regular
and X-Tra Large

Change 9 11-31
TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Technical Manual (TM) — CONT
TM 10-8475-200-13 Use, Inspection, Fitting, and Maintenance Instructions for Anti-Exposure
Assembly, Type CWU-21/P or CWU-21A/P(TO 14P3-5-81)
TM 10-8475-202-13 Operation, Service and Maintenance Instructions for Quick Donning
Anti-Exposure Flying Coveralls Assembly. Type CWU-16/P (T.O. 14P3-5-61)
TM 11-5820-640-15 Operator’s Organizational, Direct Support, General Support, and Depot
Maintenance Manual: Radio Sets, AN/URC-10A, AN/URC-10A, and ACR
RT-10
TM 11-5820-767-12 Operator’s and Organizational Maintenance Manual Including Repair Parts
and Special Tools List; Radio Set, AN/URC-68
TM 11-5820-767-34 Direct Support and General Support Maintenance Manual Including Repair
Parts and Special Tools List (Including Depot Maintenance Repair Parts and
Special Tools) for Radio Set, AN/URC-68
TM 11-5820-800-13&P Operator’s and Organizational Maintenance Manual, (Including Repair Parts
and Special Tools List) Radio Set AN/PRC-90
TM 11-5965-279-13P Operator’s Organizational and Direct Support Maintenance Repair Parts
and Special Tools List for Headset-Microphone Kit MK-896/AIC for Helmet,
Flyers Protective SPH-4
Technical Manual (TM) — CONT
TM 11-5965-285-23 Organizational and DS Maintenance Manual (Including Repair Parts and
Special Tools List) Headset Microphone 19LB-87
TM 11-6625-2631-14 Operator’s Organizational, Direct Support and General Support Maintenance
Manual Including Repair Parts and Special Tools List: Test Set, TS-2530/UR
and TS-2530A/UR
TM 11-6625-2632-14 Operator’s Organizational, Direct Support and General Support Maintenance
Manual (Including Depot Maintenance Repair Parts and Special Tools) For
Radio Set AN/PRM-32
TM 38-711-2 Standard Army Intermediate Level Supply Subsystem (SAILS) Procedures
for Customers
TM 55-1660-247-12 Operation, Fitting, Inspection and Maintenance Instructions with Illustrated
Parts Breakdown for MBU-12/P Pressure Demand Oxygen Mask
Deleted

11-32 Change 9
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Technical Manual (TM) — (CONT)
Deleted
TM 55-4240-284-12 Operating and Maintenance Manual, Rescue Seat, Forest Penetrating
Including Repair Parts and Special Tools List
Deleted
Deleted
TM 55-1680-350-10 Operator’s Manual: Survival Kit, Overwater, Individual
Deleted
TM 55-1680-322-12 Operations and Service, Distress Marker, Light Part No. SDU-5/E
TM 750-244-1-2 Procedures for the Destruction of Life Support Equipment to Prevent Enemy
Use
TM 750-244-1-5 Procedures for Destruction of Aircraft and Associated Equipment to Prevent
Enemy Use
Field Manuals (FM)
FM1-100 Combat Aviation Operations
Deleted
FM 10-267 General Repair for Clothing and Textiles
FM 20-151 Aircraft Emergency Procedures Overwater
FM 21-15 Care and Use of Individual Clothing and Equipment
FM 3-05.70 Survival
FM 38-725-23 Logistic Codes NICP/Depot and DS/GS/Installation
Technical Bulletins (TB)
TB CML 93 Adapter, Compressed Air Breathing Apparatus, M4 (End Item Code 201) and
Detector Kit, Carbon Monoxide, Colormeter, M23
TB 9-1300-385 Munitions: Suspended or Restricted
TC 3-04.72 Maintaining Aviation Life Support Equipment (ALSE): Maintenance Program

Change 9 11-33
TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Technical Bulletins (TB) — CONT
TB 34-9-127 Medical Gas Cylinders
TB 34-9-210 NATO Standardization Agreement for Air Pyrotechnics Interchangeability
Chart STANG 3398
TB 34-9-242 Aircraft Gaseous Oxygen Replenishment Connections
TB 34-9-243 Aircraft Compressed Air Replenishment Connections
TB 34-9-245 Compressed Breathing Air Characteristics
TB 34-9-330 Mask, Protective, Aircraft, ABC-M24 and Hood Aircraft Protective Mask,
ABC-M7
TB 43-0002-4 Maintenance Expenditure Limits for FSC Group 16, FSC Classes 1610,
1615, 1620, 1630, 1650, 1660, 1670, and 1680
TB 43-180 Calibration and Repair Requirements for the Maintenance of Army Material
TB 740-10 Quality Control Depot Serviceability Standards
Supply Bulletins (SB)
SB 3-30-2 Chemical, Biological Canisters and Filter Elements Serviceability Lists
SB8-75-SERIES Army Medical Department Supply Information SB 8-75-1 through 8-75-35
SB11-6 FSC Class 6135; Dry Battery Supply Data
SB11-30 FSC Class 6135; Primary Battery Management Data
SB 11-576 Cold Weather Batteries for Radio Sets AN/PRC-6, 8, 8A, 9A, 10, 10A, 25, 28
and 77 and Cable Assemblies for Cold Weather Operation of Transmitting
Set Radio AN/PRT-4 and Receiving Set, Radio AN/PRR-9
SB700-20 Army Adopted/Other Items Selected for Authorization/List of Reportable
Items
SB708-30 Department of Defense Ammunition Code (Cataloging Handbook H3)
(GSA-FSS-H-3)

11-34
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Supply Bulletins (SB) — CONT
SB 708-6 Federal Item Directory for Supply Cataloging
SB 708-21 Federal Supply Classification; Part 1-Groups and Classes (Cataloging
Handbook H2-1)
SB 708-22 Federal Supply Classification; Part 2 Numeric Index of Classes (Cataloging
Handbook H2-2) (GSA-FSS-H2-2)
SB708-41/SB 708-42 Federal Supply Code for Manufacturers; United States and Canada-Name to
Code (Cataloging Handbook H4-1) (GSA-FSS-H4-1/H4-2)
SB 708-43 Cataloging Handbook H4/H8 Commercial and Government Entity (GAGE)
SB 742-1 Ammunition Surveillance Procedures
SB742-1370-94-721 Signal, Smoke and Illumination, Marine: AN-MK 13 MOD O Ammunition
(DODAC 1370-L 275) Surveillance Procedures
Supply Catalogs (SC)
SC5180-91-CL-R07 Tool Kit, Electronic Equipment, TK-105/G
SC5180-91-CL-R13 Tool Kit, Electronic Equipment, TK-101/G
Department of the Army Supply Catalogs (Federal)
C 1 ARMY Introduction to the Federal Supply Catalog and Related Publications
C 6500-AL Federal Supply Catalog: Alphabetical Index (Medical Materiel)

Change 2 11-35
TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Department of the Army Supply Catalogs (Federal) — CONT
C 6505-GL FSC Glossary of Colloquial Names and Therapeutic Index (FSC Class 6505)
MCRL-1 Master Cross Reference List - 1, Cross Reference from Part Number to NSN
MCRL-2 Master Cross Reference List - 2, Cross Reference from NSN to Part Number
C 6700/9500-ML Management Data List: FSC Groups 67 Thru 95 (Items of Medical Materiel
Only)
C 8900-SL Federal Supply Catalog: Stock List, FSC Group 89, Subsistence
Department of the Army Pamphlets (PAM)
PAM 25-30 Consolidated Index of Army Publications and Blank Forms
PAM 310-10 The Standard Army Publications System (STARPUBS) User’s Guide
PAM 310-13 Posting and Filing Publications
PAM 700-3 Why and How to Use SF 364 to Report Package Discrepancies
PAM 710-2-1 Using Unit Supply System Manual Procedures
PAM 738-751 Functional User’s Guide to the Army Maintenance Management
System-Aviation (TAMMS-A)
Common Tables of Allowance (CTA)
CTA 8-100 Army Medical Department Expendable/Durable Items
CTA 50-900 Clothing and Individual Equipment
CTA 50-909 Field and Garrison Furnishings and Equipment
CTA 50-970 Expendable/Durable Items (Except: Medical, Class V, Repair Parts and
Heraldic Items)

11-36 Change 2
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Air Force Technical Orders (TO)
TO: 0-1-01 Numerical Index
TO: 0-1-02 Numerical Index
TO: 00-5-1 Technical Order System
TO: 00-5-2 Technical Order Distribution System
TO: 00-35A-39 Instructions for Procurement, Issue, Use and Maintenance of Medical Kits
TO: 11A-1-1 Ammunition Restricted or Suspended
TO: 11A10-24-7 Storage and Maintenance Procedures, Pyrotechnics
TO 12R2-2PRC90-2 PRC-90 Survival Radio
TO 12R2-2PRC90-3 PRC-90 Survival Radio
TO 12R2-2PRC90-4 PRC-90 Survival Radio
TO 14S-1-102 Maintenance Instructions with Parts Breakdown USAF Flotation Equipment
TO: 14S1-4-1 Distillation Kit
TO: 14S10-2-2-SDU-5/E Marker Distress Light
TO: 14S1-4-22 Desalting Kit
TO 15X1-1 Oxygen Equipment
TO: 15X1-4-2-4 Bail Out Bottles (Parts Manual)
TO: 15X1-4-2-12 Bail Out Bottles (Maintenance Manual)
TO: 15X3-3-4-3 MB4 Diluter Demand
TO: 15X5-3-6-1 MBU-12/P Pressure-Demand Oxygen Mask Operation, Fitting, Inspection
and Maintenance Instructions with Illustrated Parts Breakdown
TO: 15X5-4-1-101 Oxygen Mask Connector (CRU-60/P)

11-37
TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Naval Publications
Department of the Army (DA) Forms
DA Form 12-R Request for Establishment of a Publications Account
DA Form 12 Series Requirements for DA Publications
DA Form 17 Requisition for Publications and Blank Forms
DA Form 17-1 Requisition for Publications and Blank Forms (Continuation Sheet)
DA Form 581 Request for Issue and Turn-In of Ammunication

11-38 Change 2
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Department of the Army (DA) Forms — CONT
DA Form 2028 Recommended Changes to Publications and Blank Forms
DA Form 2062 Hand Receipt/Annex Number
DA Form 2063-R Prescribed Load List (LRA)
DA Form 2064 Document Register for Supply Actions
DA Form 2402 Exchange Tag
DA Form 2404 Equipment Inspection and Maintenance Worksheet
DA Form 2405 Maintenance Request Register
DA Form 2407 Maintenance Request
DA Form 2407-1 Maintenance Request - Continuation Sheet
DA Form 2408-21 Life Raft Inspection Record
DA Form 2408-22 Helmet and Oxygen Mask/Connector Inspection Record
DA Form 2408-23 Survival Radio/Emergency Locator Transmitter (ELT) Inspection Record
DA Form 2408-24 Survival Kit Inspection and Maintenance Record
DA Form 2408-25 Mesh Net Survival Vest Inspection Record
DA Form 2408-26 Life Preserver Inspection Record
DA Form 2408-27 Life Preserver Data
DA Form 2408-28 Oxygen Console Service Record
DA Form 2408-29 Anti-Exposure Coveralls Inspection Record
DA Form 2696-R Operational Hazard Report
DA Form 2765-1 Request for Issue or Turn-In
DA Form 3161 Request for Issue or Turn-In
DA Form 3749 Equipment Receipt
DA Form 4569 USAPC Requisition Code Sheet

11-39
TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References — Continued

Publication Description
Department of Defense (DD) Forms — CONT
DD Form 173/1 Joint Message Form
DD Form 448 Military Interdepartmental Purchase Request
DD Form 1348 DOD Single Line Item Requisition System Document (MANUAL)
DD Form 1348-1 DOD Single Line Item Release/Receipt Document
DD Form 1348-6 DOD Single Line Item Requisition System Document (MANUAL-LINE FORM)
DD Form 1574 Serviceable Tag-Materiel
DD Form 1574-1 Serviceable Label-Materiel
DD Form 1575 Suspended Tag-Materiel
DD Form 1575-1 Suspended Label-Materiel
DD Form 1576 Test/Modification Tag-Materiel
DD Form 1576-1 Test/Modification Label-Materiel
DD Form 1577 Unserviceable (Condemned) Tag-Materiel
DD Form 1577-1 Unserviceable (Condemned) Label-Materiel
DD Form 1577-2 Unserviceable (Repairable) Tag-Materiel
DD Form1577-3 Unserviceable (Repairable) Label-Materiel
Standard Forms (SF)
SF 364 Report of Discrepancy (ROD)
SF 368 Quality Deficiency Report (Category II)

11-40
 TM 1-1500-204-23-1

CHAPTER 12
PYROTECHNICS

12-1. GENERAL. The following paragraphs explain 12-4. EXTERNAL STORES CARTRIDGES. External
pyrotechnics used on Army aircraft. Refer to TM 9-1377- stores cartridges are used to release external stores
200-20&P for descriptive information, care and handling from racks.
of stock class 1377 cartridges.

Electrically activated cartridges shall be protec-

Electrically activated cartridges shall be protec- tively wrapped in aluminum foil or electrically
tively wrapped in aluminum foil or electrically shunted whenever removed from the aircraft in-
shunted whenever removed from the aircraft in- stallation to preclude "STRAY" electrical voltage
stallation to preclude "STRAY" electrical voltage activation and resulting personal injury.
activation and resulting personal injury.

12-2. EJECTION SEATS. Ejection seats use py-

rotechnics for seat ejection, automatic parachute
deployment, and separation of seat from occupant after Do not use damaged cartridges. Damaged car-
ejection. tridges may function erratically and cause dam-
age to equipment.

12-5. CABLE CUTTER CARTRIDGES. The cargo

Electrically activated cartridges shall be protec- hoist cable cutter is a mechanical cable shearing device
tively wrapped in aluminum foil or electrically mounted on the hoist cable guide. It is actuated by an
shunted whenever removed from the aircraft in- electrically fired cartridge. When the pilot throws the
stallation to preclude "STRAY" electrical voltage CABLE SHEAR switch or the aft pilot throws the HOIST
activation and resulting personal injury. CABLE SHEAR switch, electrical power, supplied by
the 28 vdc primary bus through the HOIST CABLE
12-3. FIRE BOTTLE CARTRIDGES. Fire bottles use SHEAR circuit breaker on the overhead circuit breaker
cartridges to discharge extinguishing agents when ac- panel, fires the cartridge, actuating the cable cutter,
tivated by aircraft crewmember or automatic detecting and shearing the cable. After firing, the cable cutter
device. assembly must be replaced.

Change 10 12-1
TM 1-1500-204-23-1

12-6. PYROTECHNIC PISTOLS. The pyrotechnic

pistol fires devices such as flares. The following proce-
dures are for the maintenance of these pistols:
Handle pyrotechnic flares with the same care
a. Clean and oil pistol thoroughly after firing, us- as high explosives. Personnel injury may result
ing lightweight preservative lubricating oil, MIL-L-7870. from improperly handled flares.
Also, perform this maintenance function at regular in-
spection intervals as prescribed in aircraft organizational c. Protect flares and signals from moisture.
maintenance manual.
NOTE
b. Daily maintenance is required under dusty, wet,
or salt. air conditions. Open all containers which show signs of damp-
ness or moisture. Destroy contents when there
is evidence of moisture.
12-7. PYROTECHNICS STORAGE AND HAN-
DLING. Existing safety requirements and precautions
shall be complied with by all personnel handling d. Disassembly of flares is strictly prohibited.
pyrotechnic signal flares. This type pyrotechnic is haz-
ardous due to the nature of its explosive, flammable, or e. Do not use flares when dented or deformed.
toxic filler. The following precautions in handling signals
and flares used in pyrotechnic pistols will be followed in f. Avoid any rough handling, throwing, or dropping
order to prevent personal injuries. of pyrotechnics.

a. Store flares and signals in a dry, well-ventilated g. Remove flares and signals from aircraft that are
place, out of direct rays of sun and protected against parked in maintenance or storage hangars, and from
excessive or variable temperatures. survival kits placed in storage.

b. Post NO SMOKING signs in storage area.

12-2 Change 1
 TM 1-1500-204-23-1

CHAPTER 13
AIRCRAFT CLEANING

13-1. GENERAL. Proper and frequent cleaning is the Some solvents can damage rubber, neoprene, and elec-
most important part of a corrosion control program. Fre- trical insulation. They can also damage paint and should
quency of cleaning and related treatment will depend on be removed as soon as possible.
type of aircraft and local conditions. All aircraft shall be
washed and cleaned every 30 days, unless aircraft are (2) To protect against cleaning solution entrap-
stationed within two miles of salt water. Extended or low ment, inspect all lubrication points that have exposure
level operations over salt water require daily fresh water type lubrication fittings. Lubricate those that have not
rising. External corrosion prone areas will require more been regularly lubricated in accordance with the appli-
frequent cleaning. cable maintenance manual.

(3) Close all doors and emergency openings.

Do not use synthetic wiping cloths with highly (4) Make sure that all drain holes are clear by
flammable solvents having a flash point of inserting a probe such as a pipe cleaner, except where
100°F (37.8°C) or less, such as aliphatic naph- pressurized flapper valves are located.
tha TT-N-95. Static electricity may build up and
cause ignition.

Cleaning Compound, MIL-PRF-85570, Type

II, can irritate eyes, skin, and respiratory tract.
DELETED Wear protective gloves and goggles. Avoid
repeated or prolonged contact. Use in well
NOTE ventilated areas.
Use only authorized cleaning materials and
equipment. b. Cleaning Methods. Various cleaning methods
are explained in the following paragraphs. The method
13-2. CLEANING PRACTICES AND PROCEDURES. used depends upon the availability of tap water.
The following paragraphs explain preparation for clean-
ing, cleaning methods, cleaning of corrosion prone ar- (1) Waterless wipedown. Waterless
eas, and post-cleaning. wipedown procedures will be used when water is not
available for rinsing or when cold weather prevents
a. Preparation for Cleaning. Prepare aircraft for the use of water. The preferred waterless wipedown
cleaning by accomplishing the following procedures: method for removing soils and corrosive salt residues
is accomplished using the following procedures.

Make sure that static vents are not fouled by

tape adhesive transfer. Cover static vents with a Open all circuit breakers associated with battery
properly sized disc of suitable material, then ap- power prior to application of MIL-C-43616 lean-
ply masking tape. Fouled vents will give wrong ing compound. This compound is flammable.
readings.
DELETED
(1) Prior to lubricating any components or parts,
remove all foreign matter from joints, fittings, and bear- (a) Spray the exterior surfaces of the
ing surfaces. Cleaning cloth CCC-C-46 shall be used for aircraft with water emulsion cleaning compound
this purpose. Clean up all spilled or excess oil or grease. MIL-PRF-85570.

Change 5 13-1
TM 1-1500-204-23-1

(b) When the foam begins to break, wipe

cleaner and soil from the surface.

(c) Rinsing with a cloth wet with fresh water Open all circuit breakers associated with battery
following the use of MIL-C-43616 is desirable. power prior to application of MIL-C-43616 lean-
ing compound. This compound is flammable.
(d) Rinse the cleaned surface with fresh wa-
ter when water becomes available. DELETED

(2) Detergent cleaning with limited water. (a) Mix one part of aircraft cleaner MIL-PRF-
When limited water is available, the following no rinse 85570 or MIL-PRF-87937 with nine parts water.
procedures may be used:
(b) Apply the mixture using foaming equip-
ment with aircraft washing kit or fiber brush.

(c) To prevent streaking, start at the lower

Open all circuit breakers associated with battery
surfaces, working upward and out. Scrub the surface
power prior to application of MIL-C-43616 lean-
with the washing kit or fiber brush.
ing compound. This compound is flammable.
DELETED

(a) Mix one part of aircraft cleaning com-

Do not rinse aircraft with a solid stream of wa-
pound MIL-C-43616 or MIL-C-25769 and nine parts of
ter. Use a soft, spray pattern to avoid damaging
water in a bucket.
fragile sections or causing water intrusion.
(b) Apply the cleaner with a scrub brush,
(d) Rinse away the loosened soil and cleaner
sponge, rag, or cleaning and polishing pad. Apply to
with a stream of water. For rinsing, a rubber padded
one small area at a time.
shutoff-spray nozzle is recommended.
(c) Scrub the area and remove the cleaner
(4) Rinsing. Rinse the cleaner and loosened
and loosened soil with a cloth.
soil from aircraft surface with pressure equipment hav-
NOTE ing a fan spray nozzle. Direct water at an angle between
15 and 30 degrees from the surface to rinse it. Continue
For soils that are resistant to the limited water rinsing until all evidence of cleaner and soils have been
procedure, clean again with a mixture of one removed from aircraft.
part cleaner in four parts water.
(5) Deluge rinsing. To prevent buildup of salt
(d) Apply MIL-PRF-81309 Type II and wipe deposits, the deluge rinse facilities shall be used as fre-
with a clean dry cloth. quently as possible.
(3) Water detergent cleaning (preferred NOTE
method). Where water of suitable quality is available
for rinsing purposes, the following procedures shall be Use of deluge rinsing facilities does not replace
used: aircraft washing requirements.

13-2 Change 7
 TM 1-1500-204-23-1

c. Cleaning of Corrosion Prone Areas. Specific (3) Inspect for corrosion and deterioration as
efforts shall be made to clean all corrosion prone ar- part of routine maintenance procedures.
eas as frequently as possible, even if unusual conditions
prevent complete aircraft cleaning. Refer to the applica- (4) Relubricate, preserve, and seal.
ble maintenance manual.
(5) Polish and wax.
d. Post-Cleaning. Corrosion prevention depends
on carrying out the prescribed preservation and lubri- 13-3. CLEANING SAFETY. All cleaning procedures
cation procedures. Strict compliance with the following should be accomplished with the applicable mainte-
procedures is essential. Post-cleaning procedures shall nance manual. Proper precautions must be taken when
be done in the following order: working with cleaning substances.

(1) Remove covers from all static vents, pitot NOTE

tubes, air ducts, heater ducts, etc. Tape shall be re-
moved from all other openings sealed with masking The use of cleaning agents with high alkaline
tape. content should not be used. Failure to comply
with this note will cause components and as-
(2) Clean all drain holes by inserting a probe semblies to corrode at an accelerated rate. At
such as a pipe cleaner except where pressurized flap- no time should cleaners high in alkaline be used
per valves are located. Assure that all areas accumu- in areas that have parts made of magnesium or
lating water have been drained. Whenever this is recur- aluminum or other areas not protected by a cor-
ring problem, procedures shall be developed and imple- rosion protective coating.
mented to remove entrapped water and prevent accu-
mulation.

Change 3 13-3/(13-4 blank)

 TM 1-1500-204-23-1
APPENDIX A
REFERENCES

AFM 64-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aircrew Survival

ANA Bulletin 166 . . . . . . . . . . . . . . . . . . . . . . Army-Navy Aeronatical Bulletin No. 166
AR 25-400-2 . . . . . . . . . . . . . . . . . . . . . . . . . . The Modern Army Record Keeping Systems (Marks)
AR 32-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Classification and Inspection
AR 40-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Medicine
AR 40-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temporary Flying Restrictions Due to Exogenous Factors
AR 40-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Medical Logistics Policies and Procedures
AR 40-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standards of Medical Fitness
AR 40-656 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Veterinary Surveillance Inspection of Subsistence
AR 40-657 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Veterinary Medical Food Inspection and Laboratory Service
AR 40-660 . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOD Hazardous Food and NON Prescription Drug Recall System
AR 95-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Aviation: Flight Regulations
...................................... Deleted
AR 190-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical Security of Arms, Ammunition, and Explosives
AR 310-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Interservicing of Technical Manuals and Related Technology
AR 340-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Records Management Program
AR 528-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personnel Recovery
AR 385-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Army Safety Program
AR 385-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Color Code Markings and Signs
AR 385-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protective Clothing and Equipment
AR 385-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ammunition and Explosives Safety Standards
AR 385-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Aviation Accident Prevention
AR 700-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification, Control, and Utilization of Shelf Life Items
AR 710-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centralized Inventory Management of the Army Supply System
AR 710-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supply Policy Below the Wholesale Level
AR 725-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requisitioning, Receipt, and Issue System
AR 746-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packing of Army Materiel for Shipment and Storage
AR 750-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Material Maintenance Policies
AR 750-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Materiel Maintenance Policies
AR 750-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Operating Time Limits
AR 750-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Airdrop, Parachute Recovery and Aircraft Personnel Escape Systems
AR 755-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reporting, Utilization, and Redistribution of Installation USAMC, and
Overseas Command Excess Property
AR 755-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal of Excess, Surplus, Foreign Excess, Captured and Unwanted
Material
C 1 ARMY . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction to the Federal Supply Catalog and Related Publications
C 6500-AL . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Supply Catalog: Alphabetical Index (Medical Materiel)

Change 9 A-1
TM 1-1500-204-23-1
C 6505-GL . . . . . . . . . . . . . . . . . . . . . . . . . . . . FSC Glossary of Colloquial Names and Therapeutic Index (FSC Class
6505)
C 6545-IL-VOL 2 . . . . . . . . . . . . . . . . . . . . . . Federal Supply, Catalog: Identification List, FSC 6545, Medical Sets,
Kits and Outfits
C 6700/9500-ML . . . . . . . . . . . . . . . . . . . . . . Management Data List: FSC Groups 67 Thru 95 (Items of Medical Ma-
teriel Only)
C 8900-SL . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Supply Catalog: Stock List, FSC Group 89, Subsistence
CTA 8-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Medical Department Expendable/Durable Items
CTA 50-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . Clothing and Individual Equipment
CTA 50-909 . . . . . . . . . . . . . . . . . . . . . . . . . . . Field and Garrison Furnishings and Equipment
CTA 50-970 . . . . . . . . . . . . . . . . . . . . . . . . . . . Expendable/Durable Items (Except: Medical, Class V, Repair Parts and
Heraldic Items)
DA Form 12-R . . . . . . . . . . . . . . . . . . . . . . . . . Request for Establishment of a Publications Account
DA Form 12 Series . . . . . . . . . . . . . . . . . . . . Requirements for DA Publications
DA Form 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . Requisition for Publications and Blank Forms
DA Form 17-1 . . . . . . . . . . . . . . . . . . . . . . . . . Requistion for Publications and Blank Forms (Continuation Sheet)
DA Form 581 . . . . . . . . . . . . . . . . . . . . . . . . . . Request for Issue and Turn-In of Ammunication
DA Form 2028 . . . . . . . . . . . . . . . . . . . . . . . . Recommended Changes to Publications and Blank Forms
DA Form 2062 . . . . . . . . . . . . . . . . . . . . . . . . Hand Receipt/Annex Number
DA Form 2063-R . . . . . . . . . . . . . . . . . . . . . . Prescribed Load List (LRA)
DA Form 2064 . . . . . . . . . . . . . . . . . . . . . . . . Document Register for Supply Actions
DA Form 2402 . . . . . . . . . . . . . . . . . . . . . . . . Exchange Tag
DA Form 2404 . . . . . . . . . . . . . . . . . . . . . . . . Equipment Inspection and Maintenance Worksheet
DA Form 2405 . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Request Register
DA Form 2407 . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Request
DA Form 2407-1 . . . . . . . . . . . . . . . . . . . . . . . Maintenance Request - Continuation Sheet
DA Form 2408 . . . . . . . . . . . . . . . . . . . . . . . . Symbols And Codes To Be Used On Aircraft Operational And Mainte-
nance Forms
DA Form 2408-1-E . . . . . . . . . . . . . . . . . . . . . Equipment Daily Log
DA Form 2408-13-1 . . . . . . . . . . . . . . . . . . . . Aircraft Inspection And Maintenance Record
DA Form 2408-13-1-E . . . . . . . . . . . . . . . . . . Aircraft Inspection And Maintenance Record (Ega)
DA Form 2408-5 . . . . . . . . . . . . . . . . . . . . . . . Equipment Modification Record
DA Form 2408-13 . . . . . . . . . . . . . . . . . . . . . Aircraft Status Information Record
DA Form 2408-16 . . . . . . . . . . . . . . . . . . . . . Aircraft Component Historical Record
DA Form 2408-18 . . . . . . . . . . . . . . . . . . . . . Equipment Inspection List
DA Form 2408-21 . . . . . . . . . . . . . . . . . . . . . Life Raft Inspection Record
DA Form 2408-22 . . . . . . . . . . . . . . . . . . . . . Helmet and Oxygen Mask/Connector Inspection Record
DA Form 2408-23 . . . . . . . . . . . . . . . . . . . . . Survival Radio/Emergency Locator Transmitter (ELT) Inspection Record
DA Form 2408-24 . . . . . . . . . . . . . . . . . . . . . Survival Kit Inspection and Maintenance Record
DA Form 2408-25 . . . . . . . . . . . . . . . . . . . . . Mesh Net Survival Vest Inspection Record
DA Form 2408-26 . . . . . . . . . . . . . . . . . . . . . Life Preserver Inspection Record
DA Form 2408-27 . . . . . . . . . . . . . . . . . . . . . Life Preserver Data

A-2 Change 9
 TM 1-1500-204-23-1
DA Form 2408-28 . . . . . . . . . . . . . . . . . . . . . Oxygen Console Service Record
DA Form 2408-29 . . . . . . . . . . . . . . . . . . . . . Anti-Exposure Coveralls Inspection Record
DA Form 2410 . . . . . . . . . . . . . . . . . . . . . . . . Component Removal And Repair/Overhaul Record
DA Form 2696-R . . . . . . . . . . . . . . . . . . . . . . Operational Hazard Report
DA Form 2765-1 . . . . . . . . . . . . . . . . . . . . . . . Request for Issue or Turn-In
DA Form 3161 . . . . . . . . . . . . . . . . . . . . . . . . Request for Issue or Turn-In
DA Form 3749 . . . . . . . . . . . . . . . . . . . . . . . . Equipment Receipt
DA Form 3912 . . . . . . . . . . . . . . . . . . . . . . . . Army Parachute Log Record
DA Form 4569 . . . . . . . . . . . . . . . . . . . . . . . . USAPC Requisition Code Sheet
DA PAM 310-13 . . . . . . . . . . . . . . . . . . . . . . . Army Parachute Log Record
DA PAM 738-751 . . . . . . . . . . . . . . . . . . . . . . Functional Users Manual For the Army Maintenance Management Sys-
tem Aviation (TAMMS-A)
DD Form 314 . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance Schedule And Record
DD Form 448 . . . . . . . . . . . . . . . . . . . . . . . . . . Military Interdepartmental Purchase Request
DD Form 1348 . . . . . . . . . . . . . . . . . . . . . . . . DOD Single Line Item Requisition System Document (MANUAL)
DD Form 1348-1 . . . . . . . . . . . . . . . . . . . . . . . DOD Single Line Item Release/Receipt Document
DD Form 1348-6 . . . . . . . . . . . . . . . . . . . . . . . DOD Single Line Item Requisition System Document (MANUAL-LINE
FORM)
DD Form 1574 . . . . . . . . . . . . . . . . . . . . . . . . Serviceable Tag-Materiel
DD Form 1574-1 . . . . . . . . . . . . . . . . . . . . . . . Serviceable Label-Materiel
DD Form 1575 . . . . . . . . . . . . . . . . . . . . . . . . Suspended Tag-Materiel
DD Form 1575-1 . . . . . . . . . . . . . . . . . . . . . . . Suspended Label-Materiel
DD Form 1576 . . . . . . . . . . . . . . . . . . . . . . . . Test/Modification Tag-Materiel
DD Form 1576-1 . . . . . . . . . . . . . . . . . . . . . . . Test/Modification Label-Materiel
DD Form 1577 . . . . . . . . . . . . . . . . . . . . . . . . Unserviceable (Condemned) Tag-Materiel
DD Form 1577-1 . . . . . . . . . . . . . . . . . . . . . . . Unserviceable (Condemned) Label-Materiel
DD Form 1577-2 . . . . . . . . . . . . . . . . . . . . . . . Unserviceable (Repairable) Tag-Materiel
DD Form1577-3 . . . . . . . . . . . . . . . . . . . . . . . Unserviceable (Repairable) Label-Materiel
DD Form 1584-1 . . . . . . . . . . . . . . . . . . . . . . . Serviceable Label Materiel
DD Form 173/1 . . . . . . . . . . . . . . . . . . . . . . . . Joint Message Form
DLAM 4155.5 . . . . . . . . . . . . . . . . . . . . . . . . . Quality Control Depot Serviceabilty Standards (Medical Supplies), Ap-
pendix M
DOD Medical Catalog . . . . . . . . . . . . . . . . . . VOL I, VOL II, VOL III MCRL I, II, III
DOD 4160.21-M . . . . . . . . . . . . . . . . . . . . . . . Defense Utilization and Disposal Manual
DOD 5154.4S . . . . . . . . . . . . . . . . . . . . . . . . . DOD Ammunition and Explosives Safety Standards
DOD Directive 4160.21M . . . . . . . . . . . . . . . DOD Directive 4160.21M

Change 9 A-3
TM 1-1500-204-23-1
FED-STD-595 . . . . . . . . . . . . . . . . . . . . . . . . . Federal Standard 595 Paint Spec
FED STD 757 . . . . . . . . . . . . . . . . . . . . . . . . . Stitches, Seams, and Stitching
FM 10-67-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Concepts And Equipment Of Petroleum Operations
FM1-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combat Aviation Operations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleted
FM 1-544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standardized Maintenance Test Flight Procedures
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleted
FM 10-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aircraft Refueling
FM 10-267 . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Repair for Clothing and Textiles
FM 10-1269 . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair of Canvas and Webbing
FM 20-151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aircraft Emergency Procedures Overwater
FM 21-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Care and Use of Individual Clothing and Equipment CTA 50-900 Clothing
and Individual Equipment
FM 21-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Signals
FM 3-05.70 . . . . . . . . . . . . . . . . . . . . . . . . . . . Survival
FM 38-725-23 . . . . . . . . . . . . . . . . . . . . . . . . . Logistic Codes NICP/Depot and DS/GS Installation
Code of Federal Regulations 29 CFR Occupational Safety And Health Standards
1910 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MCRL-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Cross Reference List - 1, Cross Reference from Part Number to
NSN
MCRL-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Cross Reference List - 2, Cross Reference from NSN to Part
Number
Medical Catalog . . . . . . . . . . . . . . . . . . . . . . . Containing VOL I, VOL II, VOL III.
MIL-C-8349 . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Specification" Altimeter, Servo Controlled, Automatic Pres-
sure Standby (12-Mar-2008)
MIL-C-83413 . . . . . . . . . . . . . . . . . . . . . . . . . . Connectors and Assemblies, Electrical, Aircraft Grounding: Decalcoma-
nia for Grounding Receptacle Identification, Decal
MIL-D-8634 . . . . . . . . . . . . . . . . . . . . . . . . . . . Decal, Elastomeric Pigmented Film, For Use On Exterior Surfaces (S/S
By Mil-M-43719)
MIL-D-8635 . . . . . . . . . . . . . . . . . . . . . . . . . . . Decals, for Use on Interior Surfaces (S/S by MIL-M-43719)
MIL-STD-101 . . . . . . . . . . . . . . . . . . . . . . . . . . Color Code for Pipelines and for Compressed Gas Cylinders
MIL-STD-1247 . . . . . . . . . . . . . . . . . . . . . . . . Markings, Functions and Hazards Designations of Hose, Pipe, and Tube
Lines for Aircraft Missile, and Space Systems
MS87033 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tape, Aircraft Tubing Identification Marker
NAVAIR 03-50-1 . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 03-50-1 Maintenance Instructions: Oxygen Equipment
PAM 25-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consolidated Index of Army Publications and Blank Forms
PAM 310-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . The Standard Army Publications System (STARPUBS) User’s Guide
PAM 310-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . Posting and Filing Publications

A-4 Change 9
 TM 1-1500-204-23-1
PAM 700-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Why and How to Use SF 364 to Report Package Discrepancies
PAM 710-2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . Using Unit Supply System Manual Procedures
PAM 738-751 . . . . . . . . . . . . . . . . . . . . . . . . . Functional User’s Guide to the Army Maintenance Management System-
Aviation (TAMMS-A)
SB 3-30-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chemical, Biological Canisters and Filter Elements Serviceability Lists
SB11-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FSC Class 6135; Dry Battery Supply Data
SB11-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FSC Class 6135; Dry Battery Management Data
SB 11-576 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Weather Batteries for Radio Sets AN/PRC-6, 8, 8A, 9A, 10, 10A, 25,
28 and 77 and Cable Assemblies for Cold Weather Operation of Trans-
mitting Set Radio AN/PRT-4 and Receiving Set, Radio AN/PRR-9
SB700-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Adopted/Other Items Selected for Authorization/List of Reportable
Items
SB 708-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Item Directory for Supply Cataloging
SB 708-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Supply Classification; Part 1-Groups and Classes (Cataloging
Handbook H2-1)
SB 708-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Supply Classification; Part 2 Numeric Index of Classes (Cata-
loging Handbook H2-2) (GSA-FSS-H2-2)
SB708-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Department of Defense Ammunition Code (Cataloging Handbook H3)
(GSA-FSS-H-3)
SB708-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Supply Code for Manufacturers; United States and Canada-
Name to Code (Cataloging Handbook H4-1) (GSA-FSS-H4-1/H4-2)
SB 708-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Supply Code for Manufacturers; United States and Canada-
Name to Code (Cataloging Handbook H4-1) (GSA-FSS-H4-1/H4-2)
SB 708-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cataloging Handbook H4/H8 Commercial and Government Entity
(GAGE)
SB 742-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ammunition Surveillance Procedures
SB742-1370-94-721 . . . . . . . . . . . . . . . . . . . Signal, Smoke and Illumination, Marine MK13, MOD O Surveillance
Function Test
SC5180-91-CL-R07 . . . . . . . . . . . . . . . . . . . . Tool Kit, Electronic Equipment, TK-105/G
SC5180-91-CL-R13 . . . . . . . . . . . . . . . . . . . . Tool Kit, Electronic Equipment, TK-101/G
SB8-75-SERIES . . . . . . . . . . . . . . . . . . . . . . . Army Medical Department Supply Information 8-75-1 thru 8-75-35
SF 364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Report of Discrepancy(ROD)
SF 368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quality Deficiency Report (Category II)
TB 9-1300-385 . . . . . . . . . . . . . . . . . . . . . . . . Munitions Suspended or Restricted
TC 3-04.72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aviation Life Support System Management Program
TM 10-227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting of Army Uniforms and Footwear
TB 34-9-127 . . . . . . . . . . . . . . . . . . . . . . . . . . Medical Gas Cylinders
TB 34-9-210 . . . . . . . . . . . . . . . . . . . . . . . . . . NATO Standardization Agreement for Air Pyrotechnics Interchangeability
Chart STANG 3398
TB 34-9-242 . . . . . . . . . . . . . . . . . . . . . . . . . . Aircraft Gaseous Oxygen Replenishment Connections

Change 9 A-5
TM 1-1500-204-23-1
TB 34-9-243 . . . . . . . . . . . . . . . . . . . . . . . . . . Aircraft Compressed Air Replenishment Connections
TB 34-9-245 . . . . . . . . . . . . . . . . . . . . . . . . . . Compressed Breathing Air Characteristics
TB 34-9-330 . . . . . . . . . . . . . . . . . . . . . . . . . . Mask, Protective, Aircraft, ABC-M24 and Hood Aircraft Protective Mask,
ABC-M7
TB 43-180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration and Repair Requirements for the Maintenance of Army Ma-
terial
TB 43-0002-4 . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Expenditure Limits for FSC’s 1610, 1615, 1620
TB 55-1500-328-25 . . . . . . . . . . . . . . . . . . . . Organizational, Direct Support and General Support Maintenance
Manual: Aeronautical Equipment Maintenance Management Policies
and Procedures
TB 55-2925-200-25 . . . . . . . . . . . . . . . . . . . . Aircraft Spark Plugs
TB 740-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quality Control Depot Storage Standards. Appendix M Medical Supplies
TB CML 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adapter, Compressed Air Breathing Apparatus, M4 (End Item Code 201)
and Detector Kit, Carbon Monoxide, Colormeter, M23
TC 3-04.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Aviation Maintenance
TM 1-1500-204-23-2 . . . . . . . . . . . . . . . . . . . Aviation Unit Maintenance (AVUM) and Aviation Intermediate Mainte-
nance (AVIM) Manual for General Aircraft Maintenance (Pneudraulics
Maintenance And Practices) Volume 2
TM 1-1500-204-23-6 . . . . . . . . . . . . . . . . . . . Aeronautical Equipment Maintenance Management Policies and Proce-
dures
TM 1-1500-204-23-10 . . . . . . . . . . . . . . . . . . Technical Manual Aviation Unit Maintenance (Avum) And Aviation Inter-
mediate Maintenance (Avim) Manual For General Aircraft Maintenance
(Sheet Metal Shop Practices) Volume 10
TM 1-1500-328-23 . . . . . . . . . . . . . . . . . . . . . Technical Manual Aeronautical Equipment Maintenance Management
Policies And Procedures
TM 1-1680-377-13&P . . . . . . . . . . . . . . . . . . Interactive Electronic Technical Manual (IETM) For Air Warrior
TM 3-4240-280-10 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual for Mask Chemical-Biological: Aircraft ABC-M24 and
Accessories Mask Chemical-Biological, Tank M24/M24A1 and Acces-
sories
TM 3-4230-216-10 . . . . . . . . . . . . . . . . . . . . . TM 3-4230-216-10 Operator’s Manual for Decontaminating Kit, Skin
M258A1, and Training Aid Skin Decontaminating M581A
TM 3-4240-312-12&P . . . . . . . . . . . . . . . . . . Aviation Unit Maintenance, Chemical-Biological Mask: Aircrew M43
TM 5-803-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . Planning of Army Aviation Facilities
TM 5-4220-201-12 . . . . . . . . . . . . . . . . . . . . . Operator’s and Organizational, Maintenance, Life Preserver, Underarm,
Parachutist (B-7)
TM 9-1290-333-15 . . . . . . . . . . . . . . . . . . . . . Operator‘S, Organizational, Direct Support, General Support and De-
pot Maintenance Manual (Including Repair Parts and Special Tools List):
Compass, Magnetic, Unmounted: M2
TM 9-1300-200 . . . . . . . . . . . . . . . . . . . . . . . . Ammunition, General
TM 9-1300-214 . . . . . . . . . . . . . . . . . . . . . . . . Military Explosive
TM 9-1300-250 . . . . . . . . . . . . . . . . . . . . . . . . Ammunition Maintenance
TM 9-1370-206-10 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual: Pyrotechnic Signals

A-6 Change 9
 TM 1-1500-204-23-1
TM 9-1370-203-20&P . . . . . . . . . . . . . . . . . . Organizational Maintenance Manual for Military Pyrotechnics
TM 9-1377-200-20&P . . . . . . . . . . . . . . . . . . Organizational Maintenance Manual (Including Repair Parts and Spe-
cial Tool List) for Cartridges, Activate Devices and Propellant Activate
Devices
TM 9-4940-461-15P . . . . . . . . . . . . . . . . . . . Operator’s Organizational, DS, GS, and Depot Maintenance Repair
Parts and Special Tools List for Separator Oil and Water, Spray Gun,
Wall MTD
TM 10-1670-1 . . . . . . . . . . . . . . . . . . . . . . . . . Survival and Emergency Use of the Parachutes (AFP 64-15)
TM 10-1670-213-10 . . . . . . . . . . . . . . . . . . . . Operator’s Manual for Parachute Personnel, Types 28 Foot Diameter,
Back; 28 Foot Diameter, Chest; NB-8 Back and Martin Baker Ejection
Seat Harnesses
TM 10-1670-250-20 . . . . . . . . . . . . . . . . . . . . Organizational Maintenance Manual (Including Repair Parts and Special
Tools List): Parachute System Used w/Martin Baker MK-J5D Ejection
Seat
TM 10-1670-251-12 . . . . . . . . . . . . . . . . . . . . Operator’s and Organizational Maintenance Manual (Including, Repair
Parts and Special Tool List): Lowering Device, Cargo and Personnel,
500 LB Capacity
TM 10-1670-262-12 . . . . . . . . . . . . . . . . . . . . Operator’s and Organizational Maintenance Manual (Including, Repair
Parts and Special Tools List): For Personnel Stabo Extractson System
and Cargo and Personnel Lowering Anchor Device
TM 10-3530-202-24 . . . . . . . . . . . . . . . . . . . . Organizational and Field Maintenance Manual: Sewing Machines for the
Repair of Parachutes and Allied Equipment
TM 10-8400-201-23 . . . . . . . . . . . . . . . . . . . . General Repair Procedures for Clothing and Individual Equipment
TM 10-8400-202-13 . . . . . . . . . . . . . . . . . . . . Maintenance Instructions for NOMEX Flight Gear Coveralls Types
CWU-27/P and CWU-28P; Gloves, Type GS-FRP-2; Jacket Flyer’s,
Summer, Type CWU-35/P and Winter, Type CWU-45/P Hood, CWJ-18/P
(TO 14P3-1-112)
TM 10-8415-206-12&P . . . . . . . . . . . . . . . . . SPH-4 Flight Helmet
TM 10-8470-202-13 . . . . . . . . . . . . . . . . . . . . Operation and Service Instructions for Ground and Aircrew Body Armor
TM 10-8475-200-13 . . . . . . . . . . . . . . . . . . . . Use, Inspection, Fitting, and Maintenance Instructions for Anti-Exposure
Assembly. Type CWU-21/P (TO 14P3-5-81)
TM 10-8475-202-13 . . . . . . . . . . . . . . . . . . . . Operation, Service, and Maintenance Instructions for Quick Donning
Anti-Exposure Flying Coverall
TM 11-5820-640-15 . . . . . . . . . . . . . . . . . . . . Operator’s, Organizational, Direct Support, General Support Depot
Maintenance Radio Sets AN/URC-10, AN/URC-10A and ACR RT-10
TM 11-5820-767-12 . . . . . . . . . . . . . . . . . . . . Operator’s and Organizational Maintenance Manual Including Repair
Parts and Special Tools List; AN/URC-68
TM 11-5820-767-34 . . . . . . . . . . . . . . . . . . . . Direct Support and General Support Maintenance Manual Including Re-
pair Parts and Special Tools List (Including Depot Maintenance Repair
Parts and Special Tools) for Radio Set, AN/URC-68
TM 11-5820-800-13&P . . . . . . . . . . . . . . . . . Operator’s Aviation Unit and Intermediate Maintenance Manual Including
Repair Parts and Special Tools List for Radio Set AN/PR C90
TM 11-5965-279-13P . . . . . . . . . . . . . . . . . . Operator’s Organizational and Direct Support Maintenance Repair Parts
and Special Tools List for Headset-Microphone Kit MK-896/AIC for Hel-
met, Flyers Protective SPH-4

Change 9 A-7
TM 1-1500-204-23-1
TM 11-5965-285-23 . . . . . . . . . . . . . . . . . . . . Organizational and DS Maintenance Manual (Including Repair Parts and
Special Tools List) Headset Microphone 19LB-87
TM 11-6625-2631-14 . . . . . . . . . . . . . . . . . . . Operator’s Organizational, Direct Support and General Support
Maintenance Manual for Test Set Battery TS-2530/UR and Test Set
TS-2530A/UR
TM 11-6625-2632-14 . . . . . . . . . . . . . . . . . . . Operator’s Organizational, Direct Support and General Support Mainte-
nance Manual Including Depot Maintenance Repair Parts and Special
Tools List for Radio Test Set AN/PRM-32
TM 11-6625-2632-14-1 . . . . . . . . . . . . . . . . . Operator’s, Organizational, Direct Support and General Support Mainte-
nance Manual Radio Set AN/PRM-32A
TM 11-6625-2632-24P-1 . . . . . . . . . . . . . . . Organizational, Direct Support, and General Support Maintenance Re-
pair Parts and Special Tools List for Radio Test Set AN/PRM-32A
TM 38-230-1 . . . . . . . . . . . . . . . . . . . . . . . . . . Preservation of Materiel, Preservation (Volume I)
TM 38-230-2 . . . . . . . . . . . . . . . . . . . . . . . . . . Preservation of Materiel, Preservation (Volume II)
TM 38-711-2 . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Army Intermediate Level Supply Subsystem (SAILS) Proce-
dures for Customers
TM 43-0105 . . . . . . . . . . . . . . . . . . . . . . . . . . . CORROSION CONTROL FOR ARMY AIRCRAFT (REPRINTED W/BA-
SIC INCL C1-4)
TM 55-1500-322-25 . . . . . . . . . . . . . . . . . . . . Organizational, DS, GS, AND Depot Maintenance Manual: Maintenance
Of AER
TM 55-1500-328-23 . . . . . . . . . . . . . . . . . . . . Aeronautical Equipment Maintenance Management Policies And Proce-
dures
TM 55-1500-328-25 . . . . . . . . . . . . . . . . . . . . Aeronautical Equipment Maintenance Management Policies And Proce-
dures (Reprinted W/Basic Incl C1)
TM 55-1500-335-23 . . . . . . . . . . . . . . . . . . . . Nondestructive Inspection Methods
TM 55-1500-345-23 . . . . . . . . . . . . . . . . . . . . Painting and Marking Army Aircraft
TM 55-1660-245-13 . . . . . . . . . . . . . . . . . . . . Maintenance Instructions: Oxygen Equipment
TM 55-1660-247-12 . . . . . . . . . . . . . . . . . . . . Operation, Fitting, Inspection and Maintenance Instructions for MBU-
12/P Pressure-demand Oxygen Mask.
TM 55-1680-316-10 . . . . . . . . . . . . . . . . . . . . Operator‘S Manual For Rigid Seat Survival Kit
TM 55-1660-248-12 . . . . . . . . . . . . . . . . . . . . Operation and Maintenance Instructions Aircrew Chem-Defense Ensem-
ble
TM 55-1680-317-23&P . . . . . . . . . . . . . . . . . Army Aircraft Survival Kits
TM 55-1680-321-12 . . . . . . . . . . . . . . . . . . . . Inspection, Maintenance and Disposition Instructions, Desalter Kit, Type
MK-2
TM 55-1680-322-12 . . . . . . . . . . . . . . . . . . . . Operation and Service for Distress Marker Light, P/N SDU-5/E
TM 55-1680-348-10 . . . . . . . . . . . . . . . . . . . . Survival Kit, Cold Climate, Individual
TM 55-1680-349-10 . . . . . . . . . . . . . . . . . . . . Operator’s Manual for Survival Kit, Hot Climate
TM 55-1680-350-10 . . . . . . . . . . . . . . . . . . . . Operator’s Manual for Survival Kit Overwater, Individual
TM 55-1680-351-10 . . . . . . . . . . . . . . . . . . . . Operator’s Manual for SRU-21/P Army Vest

A-8 Change 9
 TM 1-1500-204-23-1
TM 55-2620-200-24 . . . . . . . . . . . . . . . . . . . . Inspection Maintenance Instruction, Storage, and Disposition of Aircraft
Tires and Inner Tubes
TM 55-4240-284-12 . . . . . . . . . . . . . . . . . . . . Operating and Maintenance Manual, Rescue Seat, Forest Penetrating
Including Repair Parts and Special Tools List
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleted
TB 55-6650-300-15 . . . . . . . . . . . . . . . . . . . . Spectrometric Oil Analysis
TM 55-6695-217-13 . . . . . . . . . . . . . . . . . . . . Operation and Maintenance Instructions for Tester, Oxygen Mask, Head-
set, Microphone and Flash Goggles Type MQ-1A
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleted
TB 385-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Requirements for Maintenance of Electrical and Electronic Equip-
ment
TM 746-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marking, Packaging, and Shipment of Supplies and Equipment: General
Packaging Instructions for Field Units.
TM 750-244-1-2 . . . . . . . . . . . . . . . . . . . . . . . Procedures for the Destruction of Life Support Equipment to Prevent En-
emy Use
TM 750-244-1-5 . . . . . . . . . . . . . . . . . . . . . . . Procedures for Destruction of Aircraft and Associated Equipment to Pre-
vent Enemy Use
TO: 0-1-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Numerical Index
TO: 0-1-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Numerical Index
TO: 00-5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Order System
TO: 00-5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Order Distribution System
TO: 00-35A-39 . . . . . . . . . . . . . . . . . . . . . . . . Instructions for Procurement, Issue, Use and Maintenance of Medical
Kits
TO: 11A-1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Ammunition Restricted or Suspended
TO: 11A10-24-7 . . . . . . . . . . . . . . . . . . . . . . . Storage and Maintenance Procedures, Pyrotechnics
TO 12R2-2PRC90-2 . . . . . . . . . . . . . . . . . . . PRC-90 Survival Radio
TO 12R2-2PRC90-3 . . . . . . . . . . . . . . . . . . . PRC-90 Survival Radio
TO 12R2-2PRC90-4 . . . . . . . . . . . . . . . . . . . PRC-90 Survival Radio
TO 14P3-1-102 . . . . . . . . . . . . . . . . . . . . . . . . Technical Manual Operation And Service Instructions Ground And Air-
crew Body Armor
TO 14P3-1-112 . . . . . . . . . . . . . . . . . . . . . . . . Operation, Service, and Maintenance Instructions for Quick Donning
Anti-Exposure Flying Coverall
TO 14P3-5-61 . . . . . . . . . . . . . . . . . . . . . . . . . Operation, Service, and Maintenance Instructions for Quick Donning
Anti-Exposure Flying Coverall
TO 14P3-5-81 . . . . . . . . . . . . . . . . . . . . . . . . . Use, Inspection, Fitting, and Maintenance Instructions for Anti-Exposure
Assembly. Type CWU-21/P
TO: 14S1-4-1 . . . . . . . . . . . . . . . . . . . . . . . . . Distillation Kit
TO: 14S1-4-22 . . . . . . . . . . . . . . . . . . . . . . . . Desalting Kit
TO: 14S10-2-2-SDU-5/E . . . . . . . . . . . . . . . Marker Distress Light

Change 9 A-9
TM 1-1500-204-23-1
TO 14S-1-102 . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Instructions with Parts Breakdown USAF Flotation Equip-
ment
TO 15X-1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Instructions: Oxygen Equipment
TO 15X-3-6-1 . . . . . . . . . . . . . . . . . . . . . . . . . Operation, Fitting, Inspection and Maintenance Instructions for MBU-
12/P Pressure-demand Oxygen Mask.
TO 15X1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Instructions For Oxygen Equipment
TO: 15X1-4-2-4 . . . . . . . . . . . . . . . . . . . . . . . . Bail Out Bottles (Parts Manual)
TO: 15X1-4-2-12 . . . . . . . . . . . . . . . . . . . . . . Bail Out Bottles (Maintenance Manual)
TO: 15X3-3-4-3 . . . . . . . . . . . . . . . . . . . . . . . . MB4 Diluter Demand
TO: 15X5-3-6-1 . . . . . . . . . . . . . . . . . . . . . . . . MBU-12/P Pressure-Demand Oxygen Mask Operation, Fitting, Inspec-
tion and Maintenance Instructions with Illustrated Parts Breakdown
TO: 15X5-4-1-101 . . . . . . . . . . . . . . . . . . . . . Oxygen Mask Connector (CRU-60/P)

A-10 Change 9
 TM 1-1500-204-23-1
GLOSSARY
ATOMIZATION The process of changing liquid particles to a fine spray.

BONDING Two or more layers held together by adhesive.

DATUM A reference used as a basis for calculating or measuring.

DESICCANT A drying agent that absorbs moisture.

FOD Foreign Object Damage.

GROUNDING Electrically connecting an object with the earth.

HYPOXIA A deficiency of oxygen reaching the tissues of the body.

OHM A measurement of electrical resistance.

PHENOLIC A cotton fabric filled with a phenolic resin to form a hard material.

SERVING The process of winding wire tightly around cable for protection.

SPECIFIC GRAVITY Ratio of solid or liquid density compared to pure water.

VAPORIZATION The process of converting a liquid into a vapor.

VISCOSITY A fluid’s internal resistance to flow.

Glossary-1/(Glossary-2 blank)
 TM 1-1500-204-23-1
INDEX

Paragraph
Figure, Table
Subject Number

VOLUME 1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4h
Accessory Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5h
Additional Metal Particles Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5g
Adhesive Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2k, 2-3k
Adhesives, Resins, and Solvents for Repair of Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23c
Adjusting Mixture and Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9c
Adjustment of Windshield Wiper System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19b
Administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Administration Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Air Induction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Inspection, Maintenance, Cleaning, and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7a
Turbocharger and Supercharger Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7b
Aircraft and Equipment, Parking of, in Hangars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Aircraft Cleaning, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Aircraft Component, Preservation and Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Aircraft Grounding Receptacle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Aircraft, Liferafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-4
Aircraft Litters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21a
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21b
Aircraft Preparation for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Aircraft Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Fuel Truck Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d
Open-Port Hot Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b
Open-Port Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a
Rapid Hot Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c
Aircraft Removal from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Aircraft Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Metal Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20b
Polyester Fabric Seat Covers (UH-60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20e
Raschel Knit Seat Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20d
Troop Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20a
Upholstered Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20c
Aircraft, Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Aircraft, Static Grounding of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Aircraft Storage and Shipment, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Aircraft Storage and Shipment, Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Airframe Maintenance, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Airplane, First Aid Kit (Older Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-1
Alignment, Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Anti-Icing, Deicing, and Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2d
Application and Installation of Identification Tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Application and Removal of Decals, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Application of Identification Tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3c

Index-1
TM 1-1500-204-23-1
Approach Route, Fuel Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Arctic-Type Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-2
Armor Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Adhesives, Resins, and Solvents for Repair of Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23c
Armor Plating Inspection and Repair Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23a
General Inspection of Armor Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23b
Repair of Armor Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23d
Armor Plating Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-8
Armor Plating Inspection and Repair Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23a
Arctic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Anti-Icing, Deicing, and Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2d
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2a
Preflight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2c
Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2b
Prevention and Removal of Snow, Ice, and Frost Deposits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2e
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2f
Arctic, Desert, and Tropic Maintenance, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Assemblies, Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-9
Assemblies, Elastic Shock Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Assembly, Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-11
Assembly, Turbine, Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-10
Aviation Life Support Maintenance, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Axial Flow Compressor, Rotor and Stator Components of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-7
Axial-Flow Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-2

Backing Approach, Fuel Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5

Balance (of Tires and Tubes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9c
Balancing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2l, 2-3l
Basic Mechanical Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5k
Basis of Issue, First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19a
Bearing Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-8
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4c
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7i
Booster Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-20
Brake Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7b
Brake Assembly Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7g
Brake Assembly Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7c
Brake Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7d
Brake Assembly Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7h
Brake System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7j

Index-2
 TM 1-1500-204-23-1
Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7i
Brake Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7b
Brake Assembly Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7g
Brake Assembly Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7c
Brake Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7d
Brake Assembly Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7h
Brake System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7j
Brake Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7a
Corrosion Treatment of Brake Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7e
Repair and Replacement of Brake Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7f
Brake Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7a
Built-in Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-17

Cable Cutter Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

Cable Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-3
Cable Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-5
Can-Annular Combustion Chamber Components and Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-9
Can-Type Combustion Chamber Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-8
Can-Type Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-9
Carbon Monoxide Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12c
Carburetion and Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Adjusting Idle Mixture and Idles Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9c
Depreservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9b
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9a
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9f
Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9e
Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9d
Cargo Tiedown Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Cartridges, Cable Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Cartridges, External Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Cartridges, Fire Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Categories of Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a
Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2d
Short Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Centrifugal-Flow Compressor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-6
Centrifugal-Flow Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-1

Index-3
TM 1-1500-204-23-1
Chain Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3e
Checking Propeller Shaft Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-21
Cleaning, Flight Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14c
Cleaning, Flotation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16e
Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2b
Cleaning, Nuclear, Biological, and Chemical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20c
Cleaning of Corrosion Prone Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2c
Cleaning, Oxygen Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17c
Cleaning Practices and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2b
Cleaning of Corrosion Prone Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2c
Post-Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2d
Preparation for Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2a
Cleaning, Restraint Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21c
Cleaning Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Cleaning, Signaling Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18c
Cleaning, Survival Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15c
Cleaning, Tires and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9a
Clothing, Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Cockpit Check Sheet, Engine Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-23
Coding, Color (Elastic Shock Cords) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-8
Coil, Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-20
Cold Section Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6g
Color Band, Solid, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-2
Color Coding (Elastic Shock Cords) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-8
Color-Coded Tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-1
Combustion Chamber, Can-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-9
Combustion Chamber, Can-Type, Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-8
Combustion Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5e
Complete Engine Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6a
Component Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7b
Components and Airflow of a Double-Annular Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-10
Components and Arrangement, Can-Annular Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-11
Components, Fabrication (for Cables) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-2
Components, First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-8
Compressed Air and Water Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2f
Compressed Air Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3f
Compressor Blade Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-17
Compressor Blade Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6h
Compressor Blade Repair Limits, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-18
Compressor Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6f

Index-4
 TM 1-1500-204-23-1
Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5c
Compressor, Centrifugal-Flow, Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-6
Conditioning, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6, T7-2
Connecting Rod Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-9
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4d
Consolidated List of ALSE References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23, T11-11
Construction of Hard Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-3
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Consumption, Oil, Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-22
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12e
Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12f
Control Systems, Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Control, Speed-Sensitive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-13
Controlled Substances, First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19e
Controls, Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Corrosion Preventive Mixture, Discharge Nozzle for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-24
Corrosion Treatment of Brake Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7e
Covers, Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Crankcase Opposed-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-4
Crankcase, Radial-Typpe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-5
Crankcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4a
Crankshaft, Opposed-Type (Six-Cylinder) (Six-Throw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-6
Crankshaft, Radial-Type (Single-Throw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-7
Crankshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4b
Criteria, Fitting Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Criteria, Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Cntena, Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-11
Cylinder, Marking of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-12
Cylinders 7-4f

Damage Limits, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-1

Damage, Compressor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-17
Decal Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Metal Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2c
Paper Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2a
Vinyl Film Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2b
Defects of Turbine Engines, Marking of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Definitions, Armor Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-6
Deicing System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14d

Index-5
TM 1-1500-204-23-1
Deicing System Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14a
Deicing System Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14b
Deicing System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14c
Deicing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Deicing System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14d
Deicing System Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14a
Deicing System Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14b
Deicing System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14c
Depreservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9a
Depreservation of Installed Reciprocating Engines, Supplemental Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Depreservation (of Carburetors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9b
Depreservation of Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Depreservation Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13b
Preoiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13a
Depreservation Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13b
Desert Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Deterioration Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3a
Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3c
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3b
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3d
Design and Construction, Turbine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Designation Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2b
Designation Examples (Reciprocating Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2b
Details, Snap Hook Safety Guard Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-9
Details, Snap Hook Safety Pin Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-10
Detection and Extinguishing Systems, Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Deterioration Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3a
Devices, Signaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
Diffuser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5d
Discharge Pressure Pickup Line, Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-21
Disconnect, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-22
Disconnect, Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-23
Disconnect, Power Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-24
Divided Entrance Inlet Duct (Centrifugal-Flow Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-4
Double-Annular Chamber, Components and Airflow of a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-10
Duplex Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-18
Dust and Dirt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2i, 2-3i

Index-6
 TM 1-1500-204-23-1
E

Earth Ground Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4c

Earth Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Ejection Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Elastic Shock Cord Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Fabncation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26d
Fabrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26b
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26c
Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26a
Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26f
Serving Elastic Shock Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26e
Storage of Elastic Shock Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26g
Electrical Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-20
Electncal Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16b
Electncal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a
Electrical Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2g, 2-3g
Emergency Evacuation of Aircraft from Hangar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6i
Emergency Extension Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3b
Engine Components, Major (Reciprocating Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Engine Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6, T7-2
Complete Engine Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6a
Minor Engine Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6b
Engine Conditioning Cockpit Check Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-23
Engine Mounting Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10b
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10a
Turbine Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10c
Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5l
Engine Removal Criteria (Reciprocating Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Additional Metal Particles Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5g
Basic Mechanical Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5k
Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5l
Excessive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5n
Excessive Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5m
Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5o
Excessive Spark Plug Copper or Silver Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5h
Expiration of Operating Time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5a
Identification of Metal Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5e
Low Cylinder Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5i
Metal Particles in Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5d
Parts Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5j
Significance of Metal Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5f

Index-7
TM 1-1500-204-23-1
Sudden Engine Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5b
Sudden Reduction In Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5c
Engine Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7a
Engine Types and Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2, 8-2
Designation Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2b, 8-2b
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2a, 8-2a
Engine, Axial-Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-2
Engine, Centrifugal-Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-1
Engine, Opposed-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-2
Engine, Turbine, Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Engines and Components, Replacement Criteria for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Entries in Aircraft Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Entries, Method of Accomplishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Environmental Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2m
Environmental Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Repair of Flexible Air Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13b
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13a
Equipment, Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
Equipment Maintenance Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4d
Equipment Mounted In Mobile Shelters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3c
Equipment, Nuclear, Biological, and Chemical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
Equipment, Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
Equipment, Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-21
Equipment, Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-1
Equipment, Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Excessive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5n
Excessive Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5m
Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5o
Excessive Spark Plug Copper or Silver Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5h
Exhaust Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5g
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Expiration of Operating Time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5a
External Storage Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

Fabncation Components (for Cables) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-2

Fabrication of Ground Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4d
Fabrication of Static Grounding Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Fabrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26d
Fabrication Requirements (Elastic Shock Cords) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26b

Index-8
 TM 1-1500-204-23-1
Fingertip Clearance, Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Fire Bottle Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Fire Detection and Extinguishing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15a
Fire Extinguishing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15g
Maintenance of Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15c
Maintenance of Fire Extinguishing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15h
Repair or Replacement of Fire Detection Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15e
Testing of Fire Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15f
Troubleshooting of Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15d
Types of Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15b
Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15a
Fire Detection Systems, Troubleshooting of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-5
Fire Extinguisher Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
Fire Extinguishing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15g
FireSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5c
First Aid Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-8
First Aid Kit, Airplane (Older Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-1
First Aid Kit, General Purpose (Newer Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-2
First Aid Kit, References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-9
First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
Basic of lssue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19a
Controlled Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19e
First Aid Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19i
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19c
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19f
Inspection Training Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19j
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19b
Protection of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19d
Replacement of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19h
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19g
Fitting Area Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Flammable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3n
Flat-Head Pin, Lead Seal, and Identification Tag, Properly Attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-5
Flight Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14c
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14a
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14b
Flight Clothing References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-2
Flight Control Operating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12d
Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5C(5)F2-3

Index-9
TM 1-1500-204-23-1
Flightline Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2g
Flightline Operations General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Flightline Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Flightline Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2g
Foreign Object Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Hearing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Parking and Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2e
Preparation of Aircraft for Storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2f
Reflectorizing of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2h
Safety Around Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2d
Safety Around Helicopters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c
Float Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Flotation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3c, 11-16
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16e
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16c
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16a
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16d
Storage in Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16b
Flotation Equipment References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-5
Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a. 7-12e
Flyable Storage for Depreservation of Installed Reciporcating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10a
Flyable Storage for Preservation of Installed Reciporcating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5a
Foreign Object Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Foreign Object Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6e
Form Entries for Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Fuel Line Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-21
Fuel Nozzle, Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-16
Fuel Nozzle, Simplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-15
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6o
Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5k
Fuel Truck Approach Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Fuel Truck Backing Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Flue Truck Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d
Fuel Truck Required Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4

General Position Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3d

General Airframe Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
General Inspection of Armor Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23b

Index-10
 TM 1-1500-204-23-1
General Maintenance of Shock Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5d
General Procedures (Turbine Engine Inspection and Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6a
General Procedures (Ground Handling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a
General Purpose First Aid Kit (Newer Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-2
General Reciprocating Engine Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General Turbine Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
General, Aircraft Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
General, Aircraft Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General, Application and Removal of Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General, Arctic, Desert, and Tropic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
General, Aviation Life Support Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
General, Flightline Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General, Hangar and Shop Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General, Marking of Aeronautical Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General, Pyrotechnics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Governor, Speed-Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-12
Governors and Fuel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Grade 1100 Oil, Percent Dilution Versus Temperature for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-25
Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a
Pushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3c
Standard Visual Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3d
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Ground Receptacle Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3e
Ground Receptacle Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4f
Grounding Receptacle Installation, Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a

Handling, Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hangar and Shop Operations, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hangar and Shop Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a
Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5c
Machine Tool Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b
Hard Stands, Construction of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-3
Harness, Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-18
Health Indication Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6b
Hearing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Hoist Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Electrical Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1b6
Hydraulic Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16a

Index-11
TM 1-1500-204-23-1
Hoisting 2-7b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoisting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hot Section Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6i
Hot Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6c
Hydraulic Fluid Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Hydraulic Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16a

Identification, First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19c

Identification of Elastic Shock Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26c
Identification of Metal Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5e
Identification Tag, Flat-Head Pin, Lead Seal, Properly Attached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-5
Identification Tapes, Application and Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Application of Identification Tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3c
Installation of Identification Tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3d
Printed-Symbolized System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3a
Solid Color Band System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3b
Igniter Plugs, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-14
Ignition Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-18
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4i
Ignition System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6k
Ignition System, Typical, One Side of a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-13
Ignition Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5j
Indicator, Top Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-15
Induction Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-19
Induction Vibrators, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-1
Induction, Air, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Inlet Duct, Divided Entrance (Centrifugal-Flow Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-4
Inlet Duct, Single Entrance (Axial-Flow Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-3
Inlet Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5a
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9b
Inspection (Carburetors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9a
Inspection (First Aid Kits) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19f
Inspection (Flight Clothing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14a
Inspection (Flotation Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16c
Inspection (Nuclear, Biological, and Chemical Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20a
Inspection (Oxygen Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17a
Inspection (Restraint Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21a
Inspection (Signaling Devices) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18a
Inspection (Survival Kits) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15a

Index-12
 TM 1-1500-204-23-1
Inspection (Tires and Tubes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9b
Inspection and Maintenance (Desert) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3c
Inspection and Maintenance, Turbine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Inspection and Preventive Maintenance, (Tropics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4a
Inspection and Testing (Elastic Shock Cords) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-26a
Inspection Criteria, Personnel Parachute and Parachute Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22a
Inspection of Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12b
Inspection of Primer Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-1
Inspection of Stored Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Inspection of Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25c
Inspection Procedures, Personnel Parachute and Parachute Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22b
Inspection Report, Personnel Parachute and Parachute Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22c
Inspection Training Procedures, First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19j
Inspection, Maintenance, Cleaning, and Replacement (Reciprocating Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7a
Installation (Aircraft Litters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21a
Installation (of Carburetors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9f
Installation (of First Aid Kits) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19b
Installation (of Turbine Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11d
Installation (Reciprocating Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10d
Installation (Seat Belt Webbing Retarder Spring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-8
Installation (Shoulder Harness Webbing Retarder Spnng) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-7
Installation (Tires and Tubes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9e
Installation and Removal Procedures (Protective Covers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22a
Installation of Identification Tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3d
Installation of Piston Position Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-16
Installation of Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25b
Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Intermediate Storage for Depreservation of Installed Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10c
Intermediate Storage for Preservation of Installed Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5c
Intermediate Storage of Engines Mounted on Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12d
Isolators, Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

Jacking 2-7a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jacking and Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7b
Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7a

Index-13
TM 1-1500-204-23-1
K

Kit, First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19

Kits, First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15

Landing Gear Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Landing Gear Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Landing Gear Systems, Troubleshooting of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Lead-Acid Batteries (Depreservation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13e
Life Support Equipment Temporary Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Liferafts for Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-4
Lighting 2-3o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2n
Liquid Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-13
Litters, Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Loads, Test (Elastic Shock Cords) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-7
Locating Dimensions, Lockring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-10
Location of Static Ground Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6e
Lock, Liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-13
Lockring Locating Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-10
Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2d
Low Cylinder Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5i

Machine Tool Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9c
Maintenance Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Maintenance of Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15c
Maintenance of Fire Extinguishing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15h
Maintenance of Oxygen Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17b
Maintenance of Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22b
Maintenance of Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Equipment Maintenance Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4d
Major Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Maintenance of Stored Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Maintenance of Windshield Wiper System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19a
Maintenance Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12b
Maintenance Operational Checks, Test Flights and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Maintenance, Arctic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Index-14
 TM 1-1500-204-23-1
Maintenance, Desert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Maintenance, Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Maintenance, Ski . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Maintenance, Tropic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Maintenance, Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Major Engine Components (Reciprocating Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Accessones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4h
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4c
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4d
Crankcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4a
Crankshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4b
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4f
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4i
Pistons, Pins, and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4e
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4g
Major Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
Marking of Aeronautical Items, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Marking of Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-12
Marking of Defects on Turbine Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Marking Requirements (Aeronautical Items) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Marking, Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Materals, Consumable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Materiel Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Measuring Fingertip Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-6
Metal Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2c
Metal Particles in Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5d
Metal Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20b
Method of Accomplishing Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Minimum Serving Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-9
Minor Engine Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6b
Modification, Seat Belt Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-12
Moisture and Fungi, Parts and Fabncs Affected by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4b, T10-1
Moonng, Arctic-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1 0-2
Mounts, Turbine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Nameplates, Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

New Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13f
Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2h, 2-3h
Nosewheel Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3e

Index-15
TM 1-1500-204-23-1
Nuclear, Biological, and Chemical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
Cleaning 11-20c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20a
Repair . 11-20b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nuclear, Biological, and Chemical Equipment References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-10

Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6n

Oil Consumption Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-22
Oil Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
One Side of a Typical Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-15
Open Storage Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3r
Open Storage for Repaired Equipment and Consumable Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2r
Open-Port Hot Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b
Open-Port Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a
Operating Cycle (Four-Stroke) Reciprocating Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-3
Operation, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9d
Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a
Operator Position, Painting of Shop Equipment to Highlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2
Opposed-Type Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-4
Opposed-Type Crankshaft (Six-Cylinder) (Six-Throw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-6
Opposed-Type Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-2
Overhead Chain Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e
Oxygen Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13e, 11-17
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17c
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17a
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17b
Oxygen Equipment References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-6
Oxygen Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7a
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7b
Oxygen System Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17a
Oxygen Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Maintenance of Oxygen Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17b
Oxygen System Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17a
Servicing of Oxygen Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17c

Index-16
 TM 1-1500-204-23-1
P

Packaging Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12b

Painting 2-4c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Painting of Shop Equipment to Highlight Operator Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2
Paper Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2a
Parachute Harness and Personnel Parachute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
Parking and Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2e
Parking of Aircraft and Equipment in Hangars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Emergency Evacuation of Aircraft from Hangar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6i
Location of Static Ground Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6e
Parking of Aircraft in Hangars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b
Parking of Aircraft with Fuel Tanks Less Than Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6c
Safety Lanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Static Grounding of Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6g
Static Grounding of Ground Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6h
Testing of Static Ground Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6f
Usage of Drip Pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6d
Parking of Aircraft in Hangars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b
Parking of Aircraft with Fuel Tanks Less Than Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6c
Particle Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5b, F8-5
Parts and Fabncs Affected by Moisture and Fungi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4b, T10-1
Parts Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5j
Percent Dilution Versus Temperature for Grade 1100 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-25
Permanent Shop Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Adhesive Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2k
Balancing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Compressed Air and Water Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2f
Dust and Dirt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2i
Electrical Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2g
Environmental Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2m
Lighting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2n
Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2h
Open Storage for Repaired Equipment and Consumable Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2r
Overhead Chain Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e
Shop Equipment Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
Shop Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c
Shop Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Spray Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2j
Storage of Compressed Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2p
Storage of High-Value Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2q
Storage of Shop Stocks, Repair Parts, and Consumable Matenals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2o
Typical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a

Index-17
TM 1-1500-204-23-1
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Personnel Parachute and Parachute Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22a
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22b
Inspection Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22c
Pistols, Pyrotechnic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Piston Position Indicators, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-16
Piston, Pin, and Ring Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-10
Pistons, Pins, and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4e
Plating, Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Pneumatic Deicing Systems, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-4
Pneumatic System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Polyester Fabric Seat Covers (UH-60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20e
Post- Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2d
Postflight and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11c
Power Lever Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-22
Practices and Procedures, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Precautions (Arctic Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2a
Precautions (Desert Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3b
Precautions (Flotation Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16a
Precautions, Turbine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Preflight (Arctic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2c
Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2b
Preoillng 7-13a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation for Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2a
Preparation for Installation (Reciprocating Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10c
Preparation for Installation (Turbine Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11c
Preparation for Removal (Reciprocating Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10a
Preparation for Removal (Turbine Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11a
Preparation of Aircraft for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Preparation of Aircraft for Storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2f
Preservation (of Carburetors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9e
Preservation and Depreservation of Turbine Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Preservation and Packaging of Aircraft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Packaging Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10b
Special Reusable Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10a
Preservation of Accident-Involved Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12a
Preservation of Inoperable Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12c
Preservation of Installed Reciprocating Engines, Supplemental Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Preservation of Operable Engines to be Removed for Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12b
Preservation of Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12e

Index-18
 TM 1-1500-204-23-1
Intermediate Storage of Engines Mounted on Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12d
Preservation of Accident-Involved Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12a
Preservation of Inoperable Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12c
Preservation of Operable Engines to be Removed for Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12b
Prevention and Removal of Snow, Ice, and Frost Deposits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2e
Preventive Maintenance (Arctic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2f
Preventive Maintenance (Desert) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3d
Primer Nozzles, Inspection of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-1
Printed-Symbolized System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3a
Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26f
Propeller Shaft Runout, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-21
Properly Attached Flat-Head Pin, Lead Seal, and Identification Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-5
Protected Storage Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3q
Protection of Contents, First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19d
Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Installation and Removal Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22a
Maintenance of Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22b
Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Purpose (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Pushing 3-3c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pyrotechnic Pistols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Pyrotechnics Storage and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
Pyrotechnics, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13d, 12-1
.........................................................................................................

Radial-Type Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-5

Radial-Type Crankshaft (Single-Throw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-7
Rapid Hot Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c
Raschel Knit Seat Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20d
Reciprocating Engine Maintenance Practices, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Reciprocating Engine Operating Cycle (Four-Stroke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-3
Reciprocating Engine Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10b
References, Consolidated List of ALSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23, T11-11
References for First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-9
References for Flight Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-2
References for Flotation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-5
References for Nuclear, Biological, and Chemical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-10
References for Oxygen Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-6

Index-19
TM 1-1500-204-23-1
References for Signaling Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-7
References for Survival Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-3
Reflectorizing of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2h
Refueling, Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Relief Tube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Removal (Aircraft Litters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21b
Removal (of Turbine Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11b
Removal (Reciprocating Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10b
Removal and Installation of Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10d
Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10c
Preparation for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10a
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10b
Removal and Installation of Turbine Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11d
Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11c
Preparation for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11a
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11b
Removal of Aircraft from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Depreservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8a
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8b
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8c
Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8d
Repair (Flight Clothing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14b
Repair (Flotation Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16d
Repair (Nuclear, Biological, and Chemical Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20b
Repair (Oxygen Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17b
Repair (Restraint Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21b
Repair (Signaling Devices) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18b
Repair (Survival Kits) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15b
Repair and Replacement of Brake Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7f
Repair of Armor Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23d
Repair of Flexible Air Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13b
Repair of Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12c
Repair of Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8c
Repair or Replacement (of Carburetors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9d
Repair or Replacement of Fire Detection Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15e
Repair Parts Van . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3p
Reparing Induction-Vibrators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-1
Replacement (Restraint Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21d
Replacement Cntena for Engines and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Component Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7b

Index-20
 TM 1-1500-204-23-1
Engine Replacement Cntena . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7a
Replacement Criteria for Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8d
Replacement of Components (First Aid Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19h
Required Spacing, Fuel Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Requirements, Marking (Aeronautical Items) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Responsibility, Aircraft Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Restraint Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21c
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21a
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21b
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21d
Retractable Landing Gear Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Emergency Extension Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3b
Gear Position Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3dd
Nosewheel Centenng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3e
Retraction Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3f
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3c
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3a
Retraction Test (Retractable Landing Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3f
Rotor and Stator Components of an Axial-Flow Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-7
Runup and Taxiing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Postflight and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11c
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11a
Taxiing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11b

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Safety Around Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2d
Safety Around Helicopters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c
Safety Devices (Retractable Landing Gear Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3c
Safety Lanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Safety Pin Retaining Cord Secured to Snap Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-11
Safety Precautions (Oxygen Servicing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7a
Safety Procedures (Engine Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10a
Safety Procedures (Runup and Taxiing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11a
Safety, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Safety, Flightlene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Scope (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Sealing (First Aid Kits) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19g
Seat Belt Latch Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-12
Seat Belt Webbing Retarder Spnng Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-8
Seats, Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

Index-21
TM 1-1500-204-23-1
Seats, Ejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Separator, Particle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-5
Servicable Tag-Matenel (DD Form 1574) (Yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-3
Servicing (Oxygen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7b
Servicing of Oxygen Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17c
Servicing, Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Servicing, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Servicing, Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Servicing, Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Serving Elastic Shock Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26e
Serving Length, Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-9
Shipment of Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Shock Strut Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5c
Shock Strut Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5a
Shock Strut Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5b
Shock Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
General Maintenance of Shock Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5d
Shock Strut Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5c
Shock Strut Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5a
Shock Strut Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5b
Shop and Hangar Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Shop Equipment Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d, 2-3d
Shop Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c
Shop Equipment, Maintenance of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Shop Installations, Permanent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Shop Installations, Temporary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Shop Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b, 2-3b
Shop, Temporary, Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Short Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Short Term Storage for Depreservation of Installed Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10b
Short Term Storage for Preservation of Installed Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Shoulder Harness Webbing Retarder Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-7
Signaling Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18c
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18a
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18b
Signaling Devices References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-7
Significance of Metal Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5f
Simplex Fuel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-17
Single Entrance Inlet Duct (Axial-Flow Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-3
Ski Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10a
Ski Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Index-22
 TM 1-1500-204-23-1
Ski Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10a
Ski Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10b
Ski Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10b
Snap Hook Safety Guard Drill Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-9
Snap Hook Safety Pin Construction Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-10
Snap Hook Secured to Safety Pin Retaining Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-11
Solid Color Band System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3d, F6-2
Special Repair Equipment and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
Special Reusable Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12a
Speed-Sensitive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-11
Speed-Set Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-12
Spray Nozzles, Types of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-1
Spray Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2j, 2-3j
Standard Visual Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3d
Static Grounding Cable Assembly, Fabncation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Static Grounding of Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6g, 3-4
Earth Ground Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4c
Earth Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Fabrication of Ground Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4d
Ground Receptacle Critena . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4e
Ground Receptacle Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4f
Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
Static Grounding of Ground Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6h
Storage and Handling, Pyrotechnics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
Storage Area Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Storage Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Storage in Aircraft, Flotation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16b
Storage of Compressed Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2p
Storage of Elastic Shock Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26g
Storage of High-Value Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2q
Storage of Shop Stocks, Repair Parts, and Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2o
Stored Aircraft, Inspection of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Stored Aircraft, Maintenance of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Struts, Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Sudden Engine Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5b
Sudden Reduction In Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5c

Index-23
TM 1-1500-204-23-1
Survival Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13a, 11-15
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15c
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15a
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15b
Survival Kit References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-3
Survival Vests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13b
System, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Systems, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Systems, Deicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Systems, Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Systems, Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Systems, Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

Tag-Materiel, Serviceable (DD Form 1574) (Yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-3

Tag-Materiel, Unserviceable (Repairable) (DD Form 1577-2) (Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-4
Tapes, Color-Coded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-1
Taxiing 3-11b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taxiing and Runup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Temperature and Humidity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3m
Temporary Shop Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Adhesive Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3k
Balancing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3l
Chain Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3e
Compressed Air Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3f
Dust and Dirt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3i
Electrical Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3g
Equipment Mounted in Mobile Shelters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3c
Flammable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3n
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3o
Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3h
Open Storage Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3r
Protected Storage Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3q
Repair Parts Van . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3p
Shop Equipment Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3d
Shop Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3b
Spray Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3j
Temperature and Humidity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3m

Index-24
 TM 1-1500-204-23-1
Typical Shop Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3a
Temporary Shop Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Temporary Storage of Life Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Flotation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13c
New Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13f
Oxygen Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13e
Pyrotechnics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13d
Survival Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13a
Survival Vests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13b
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T.11-1
Test Flights and Maintenance Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Carbon Monoxide Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12c
Maintenance Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12b
Test Flight Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12a
Test Flight Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12a
Test Loads (Elastic Shock Cords) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-7
Test, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-3
Testing of Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15f
Testing of Static Ground Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6f
Theory, Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Thermocouple Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6m
Tiedown Equipment, Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Timing Marks, Built-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-17
Tires and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9c
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9a
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9b
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9e
Valve Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9d
Tools and Special Repair Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
Top Center Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-15
Towing 3-3b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Training Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Troop Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20a
Tropic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Inspection and Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4a
Parts and Fabrics Affected by Moisture and Fungi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4b
Troubleshooting of Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15d, T9-5
Troubleshooting of Landing Gear Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Troubleshooting Pneumatic Deicing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-4

Index-25
TM 1-1500-204-23-1
Tube, Relief, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Tubes and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Turbine and Exhaust Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6j
Turbine Assembly Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-10
Turbine Bearing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61
Turbine Discharge Pressure Pickup Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-19
Turbine Engine Analysis Ground Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6d
Turbine Engine Design and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Accessory Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5h
Combustion Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5e
Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5c
Diffuser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5d
Exhaust Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5g
Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5k
Governors and Fuel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Ignition Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5j
Inlet Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5a
Particle Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5b
Turbine Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5f
Turbine Engine Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Cold Section Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6g
Compressor Blade Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6h
Compressor Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6f
Foreign Object Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6e
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6a
Health Indication Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6b
Hot Section Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6i
Hot Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6c
Ignition System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6k
Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6n
Thermocouple Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6m
Turbine and Exhaust Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6J
Turbine Bearing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61
Turbine Engine Analysis Ground Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6d
Turbine Engine Maintenance, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Turbine Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Turbine Engine Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Turbine Engine Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Turbine Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10c
Turbine Engines, Preservation and Depreservation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Turbine Engines, Removal and Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Index-26
 TM 1-1500-204-23-1
Turbine Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5f
Turbocharger and Supercharger Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7b
Types (of Reciprocating Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2a
Types (of Turbine Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2a
Types and Designations, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Types and Designations, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Types of Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-8
Types of Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Types of Environmental Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13a
Types of Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15b
Types of Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12a
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12e
Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12f
Flight Control Operating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12d
Inspection of Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12b
Repair of Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12c
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12a
Types of Retractable Landing Gear Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3a
Types of Spray Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-1
Types of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-14
Types of Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25a
Typical Compressor Blade Repair Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-18
Typical Igniter Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-14
Typical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a, 2-3a

Unserviceable (Repairable) Tag-Materiel (DD Form 1577-2) (Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-4

Upholstered Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20c
Usage of Drip Pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6d

Valve Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9d

Valve Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-14
Valves 7-4g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Inspection of Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25c
Installation of Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25b
Types of Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25a

Index-27
TM 1-1500-204-23-1
Vibrator, Induction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-19
Vinyl Film Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2b

Wheel Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8a

Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8b
Wheel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Repair of Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8c
Replacement Criteria for Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8d
Wheel Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8a
Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8b
Windshield Wiper System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Adjustment of Windshield Wiper Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19b
Maintenance of Windshield Wiper Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19a
Wiper, Windshield, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Work Area Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

Index-28
 TM 1-1500-204-23-1
VOLUME 2

Absorbing Units, Dampening and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Acceptable and Unacceptable Tube Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-5
Accumulator, Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-118
Accumulator, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15b
Accumulator, Spherical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-119
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Accumulator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15b
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15c
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15a
Actuating Cylinder, Double-Action (Extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-134
Actuating Cylinder, Double-Action (Retraction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-135
Actuating Cylinder, Single-Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-133
Actuating Cylinders (Actuators) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16g
Actuators, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-42
Adjuster Valve, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-157
After Swage Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-86
Air Cylinder, Spherical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-95
Air Cylinders, Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 h
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12e
Air Valve Cores, High-Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-174
Aircraft Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Brake Deboosters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18c
Helicopter Rotor Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18d
Maintenance of Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18b
Wheel Brake Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18e
Wheel Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18a
Alignment, Tube and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-14
Alignment, Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-20
Aluminum Protective Dust Plug and Moisture Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-54
AN Flared Fitting Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-9
Application of Mechanical Advantage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-5
Application of Swaged Tubing Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9a
Applications of MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21c, T4-43
Aromatic And Heat-Resistant Hose, MIL-H-6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-35
Aromatic, Flame, and Oil-Resistant Hose, MIL-H-7938 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-36
Aromatic-Resistant Hose, Flame and MIL-H-8794 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-34
Aromatic-Resistant Hose, Nonself-Sealing, MIL-H-5593 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-37
Aromatic-Resistant Hose, Self-Sealing, MIL-H-7061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-38
Assembly Clearance, Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-47
Assembly of High-Pressure Tetrafluoroethylene (Teflon) Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5j
Assembly of Medium-and Low-Pressure Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-43

Index-29
TM 1-1500-204-23-1
Assembly of Medium - Pressure Tetrafluoroethylene (Teflon) Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Assembly Surface, Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-46
Assembly, V-Ring Packings in Various Positions of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-71

Backup Ring Installation, Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-76

Backup Ring Installation, Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-75
Backup Ring, Teflon, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-73
Backup Ring, Teflon, Reversing Spiral of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-74
Backup Ring, Teflon, Stretching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-72
Backup Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8a
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-8b
Backup Rings, Leather, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-77
Baffles and Fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11c
Baffles, Fins, and Finger Strainer, Reservoir with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-91
Ball Size, Inspection, Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-13
Band Identification, Solid Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Band Location, Tube Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-37
Basic Swage Tool Assembly Showing Lower Die Block Assembly and Position of Fitting Locator . . . . . . . . . . F4-84
Bead Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-13
Beaded Tubing Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2h
Beading Large Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-11
Bend Radii for Conduit and Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Bend Radii of Hose for Fuel, Oil, and Coolant Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-32
Bending Machine, Bending Tube with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-4
Bending Tube with Bending Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-4
Bending Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2e
Bends, Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Bent-Axis Constant-Volume Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-101
Bleeding Brake Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-160
Blocked Flowing Hydraulic Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-142
Boss Installation, Torque Valves for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-7
Brake Assembly, Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-151
Brake Assembly, Disc, Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-152
Brake Bleeding, Gravity Method for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-161
Brake Hydraulic System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-160
Brake System, Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-159
Brake Systems, Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Index-30
 TM 1-1500-204-23-1
Bulge, Coupling, Low-and Medium-Pressure Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-44
Bulge, Coupling, MIL-H-7061 Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-30
Bulkhead and Universal Fitting Assembly, Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-27

Chafing, Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6f

Check Valve, Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-128
Check Valve, Simple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-127
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16c
Checking Swaged Joint with D9892 Inspection Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-85
Chipless Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-81
Clamp Sizes, Support (For Use with MIL-H-38360 Hose of Teflon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-29
Cleaning (of 55-Gallon Drums) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Cleaning Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Clogged Filters In Differential Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-100
Clogged Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-98
Closed Center Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17b
Combination Bulkhead and Universal Fitting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-27
Complex Shock Strut (Metering Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-171
Complex Shock Strut (Plunger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-172
Components, MS Fitting and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17
Compound Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-149
Computation of Force, Area, and Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1b
Computation of Volume, Area, and Length of Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1c
Computing Force, Pressure, and Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Computing Volume, Length, and Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2
Conduit and Fluid Lines, Bend Radii for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Connections, Tubing-to-Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-22
Constant-Volume Pump, Bent-Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-101
Constant Volume Pump Foot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-104
Constant Volume Pump (Piston Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-102
Constant Volume Pump (Piston Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-103
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Contamination, Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Contamination Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Control Units, Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Control Valve, Power Brake (Brake Applied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-152
Control Valve, Power Brake (Brake Released) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-153
Control Valve, Solenoid-Actuated (De-energized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-126
Control Valve, Solenoid-Actuated (Energized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-125

Index-31
TM 1-1500-204-23-1
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16b
Conversion of Aircraft to Fire-Resistant Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Applications of MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21c
Conversion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21e
Hydraulic Fluid MIL-H-5606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21a
Hydraulic Fluid MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21b
Non-Applicability of MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21d
Operating Temperature Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21f
Conversion Procedures (MIL-H-5606 to MIL-H-83282) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21e
Coupling Bulge, Low-and Medium-Pressure Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-44
Coupling Bulge, MIL-H-7061 Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-30
Couplings, Quick-Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Cross Section, Piston Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-163
Cross Section, Vane Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-168
Cutoff Factor, MIL-H-8788 or MIL-H-8790 (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-15
Cutoff Factors, MIL-H-38360 Hose (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-27
Cutoff Factors, Teflon Hose (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-22
Cutter, Chipless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-81
Cutting Flexible Hose, Knife for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-39
Cutting, Marking Tube Prior to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-46
Cutting, Tube with Tube Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Cutting Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2d

Damaged Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-29

Dampening and Absorbing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Hydraulic Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19a
Liquid Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19c, F4-174
Shock Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19b
Damper, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-162
Damper, Vane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-166
Data Drawing, Tube Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-6
Detecting Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a
Determining Hose Assembly Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-40
Determining Tube Thickness and Burst Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-11
Devices for Regulating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14a
Pressure Reducing Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14d
Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14c
Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14b

Index-32
 TM 1-1500-204-23-1
Differential Pressure Indicator (Clogged Filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-99
Differential Pressure Indicator (Normal Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-100
Dimensions, After Swage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-86
Dimensions, Beading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-13
Dimensions for Double-Flared Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Dimensions for Single-Flared Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-7
Disc Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-154
F4-155Disc Brake Assembly Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-155
Distance Between Supports for Fluid Tubing, Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-12
Double Backup Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-76
Double Lap Flare, Tubing with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-11
Double-Action Actuating Cylinder (Extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-134
Double-Action Actuating Cylinder (Retraction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-135
Double-Action Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-111
Double-Flared Tubing, Dimensions for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Dual Internal O-Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-64
Dual Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-156
Dual Parking Brake Valve (Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-157
Dual Parking Brake Valve (On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-158
Dust Cap (AN-SAE Function), Plastic Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-56
Dust Cap, Plastic Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-55
Dust Cap, Steel Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-53
Dust Plug and Moisture Seal, Aluminum Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-54
Dust Plug and Moisture Seal (AN-SAE Threaded) Plastic Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-51
Dust Plug and Moisture Seal, Steel Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-52

Ease of Installation (of Hydraulic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c

Ease of Operation (of Hydraulic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Efficiency (of Hydraulic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a
Elliptical Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7b, F4-70
External O-Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-69
External O-Ring Removal (Spoon-Type Tools) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-65
External O-Ring Removal (Wedge-Type Tools) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-66

Failure Modes and Recommended (Permaswage) Repair Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-79

Field Assembly of High Pressure Teflon Hose, MIL-H-38360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-50
Field Disassembly of Teflon Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-45

Index-33
TM 1-1500-204-23-1
Field Fabrication of High-Pressure Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-41
Filter Element Bypass Valve, Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11f
Filter Elements, Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11e
Filter Elements, Hydraulic Systems Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12c
Filter Elements, Reservoir with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-94
Filter, Fluid, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-96
Filters, Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Finger Strainers, Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 d
Fingertight-Plus Turns Methods, Hose Clamp Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-10
Fingertight-Plus Turns Methods, Hose Clamp Tightening, Beaded Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Fitting Dimensions After Swaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-39
Fittings 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flared Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Flareless Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a
Oxygen System Tapered Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b
Rosan Fluid Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3f
Straight Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c
Universal Fittings AN 832, AN 833, and AN 834, High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3e9A
Universal Fittings AN 832, AN 833, and AN 834, Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3d
Fittings, Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-29
Fittings, Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15
Flame and Aromatic Resistant Hose, MIL-H-8794 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-34
Flame, Aromatic, and Oil-Resistant Hose, MIL-H-7938 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-36
Flared Fitting Identification, AN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-9
Flared Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3g
Flareless Fitting Installation, Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-24, T4-4
Flareless Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a
Flareless Fittings, MS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-18
Flaring Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2f
Flexible Hose Assemblies
Assembly of High-Pressure Tetrafluoroethylene (Teflon) Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5j
Assembly of Medium-Pressure Tetrafluoroethylene (Teflon) Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5i
Identification of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5a
Identification Tags for Field Fabricated Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5g, F4-42
Instructions for Assembly of High-Pressure (3000 psi) Hose Assemblies MS28759 and MS28762 . . . . . . . . . 4-5e
Instructions for Assembly of Medium-Pressure, MS28741, and Low-Pressure, AN6270, Hose Assemblies . 4-5h
Instructions for Repair of Flexible Rubber Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5d
Proof Testing of Flexible Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5f

Index-34
 TM 1-1500-204-23-1
Replacement of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5c
Self-Sealing Hose for Aromatic Fuel, MIL-H-7061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5k
Storage of Hose and Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Use of Dust Plugs, Dust Caps, and Moisture Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Flexible Hose, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Floating Piston Shock Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-173
Floating Piston Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-132
Flow Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Actuating Cylinders (Actuators) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16g
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16c
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16b
Hydraulic Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16k
Hydraulic Servos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16i, F4-138
Irreversible Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16j, F4-139
Maintenance of Hydraulic Flow Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-161
Priority Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16e
Rachet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16h
Selector Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16a
Sequence Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16d
Shuttle Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16f
Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Contamination Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Detecting Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a
System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
Fluid Dispenser, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Fluid Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-96
Fluid Filter (Clogged) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-98
Fluid Filter (Normal Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-97
Fluid-Pressurized Reservoir (Pressurized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-93
Fluid-Pressurized Reservoir (Unpressurized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-92
Full Flow in Hydraulic Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-141
Fuse Assembly, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-140

Gasket Installation, MS Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-19

Gauge, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-114
General Hydraulic Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Shop Rules (Hydraulic Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1la
Shop Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1b
Shop Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1id

Index-35
TM 1-1500-204-23-1
Shop Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1c
Gravity Method for Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-161

Hand Pump Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-112

Hand Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13c
Handling of Hydraulic Fluid in 55-Gallon Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a
Transporting Fluid to Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3d
Withdrawing Fluid from Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3c
Helicopter Rotor Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18d
High-Pressure Air Valve Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-174
High-Pressure Hose Assemblies, Field Fabrication of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-41
High-Pressure Teflon Hose, MIL-H-38360, Field Assembly of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-50
High-Pressure Tubing, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-33
Hose Assemblies, Flexible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Hose Assembly Length, Determining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-42
Hose Clamp, In Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Hose Clamp Tightening, Fingertight-Plus Tums Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-10
Hose Clamp Tightening, Fingertight-Plus Tums Method, Beaded Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-3
Hose Clamp, Tightening, With Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-32
Hose Connections to Engines, Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6h
Hose Cutoff Factor, MIL-H-8788 or MIL-H-8790 Hose (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-14
Hose Cutoff Factors, MIL-H-38360 Hose (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-27
Hose End Fitting and Coupling Nut Installation Torque In Inch-Pounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-34
Hose Installation, Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Hose Line Installation Aids for All Types of Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-57
Hose Markings, and Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6j
Hose, MIL-F-27272, Tetrafluoroethylene (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-21
Hose, MIL-H-38360, Tetrafluoroethylene (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-27
Hose Restrictions, Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6d
Hydraulic Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19a
Hydraulic Filler and Bleeder Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Hydraulic Fluid (Fire Resistant), Conversion of Aircraft to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Hydraulic Fluid in Army Aircraft, Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Fluid in 55-Gallon Drums, Handling of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydraulic Fluid MIL-H-5606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21a
Hydraulic Fluid MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21b
Hydraulic Fuse Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-140
Hydraulic Fuse (Blocked Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-142
Hydraulic Fuse (Full Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-141

Index-36
 TM 1-1500-204-23-1
Hydraulic Hose Testing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2d
Hydraulic Hose Testing Unit, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Hydraulic Maintenance Practices, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-113
Hydraulic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13d
Hydraulic Packings and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Elliptical Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7b, F4-70
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7a
V-Ring Packings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7c
Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Air Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11h
Baffles and Fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11c
Filter Element Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11f
Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11e
Finger Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11d
Maintenance of Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111
Standpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11g
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11b
Types of Hydraulic Reservoirs Used in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11a
Hydraulic Servos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-161, F4-138
Hydraulic System Filler and Bleeder, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Hydraulic System Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12e
Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12c
Servicing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12f
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12b
Two-Stage Fluid Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12d
Uses of Filters In Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12a
Hydraulic System, Open-Center (Valve Closed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-143
Hydraulic System, Open-Center (Valve Open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-144
Hydraulic Systems In Army Aircraft, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Test Stand, Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Hydraulic Test Stand, Portable, Gasoline Engine-Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c
Hydraulic Test Stand, Typical Gasoline Engine-Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2

Identification of Backup Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8a

Identification of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5a
Identification of O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-63
Identification Tags for Field Fabricated Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5g, F4-42
Identification Tape, Printed-Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1
In-Line Cam-Operated Selector Valve (Actuator Extending) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-123

Index-37
TM 1-1500-204-23-1
In-Line Cam-Operated Selector Valve (Actuator Retracting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-122
Inspection
of Quick Disconnect Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10b
of Swaged Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9g
Inspection Ball Size Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-13
Inspection Checking (of Swaging), Troubleshooting Guide for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-38
Installation
Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6b
of Backup Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8b
of Beaded Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2j
of Flared Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21i
of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
of Quick-Disconnect Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10a
Installation Aids, Hose Line, for all Types of Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-57
Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6c
Chafing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6f
Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6i
Hose Connections to Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6h
Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6b
Hose Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6j
Hose Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6d
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6a
MS Flared Swivel Connections Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6k
Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6e
Temperature Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6g
Installation of Leather Backup Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-77
Installation of MS33514 Fitting End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-25
Installation Procedures, Teflon Hose, Right and Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-49
Installation Torque Values MS Flared Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-25
Installation Torque Values MS Flared Swivel Nut Fittings (Reference AND100064) . . . . . . . . . . . . . . . . . . . . . . . T4-33
Installed Low-Pressure Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-16
Installing Teflon Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-73
Instructions
for Assembly of High Pressure (3000 psi) Hose Assemblies MS28759 and MS28762 . . . . . . . . . . . . . . . . . . . . 4-5e
for Assembly of Medium-Pressure, MS28741, and Low-Pressure, AN6270, Hose Assemblies . . . . . . . . . . . . 4-5h
for Repair of Flexible Rubber Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5d
Internal O-Ring Installation (Metallic Sleeve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-68
Internal O-Ring Installation (Paper Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-67
Internal O-Ring Removal (Pull-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-61

Index-38
 TM 1-1500-204-23-1
Internal O-Ring Removal (Push-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-63
Internal O-Ring Removal (Wedge-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-62
Introduction
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Irreversible Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16j, F4-139

Jamnut (AN924) Used on Fittings, Torque Values for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-8

Kellogg Stroke Reduction Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-109

Kellogg Stroke Reduction Pump (Reduced Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-110
Knife for Cutting Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-39

Landing Gear System Using Mechanically Actuated Sequence Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-129

Large Tubing, Beading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-12
Liquid Spring, Tailwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-176
Liquid Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19c, F4-175
Low-Pressure Hose, Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-16
Low-Pressure Tubing, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-30
Low-Pressure Tubing Repair, Tubing End Clearance for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-31
Lubricant Selection, Packing and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-6
Lubrication (during Installation of Flexible Hose) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6a
Lubrication (of Hydraulic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e

Main Rotor Assembly with Piston Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-168

Maintenance of Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15c
Maintenance of Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18e
Maintenance of Power Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13b
Maintenance of Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111
Maintenance of Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic Filler and Bleeder Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Hydraulic Hose Testing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2d

Index-39
TM 1-1500-204-23-1
Hydraulic Test Stand, Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Hydraulic Test Stand, Portable, Gasoline Engine-Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c
Master Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2f
Tube Bending Machine, Hand-Operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2e
Marking MS Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-23
Marking, Tube End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-83
Marking with Permaswage Marking Tool, D9862-S, M, and L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-82
Master Cylinder, Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-149
Master Cylinder, Power-Boost (Brake Applied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-150
Master Cylinder, Power-Boost (Brake Released) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-151
Master Cylinder, Simple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-148
Master Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2f
Master Gauge Unit, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Maximum Distance Between Supports for Fluid Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-12
Mechanical Advantage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1e, F2-4
Mechanical Advantage, Application of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-5
Medium-and Low-Pressure Hose Assemblies, Assembly of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-45
Medium-Pressure Teflon Hose Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-48
MIL-H-83282, Applications of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-43
MIL-H-83282, Non-Applicability of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21d, T4-44
MIL-H-83282, Operating Temperature Limitations of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-45
Minimum Bend Radii of Hose for Fuel Oil, and Coolant Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-32
Motor, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-113
Motors, Pumps and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
MS Fitting and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17
MS Fitting Gasket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-19
MS Fittings, Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-23
MS Flared Swivel Connectors Torquing, and Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6k
MS Flareless Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-18
MS Turns and Torque Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-21
MS21921 Coupling Nut, Torque Values for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-5
MS33514 Fitting End, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-25

Nipple Assembly Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-47

Nipple Assembly Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-46
Non-Applicability of MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 d, T4-44
Nonself-Sealing, Aromatic and Heat-Resistant Hose, MIL-H-6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-35
Nonself-Sealing, Aromatic-Resistant Hose, MIL-H-5593 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-37
Normal Flow in Differential Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-99
Normal Flow in Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-97

Index-40
 TM 1-1500-204-23-1
Nose Landing Gear with Piston Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-164
Nose Landing Gear with Vane Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-168
Nut Installation Torque in Inch-Pounds, Hose End Fitting and Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-34

O-Ring Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-59

O-Ring Installation, External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-69
O-Ring Installation, Internal (Metallic Sleeve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-68
O-Ring Installation, Internal (Paper Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-69
O-Ring, Removal of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-60
O-Ring Removal, Dual Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-64
O-Ring Removal, External (Spoon-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-65
O-Ring Removal, External (Wedge-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-66
O-Ring Removal, Internal (Pull-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-61
O-Ring Removal, Internal (Push-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-63
O-Ring Removal, Internal (Wedge-Type Extractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-62
O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7a
Open-Center Hydraulic System (Value Closed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-143
Open-Center Hydraulic System (Value Open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-144
Operating Pressure (psi) for MIL-H-7061, Proof Test and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-31
Operating, Proof, and Burst Test Pressures for AN6270 Hose Assembly using MIL-H-5593 Low Pressure
Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-19
Operating, Proof, and Burst Test Pressures for MIL-H-83796 Medium Pressure Hose Assembly, Lightweight T4-17
Operating, Proof, and Burst Test Pressures for MIL-H-83797 Medium Pressure Hose . . . . . . . . . . . . . . . . . . . . T4-18
Operating, Proof, and Burst Test Pressures for MS28741 Medium Pressure Hose Assemblies, using Single Wire
Braid Hose, Military Specification MIL-H-8794 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-16
Operating, Proof, and Burst Test Pressures for MS28759 and MS28762 Hose Assemblies using MIL-H-8788 High
Pressure Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-15
Operating Temperature Limitations (of Hydraulic Fluid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21f
Operating Temperature Limitations of MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-45
Orifice Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-128
Oxygen System Tapered Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b

Packing and Lubricant Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-6

Packings and O-Rings, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Index-41
TM 1-1500-204-23-1
Parking Brake Valve, Dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-156
Parking Brake Valve, Dual (Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-157
Parking Brake Valve, Dual (On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-158
Pascal’s Law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1d, F2-3
Permaswage Fittings, Typical Styles of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-78
Permaswage Marking Tool, D9862-S, M, and L, Marking with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-82
Permaswage Repair with D10000 Series Tooling-Tube Material and Maximum Operating Pressure Limitations
(psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-35
Petroleum-Base Fluid (Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3b
Pipe Thread, Straight Thread and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-26
Piston Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-162
Piston Damper Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-163
Piston Damper, Nose Landing Gear with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-164
Piston Dampers, Main Rotor Assembly with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-165
Piston-Type Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-115
Plastic Protective Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-55
Plastic Protective Dust Cap (AN-SAE Friction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-56
Plastic Protective Dust Plug and Moisture Seal (AN-SAE Threaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-51
Pneudraulic Systems, Types of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Closed-Center Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17b
Open-Center Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17a
Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17c
Pneudraulics Theory and Basic Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Computation of Force, Area, and Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1b
Computation of Volume, Area, and Length of Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1c
Mechanical Advantage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1e, F2-4
Pascal’s Law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1d, F2-3
Qualities of Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1a
Use of Air in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1f
Pnuematic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17c
Power Brake Control Valve (Brake Applied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-152
Power Brake Control Valve (Brake Released) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-153
Power Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13a
Power-Boost Master Cylinder (Brake Applied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-150
Power-Boost Master Cylinder (Brake Released) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-151
Precautions
for Hydraulic Fluid Selection and Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3d
for Repair of Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4a
Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-114
Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14a
Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14d
Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14c
Pressure Switch, Piston-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-115

Index-42
 TM 1-1500-204-23-1
Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14b
Pressure-Actuated Sequence Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-130
Pressure-Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-117
Pressures, Proof Test, High-Pressure Teflon Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-30
Pressures, Proof Test, Medium-Pressure Teflon Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-23
Printed-Symbol Identification Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1
Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-131
Procedures, for Use of Test Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20b
Proof Test and Operating Pressure (psi) for MIL-H-7061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-31
Proof Test Pressures, High-Pressure Teflon Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-28
Proof Test Pressures, Medium-Pressure Teflon Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-23
Proof Test Torque Values MS Flared Swivel Nut Fittings (Reference AND10064) . . . . . . . . . . . . . . . . . . . . . . . . T4-20
Proof Testing of Flexible Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5f
Properly Burred Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-9
Pump Assembly, Kellogg Stroke Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-109
Pump, Constant Volume, Bent-Axi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-101
Pump, Constant Volume, Foot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-104
Pump, Constant Volume, (Piston Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-102
Pump, Constant Volume, (Piston Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-103
Pump, Hand, Double-Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-111
Pump, Hand, Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-112
Pump, Kellogg Stroke Reduction (Reduction Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-110
Pump, Stratopower Effective Stroke (Full Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-105
Pump, Stratopower Effective Stroke (Zero Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-106
Pump, Vickers Stroke Reduction (Full Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-108
Pump, Vlckers Stroke Reduction (Zero Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-107
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13c
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13d
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13b
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13a
Purpose (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Qualities of Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1a

Quick-Disconnect Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10b
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10a

Index-43
TM 1-1500-204-23-1
R

Rachet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16h

Rachet Valve (Moving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-137
Rachet Valve (Static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-136
Radial Cam-Operated Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-124
Recommended (Permaswage) Repair Methods, Failure Modes and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-79
Regulating Pressure, Devices for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Relief Valve, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-116
Repair
of High-Pressure Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4c
of Low-Pressure Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4b
of Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Repair of Low-Pressure Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-30
Repair of Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4a
Repair of High-Pressure Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4c
Repair of Low-Pressure Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4b
Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4d
Repairing High-Pressure Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-33
Replacement of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5c
Reservoir, Fluid-Pressurized (Pressurized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-93
Reservoir, Fluid-Pressunzed (Unpressurized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-92
Reservoir with Baffles, Fins and Finger Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-91
Reservoir with Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-94
Reservoirs, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Responsibility (for Hydraulic Shop Rules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1a
Reversing Spiral of Teflon Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-74
Rings, Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Rotary-Type, Closed-Center Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-120
Rotor Blade Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-159

Safety (in Use of Test Stands) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20a

Scope (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Selector Valve A Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-145
Selector Valve B Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-146
Selector Valve C Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-147
Selector Valve, In-Line Cam-Operated (Actuator Extending) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-123
Selector Valve, In-Line Cam-Operated (Actuator Retracting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-122
Selector Valve, Radial Cam-Operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-124
Selector Valve, Rotary-Type, Closed-Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-120
Selector Valve, Spool-Type, Open-Center (Closed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-121

Index-44
 TM 1-1500-204-23-1
Selector Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16a
Self-Sealing, Aromatic-Resisting, Hose MIL-H-7061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-38
Self-Sealing, Hose for Aromatic Fuel, MIL-H-7061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5k
Separable Fittings, Utilizing 0.150 Tube End Gap Tolerance on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-89
Sequence Valve, Landing Gear System Using Mechanically Actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-129
Sequence Valve, Pressure-Actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-130
Sequence Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16d
Servicing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12f
Shaped Fittings, Utilizing 0.300 Inch Tube End Gap Tolerance on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-92
Shock Strut, Complex (Metering Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-171
Shock Strut, Complex (Plunger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-172
Shock Strut, Floating Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-173
Shock Strut, Simple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-170
Shock Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19b
Shop Equipment, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Shop Housekeeping (Hydraulic Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1b
Shop Rules, General (Hydraulic Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Shop Safety (Hydraulic Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1c
Shop Tools and Materials (Hydraulic Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1d
Shuttle Valve, Floating-Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-132
Shuttle Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16f
Simple Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-127
Simple Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-148
Simple Shock Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-170
Single Backup Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-75
Single Flared Tubing, Dimensions for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-7
Single-Action Actuating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-133
Size (of Hydraulic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
Solenoid-Actuated Control Valve (De-energized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-126
Solenoid-Actuated Control Valve (Energized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-125
Solid Color Band Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Spherical Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-119
Spherical Air Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-95
Spool-Type, Open-Center, Selector Valve (Closed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-121
Stabilizer Bar with Vane Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-169
Standard Union Fittings, Tube Insertion Limits when Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-90
Standard Union Fittings, Utilizing 0.300 Inch Tube End Gap Tolerance with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-87
Standpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11g
Steel Protective Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-53
Steel Protective Dust Plug and Moisture Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-52
Storage of Hose and Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Storage (55-Gallon Drums) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a

Index-45
TM 1-1500-204-23-1
Straight Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c
Straight Thread and Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-26
Stratopower Effective Stroke Pump (Full Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-105
Stratopower Effective Stroke Pump (Zero Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-106
Stretching Teflon Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-72
Support Clamp Sizes (for Use with MIL-H-27267 Hose of Teflon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-24
Support Clamp Sizes (for Use with MIL-H-38360 Hose of Teflon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-29
Support, of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6e
Swage Tool Assembly Showing Lower Die Block Assembly and Position of Fitting Locator, Basic . . . . . . . . . F4-84
Swaged Joint, Checking, with D9892 Inspection Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-85
Swaged Tubing Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9a
Inspection of Swaged Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9g
Swaging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9f
Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9b
Tube Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9c
Tube Debumng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9d
Tube End Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9e
Swaging, Fitting Dimensions After . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-39
Swaging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9f
Synthetic-Base Fluid MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3c
System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-116
Systems and Repairs, Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Tallwheel Liquid Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-176

Technique, Swaged Tubing Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9b
Teflon Hose Assembly Procedure, Medium-Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-48
Teflon Hose Cutoff Factures (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-23
Teflon Hose, Field Disassembly of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-47
Teflon Hose Installation Procedures, Right and Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-49
Temperature Protection and Installation of Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6g
Template for Repair of Tubing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4d
Test Pressures, Operating, Proof, and Burst, for AN6270 Hose Assembly using MIL-H-5593 Low Pressure
Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-19
Test Pressures, Operating, Proof, and Burst, for MIL-H-83796 Medium Pressure Hose Assembly . . . . . . . . . T4-17
Test Pressures, Operating, Proof, and Burst, for MIL-H-83797 Medium Pressure Hose . . . . . . . . . . . . . . . . . . . T4-18
Test Pressures, Operating, Proof, and Burst, for MS28741 Medium

Index-46
 TM 1-1500-204-23-1
Pressure Hose Assemblies, Using Single Wire Braid Hose, Military Specification MIL-H-8794 . . . . . . . . . . . . T4-16
Test Pressures, Operating, Proof, and Burst, for MS28759 and MS28762 Hose Assemblies . . . . . . . . . . . . . . T4-15
Test Stands, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Tetrafluoroethylene Hose MIL-F-27272 (In Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-21
Tetrafluoroethylene Hose MIL-H-38360 (in Inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-26
Theory and Basic Principles of Pneudraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Theory of Operation, Hydraulic Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 b
Theory of Operation, Hydraulics System Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12b
Tightening Hose Clamp with Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-32
Tool, Flaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-10
Torque Values for AN924 Jamnut Used On Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-8
Torque Values for Boss Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-7
Torque Values for MS21921 Coupling Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-5
Torque Values, Hydraulic Tubing B-Nut (AN818) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-2
Torque Values, Installation, MS Flared Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-25
Torque Values, MS Flared Swivel Nut Fittings (Reference AND10064), Installation . . . . . . . . . . . . . . . . . . . . . . . T4-33
Torque Values, MS Flared Swivel Nut Fittings (Reference AND10064), Proof Test . . . . . . . . . . . . . . . . . . . . . . . T4-20
Torque Values, MS Turns and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-21
Transporting Fluid to Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3d
Troubleshooting Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-40
Troubleshooting Guide for Inspection Checking (of Swaging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-38
Troubleshooting Wheel Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-41
Tube and Fitting Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-13
Tube Bend Data Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-6
Tube Bending Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Tube Bending Machine, Hand-Operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2e
Tube Bends, Acceptable and Unacceptable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-5
Tube Cutter, Cutting Tube with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Tube Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9c
Tube Deburnng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9d
Tube End Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-83
Tube Insertion Band Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-37
Tube Insertion Limits when Using Standard Union Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-90
Tube Material and Maximum Operating Pressure Limitations (psi) for Permaswage Repair with D10000 Senes Tool-
ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-35
Tube, Properly Burred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-9
Tube Thickness and Burst Pressure, Determining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-11
Tubing Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-20

Index-47
TM 1-1500-204-23-1
Tubing Assemblies, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Tubing Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Tubing End Clearance for Low-Pressure Tubing-Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-31
Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15
Tubing Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Tubing Repairs, Swaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Tubing Systems and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Beaded Tubing Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2h
Bending Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2e
Cleaning Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2g
Cutting Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2d
Flaring Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2f
Installation of Beaded Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2j
Installation of Flared Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2i
Tubing Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Tubing Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a
Tubing with Double Lap Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-11
Tubing-to-Tubing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-22
Two-Stage Fluid Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12d
Types of Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15a
Types of Hydraulic Fluid Used in Army Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Petroleum-Base Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3b
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3d
Synthetic-Base Fluid MIL-H-83282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3c
Vegetable-Base Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3a
Types of Hydraulic Reservoirs Used in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11a
Types of Pneudraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Types of Tubing Systems and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a
Typical Gasoline Engine-Driven Hydraulic Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Typical Hydraulic Hose Testing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Typical Hydraulic System Filler and Bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Typical Master Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Typical Styles of Permaswage Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-78

Universal Fittings AN832, AN833, AN834 High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3e

Universal Fittings AN832, AN833, AN834 Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3d
Use of Air in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1f
Use of Dust Plugs, Dust Caps, and Moisture Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5l
Use of Test Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Index-48
 TM 1-1500-204-23-1
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20b
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20a
Uses of Filter in Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12a
Uses of Hydraulic Systems in Army Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Ease of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c
Ease of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
Utilizing 0.150 Inch Tube End Gap Tolerance on Separable Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-89
Utilizing 0.300 Inch Tube End Gap Tolerance on Shaped Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-88
Utilizing 0.300 Inch Tube End Gap Tolerance with Standard Union Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-87
V-Ring Packings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7c
V-Ring Packings in Vanous Positions of Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-71
Valve A, Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-145
Valve B, Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-146
Valve C, Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-147
Valve, Pressure-Reducing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-117
Valve, Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-131
Valve, Ratchet (Moving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-137
Valve, Ratchet (Static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-136
Valve, Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-131
Vane Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-166
Vane Damper Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-167
Vane, Dampers, Nose Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-168
Vane, Dampers, Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-169
Vegetable-Base Fluid (Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3a
Vickers Stroke Reduction Pump (Full Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-108
Vickers Stroke Reduction Pump (Zero Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-107
Volume, Length, and Area, Computing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2

Wheel Brake Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18b

Wheel Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18a
Wheel Brake Systems, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-41
Withdrawing Fluid from Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-3c

Index-49
TM 1-1500-204-23-1
VOLUME 3

Aeroquip Corporation Series 3700 and 3750 Quick Thread Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5h
Auxiliary (Booster) Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
AVGAS Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-2

Ball Lock-Type Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-19

Bladder-Type Fuel Cells, Serviceable Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-6
Bridging, Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-12

Can and Drum Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-23

Characteristics of Vaporization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Clamp Location for Tube Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
Closed-Circuit Fuel Receiver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-20
Closed-Circuit Refueling Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Cold Weather Maintenance, Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Contaminant Characteristics (of Fuel), Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-3
Contamination of Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Contamination Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4e
Microbiological Growths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
Uses of Additives to Prevent Microbiological Growths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4d
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24a
Contamination Prevention (for Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4e
Coupling
Ball Lock -Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-19
Full Gnp PustuPull-TypeF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
lnst-O-Matic Push/Pull Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-16
Quick-Threading/lndicating Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-15
Screw-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-14
Straight Flow Balin Valve-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-18
Covered Storage of Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7a

DA Form 1804 (Petroleum Sample) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-22

Drain Containers (Fuel Systems), Safety Precautions and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e
Dry-Sump Lubrication System for Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Dry-Sump Lubrication System for Turbine Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5

Index-50
 TM 1-1500-204-23-1
E

Engine Oils
Reciprocating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1
Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Engine-Driven Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-5

Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-9
Fillet Seal Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-13
Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Float Switch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-7
Float Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5e
Flushing Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6j
Fuel Cells and Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5f
Fuel Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Aviation Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3b
Turbine Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3a
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a
Fuel Lines and Drains, Safety Precautions and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a
Fuel Pump
Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F24
Engine-Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-5
Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b
Fuel Receiver Installation (Closed-Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-20
Fuel Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5d, F2-6
Fuel Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5c
Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Aeroquip Corporation Series 3700 and 3750 Quick Thread Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5h
Closed-Circuit Refueling Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5i
Float Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5e
Fuel Cells and Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5f
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a
Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b
Fuel Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5d
Fuel Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5c
Fuel System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5j
Testing Fuel Systems and Tanks/Cells for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59g
Fuel System Schematic, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-21
Fuel System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5j
Fuel System Troubleshooting, Typical, Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-9
Fuel Systems
Contamination of Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Fuel Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Index-51
TM 1-1500-204-23-1
Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Handling and Storage of Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Safety Precautions and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Fuel Tanks, Integral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-8
Full Gnp Push/Pull-Type Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-17

Gear-Type Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-13

General
Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Handling and Storage of Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6c
Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Storage Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b
Handling and Storage of Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Covered Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7a
Outside Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7b
Heat Exchanger Cooler, Turbine Engine Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1

Identification of AVGAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-2

Identification of Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
Turbine Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Inspection Valves, Quick-Disconnect Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-8
Inst-O-matic Push/Pull-Type Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-16
Integral Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-8

Jet Fuel Used in Army Aircraft (MIL-T-5624), Critical Characteristics and Specification Requirements for . . . . T2-1

Index-52
 TM 1-1500-204-23-1
L

Leak Path Examples, Long Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-10

Leaks, Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-9
Long Leak Path Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-10
Lubrication System for Reciprocating Engines
Dry-Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Wet-Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Lubrication System for Turbine Engines
Dry-Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Wet-Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F34

Magnetic Plugs and Chip Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6f

Main Oil Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-8
Marking, Can and Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-23
Marking (Fuel Containers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6c
Microblological Growths (Contaminating Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Micron Particle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2
Mixing Ratios (for Dyes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-7
Multiple Leak Paths (Single Leak Source) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-11

Oil Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c
Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b
Use of Brayco 599 3-5d
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a
Oil Cooler, Reciprocating Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-10
Oil Coolers, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6g
Oil Fitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Oil Filter, Spacers and Screens Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7
Oil Filters, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c
Oil Jets, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Oil Lines, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6b
Oil Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-12
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-13
Oil Screen Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-9
Oil Screens, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6d
Oil Systems
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Handling and Storage of Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Identification of Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Index-53
TM 1-1500-204-23-1
Oil Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Oil Systems Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Safety Precautions and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Types of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Oil Systems Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Cold Weather Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Flushing Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Magnetic Plugs and Chip Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6f
Oil Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6g
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c
Oil Jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6i
Oil Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6b
Oil Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6d
Oil Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6e
Pressure Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6h
Prevention of Sludge Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6k
Types of Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6a

Particle Size, Micron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2

Personal Precautions and Procedures, Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2f
Petroleum Sample Form DA 1804 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-22
Preservation of Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Pressure Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6h
Prevention (of Oil Contamination) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c
Prevention of Sludge Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6k
Purpose of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Quick-Disconnect Coupling Inspection Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-8

Quick Threading/lndicating Type Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-15

Ratios (for Dye Mixing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-7

Receipt (of Fuel Containers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Reciprocating Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-10
Reciprocating Engines, Identification of Oils for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
Relief Valves, Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-12

Index-54
 TM 1-1500-204-23-1
S

Safety Precautions and Procedures, Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Drain Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e
Fuel tines and Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a
Personal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2f
Tool Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Work Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
Safety Precautions and Procedures, Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Safety Precautions, Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-10
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Screen, Oil, Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-9
Screw-Type Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-14
Seal Deflection, Fillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-13
Sealant Bridging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-12
Self Sealing Fuel Cells, Serviceable Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-5
Serviceable Limits (Bladder-Type Fuel Cells) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-6
Serviceable Limits (Self-Sealing Fuel Cells) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-5
Single Leak Source, Multiple Leak Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-11
Solids (Contaminating Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
Solids (Contaminating Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b
Spacers and Screens Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7
Spacing, Support Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-4
Storage Practices, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b
Straight Flow Ball Valve Type Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-18
Support Clamp Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-4
Surge Valve Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-14

Testing Fuel Systems and Tanks/Cells for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5g

Tool Box (Fuel Systems), Safety Precautions and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c
Tools (Fuel Systems), Safety Precautions and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Tube Bends, Clamp Location for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
Turbine Engine Fuel Oil Heat Exchanger Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-11
Turbine Engine, Identification of Oils for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Turbine Engine Oil Use Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Turbine Engine Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Types of Oil Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6a
Types of Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Typical Fuel System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-21
Typical Fuel System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-9

Index-55
TM 1-1500-204-23-1
U

Use of Brayco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d

Use Temperature Chart, Turbine Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Uses of Additives to Prevent Microbiological Growth (in Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4d

Valve, Surge, Example of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-14

Vaporization Characteristics, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Visual Contaminant Characteristics, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-3

Water (Contamination of Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a

Water (Contamination of Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a
Wet-Sump Lubrication System for Reciprocating Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Wet-Sump Lubrication System for Turbine Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Work Stands (Fuel Systems), Safety Precautions and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d

Index-56
 TM 1-1500-204-23-1
VOLUME 4

AC Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6h
Airspeed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-11
Test Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Alternating Current, Basic Principles and Theory for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Alternating Current, Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2
Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3g, F4-13
Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6d
Automatic Wire Marking Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2

B-16 Master Sighting Compass Alignment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-23

Basic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5c, F2-7
Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b, F26
Senes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a, F2-5
Basic Principles and Theory for Alternating Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Basic Principles and Theory for Direct Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Bonds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 k

Centigrade-Fahrenheit Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-13

Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 n
Circuit, Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-13
Circuits, Basic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cleaning Apparatus, Mercury . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Compass
Alignment, B-16 Master Sighting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-23
Correction Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-20
Rose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-21
Components, of Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Compound Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5c, F2-7
Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1j
Connectors
Inspection of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Installation of (on Wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3c
MS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Potting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7
Rectangular Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Subminiature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Index-57
TM 1-1500-204-23-1
Continuity Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b, F2-8
Copper Wire Strippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1
Correction Card, Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-20
Counter Drum Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-13
Friction Stop and Jump Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-8
Pressure Altitude Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-10
Scale Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-6
Static Friction Error (Vibrator Inoperative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-9
Test Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-7
Cycle of Alternating Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2

D’Arsonval Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6c, F2-9

DD Form 1613 (Pilot Compass Correction Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-22
Dead Weight Testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2d
Direct Current Wave Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Direct Current, Basic Principles and Theory for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Direct Reading Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3h
Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-11
Dual Synchronous Rotor Tachometer Wiring Diagram
(Grounded Two-Wire System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17
Dual Synchronous Rotor Tachometer Wiring Diagram
(Ungrounded Three-Wire System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-16

Electrical Connectors and Common Plugs, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Electrical Liquid Indicating Systems and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3q
Electrical Resistance Temperature Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3k
Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Built-In Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4j
Electronic Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4k
Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4d
Ignition Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4n
Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4g, F3-9
Lighting Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4l
Overvoltage Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Parallel Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4c
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4f
Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4h
Storage Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4i

Index-58
 TM 1-1500-204-23-1
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4i
Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4m
Voltage Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Electrodynamic Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6i
Equipment, Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Equipment Safety
Electric Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1c
Instrument Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1c

Fahrenheit-Centigrade Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-13

Fire Safety
Electric Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1d
Instrument Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1d
Frequency Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6m
Friction Stop and Jump Error, Counter Drum Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-8
Friction Test Tolerances, Three Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T44
Fuse and Fuse Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1h

Gauge, Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1

General Shop Rules, Electric Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Equipment Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1c
Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1d
Maintenance of Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1e
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1a
Shop Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1b
General Shop Rules, Instrument Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Equipment Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1c
Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1d
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1a
Shop Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1b

Hand Wire Marking Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3

Index-59
TM 1-1500-204-23-1
I

Ignition System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-3

Indicator, Airspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3e, F4-11
Indicator Tolerances
Direct Reading Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-11
Remote Reading Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-12
Inspection of Installations of Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Inspection of Instrument Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a
Inspection Requirements for Installations of Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1a
Inspection Requirements, Instruments and Instrument Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b
Installation Inspection of Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Bonds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1k
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1n
Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1j
Fuses and Fuse Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1h
Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1a
Junctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1l
Kapton Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1o
Marking of Wires with Marking Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1f
Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1b
Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Terminals and Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1g
Toggle Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1m
Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1d
Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1c
Wire Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1e
Installation of Electrical Connectors and Common Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inspection of Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Installation of Connectors on Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3c
Types of Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a
Instruments and Instrument System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Airspeed Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3e
Altimeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3g, F4-13
Direct Reading Pressure Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3h
Electrical Liquid Indicating Systems and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3q
Electrical Resistance Temperature Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3k
Inspection of Instrument Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a
Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b
Magnetic Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3o, F4-19
Outside Air Temperature Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3m
Pitot Static System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c, F4-7
Pitot Static System Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3d
Position Indicating Systems and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3r
Remote Indicating Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3p

Index-60
 TM 1-1500-204-23-1
Remote Reading Pressure Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3i
Repair and Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3s
Tachometer Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3j
Thermocouple Temperature Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3l
Vacuum System and Instrument Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3n
Vertical Speed Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3f, F4-12
Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-9

Jetcal System Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2f

Junctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1l

Kapton Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1o

Leak Test Connections

Pitot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-9
Lighting System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-4

Magnetic Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3o, F4-19

Maintenance of Instruments and Instrument Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Maintenance of Shop Equipment, Electrical Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1e
Maintenance of Shop Equipment, Instrument Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Jetcal System Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2f, F4-6
Manoneter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a, F4-1
Pitot Static System Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2e
Scorsby Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2d, F4-5
Turntable Instrument Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c, F4-4
Vacuum Chambers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a, F4-1
Manometer Reading Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Marking of Wires with Marking Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1f

Index-61
TM 1-1500-204-23-1
Materials, Consumable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Measuring Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6d
Continuity Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b
D’Arsonval Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6c
Electrodynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6h
Frequency Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6k
Meter Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6l
Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6g
Ohmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6f
Rectifier Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6i
Test Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6e
Wattmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6j
Mercury Cleaning Apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Meter, D’Arsonval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6c, F2-9
Meter Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6l
Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-11
MS Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6g

Ohmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6f
Operational Check (of Electrical Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Outside Air Temperature Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3m

Parallel Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b, F2-6

Pilot Compass Correction Cards, DD Form 1613 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-22
Pitot
LeakTest Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Static System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c, F4-7
Static System Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3d
Static System Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2e
Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-10
Position Indicating Systems and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3r
Potting Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7
Precautions (for Troubleshooting Electrical Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b

Index-62
 TM 1-1500-204-23-1
Pressure Altitude Difference
Counter Drum Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-10
Three Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-5
Purpose (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Reading Level, Manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2

Recommended Sizes of Marking Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Rectangular Shell Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Rectifier Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6j
Relays, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-8
Remote Indicating Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3p
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-24
Remote Reading Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3i
Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-12
Repair and Replacements, Instruments and Instrument Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3s
Replacement Criteria for Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1b
Responslbllty
for Electric Shop Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1a
for Instrument Shop Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1a
Rose, Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-21
Rotary-Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-12

Scale Error
Counter Drum Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-6
Three Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-3
Schematic, of Typical Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
Scope (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Scorsby Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2g, F4-5
Series Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a, F2-5
Shop Housekeeping
Electrical Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1b
Instrument Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1b
Sizes of Marking Type, Recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Static Friction Error (Vibrator Inoperative), Counter Drum Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-9
Subminiature Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Switch
Rotary-Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-12
Toggle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-10

Index-63
TM 1-1500-204-23-1
Symbols, Charts, and Schematics for Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Symbols, Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
Synchronous Rotor Tachometer Wiring Diagram
(Grounded Two-Wire System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15
Synchronous Rotor Tachometer Wiring Diagram
(Ungrounded Three-Wire System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-14

Tachometer Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3j

Tachometer Wiring Diagram
Dual Synchronous Rotor (Grounded Two-Wire System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17
Dual Synchronous Rotor (Ungrounded Three-Wire System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-16
Synchronous Rotor (Grounded Two-Wire System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15
Synchronous Rotor (Ungrounded Three-Wire System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-14
Terminals and Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Test Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-7
Test Tolerances
Airspeed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Counter Drum Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-7
Three Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-3
Tester, Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b, F2-8
Thermocouple Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-13
Thermocouple Temperature Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Three Pointer Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-13
Friction Test Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-4
Pressure Attitude Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-5
Scale Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-2
Test Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-3
Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-10
Toggle Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1m
Troubleshooting Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Tube, Pitot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-10
Turntable Instrument Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2f, F4-4
Typical Electrical System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
Typical Ignition System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-3
Typical Lighting System Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-4
Typical Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-8

Index-64
 TM 1-1500-204-23-1
V

Vacuum Chambers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b

Vacuum System and Instrument Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3n
Varmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6l
Vertical System Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3f, F4-12
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6e

Wattmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6k
Wave Form, of Direct Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Wire Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1d
Wire Marking Machines
Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Hand F3-3
Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1c
Wire Strippers, for Copper Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1
Wire Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1e
Wiring Diagram, Remote Indicating Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-24
Wiring Diagram Symbols, Charts, and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
Wiring Diagram Symbols, Charts, and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Index-65
TM 1-1500-204-23-1
VOLUME 5

Aerodynamic Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13b

Alignment, Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Angle of Bend, Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6
Anti-Icing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 b
Anti-Icing System, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-12

Balance (of Tall Rotor Blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9c

Balance Check, Three-Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-8
Balance Check, Two-Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-7
Balance, Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Balancing, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Bends and Twists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12c
Blade Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10a
Mass Balance Weights (Bars) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10b
Spanwise Balance Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10c
Tracking Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10d
Trim Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10e
Blade Classification Data (Main Rotor Blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7d
Blade Construction (Main Rotor Blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7c
Blade Flapping Action (Vertical Plane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7
Blade Leading and Lagging (Horizontal Plane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-8
Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13d
Blade Tracking, Electronic, Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-12
Blade Tracking, Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-13
Blade, Rotor, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Blade, Rotor, Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17, F3-11

Classification, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Cleaning (of Rotors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11b
Cleaning, Powertrain Components of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Collective Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b, F3-5
Components, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Configurations, Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Construction (of Tail Rotor Blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9b
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Index-66
 TM 1-1500-204-23-1
Control System, Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Controllable Pitch Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b
Cyclic Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a, F3-4

Damaged Square Tip Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-5

Damaged Tip Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
Defects, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9, T2-2
Deicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18c
Description, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4b
Drive Shafting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4f
Engine Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4d
Freewheeling Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4c
Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4a
Rotor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4e
Drive Shafting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41, 4-5
Dynamic Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Efficiency, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Efficiency, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Electrical Deicing System, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Electronic Blade Tracker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17b
Electronic Blade Tracking Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-12
Engine Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4d, 4-5
Engine Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Mechanical Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Thermal Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Volumetnc Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8c
Extremely Low Frequency Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Feathering Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Fiberglass Blade Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12b
Flight Controls, Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Index-67
TM 1-1500-204-23-1
Fixed - Pitch Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Flag and Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17a
Flapping Action, Blade (Vertical Plane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7
Freewheeling Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4c, 4-5
Fully Articulated Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c
Fully Articulated Rotor Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6

Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4a, 4-5a

General (Blade Balance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10a
General (Tall Rotor Hubs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8a
General Shop Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2, 3-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a, 3-2a
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a
Shop Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b, 3-2b,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Shop Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c, 3-2c,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Shop Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d, 3-2d,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2d
General, Powertrain Maintenance Practices and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General, Propeller Maintenance Practices and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General, Rotor Maintenance Practices and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Governed Propellers, Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Governor, Woodward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-10
Governors, Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Hartzell Constant-Speed Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2, 2-6c

Hartzell Pitch Change Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Helicopter Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Single Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
Tandem Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Helicopter Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Helicopter Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Collective Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b
Cyclic Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c
Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a

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 TM 1-1500-204-23-1
Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2d
Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2e
Helicopter Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Extreme Low Frequency Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16a
Low Frequency Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16b
Medium Frequency Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16c
High Frequency Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16d

Icing, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Icing Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18a
Inspection (of Rotors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11c
Insallation (of Governors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16b
Installation, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Integrated Oil Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15f

Low Frequency Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16b

Main Rotor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Fully Articulated Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c
Rigid Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6a
Semi-Rigid Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6b
Main Rotor Blade Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1
Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Blade Classification Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7d
Blade Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7c
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7b
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7a
Main Rotor Hub and Blade Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-10
Main Rotor Hub and Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-9
Main Rotor Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13a
Mass Balance Weights (Bars) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10b
Materials, Consumable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Measuring Angle of Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6
Mechanical Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8a
Medium Frequency Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16c

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TM 1-1500-204-23-1
Metal Blade Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12a
Metal Propellers (Preservation and Storage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19b
Minor Defects (in Propellers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12a
Model Designation (Propellers Governors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15b
Model Number, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-1

Nomenclature (for Main Blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7b

Oil Control Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16a

Oil Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5g
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5c
Oil Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5f
Oil Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5d
Operation Checks (of Governors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16d

Painting, Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Pitch Change Mechanism, Hartzell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Pitch Control, Collective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Pitch Control, Cyclic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Single Rotor Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a
Tandem Rotor Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b
Powertrain Maintenance Practices and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Powertrain, Single Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a, F4
Powertrain, Tandem Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b, F4-2
Preservation and Storage, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Preservation and Storage, Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Pnnciples of Operation and Design of Rotor Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Procedures, Troubleshooting (Propeller System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Procedures, Troubleshooting (Rotor Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Propeller Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Aerodynamic Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13b
Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13d
Dynamic Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13c

Index-70
 TM 1-1500-204-23-1
Static Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13a
Propeller Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pusher Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b
Tractor Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a
Propeller Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11b
Propeller defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9, T2-2
Propeller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Controllable-Pitch Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b
Feathering Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6e
Fixed-Pitch Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Hartzell Constant-Speed Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6c
Reverse-Pitch Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6f
Turboprop Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6d
Propeller Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Propeller Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Integrated Oil Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15f
Model Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15b
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15a
Single Capacity Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15c
Turbo Prop Overspeed Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15e
Turbo Prop Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15d
Propeller Icing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Anti-Icing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18b
Deicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18c
Propeller Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18a
Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Propeller Maintenance Practices and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Propeller Model and Blade Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Propeller Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-1
Propeller Preservation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Metal Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19b
Wood Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19a
Propeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11a
Propeller Removal, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Propeller Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11b
Propeller Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11c
Propeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11a
Propeller Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Bends and Twist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12c
Minor Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12a
Tip Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12b

Index-71
TM 1-1500-204-23-1
Propeller RPM Adjusting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-11
Propeller Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Propeller Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-9
Purpose (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Refinishing (Rotor Blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13d

Reflector Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-13
Removal (of Rotors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11a
Removal, Main Rotor Hub and Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-9
Repair of Surface Defects (Propeller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
Repair, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Responsibility (for General Shop Rules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a, 3-2a
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a
Reverse-Pitch Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6f
Rigging (of Governors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16c
Rogging Governed Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16b
Oil Control Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16a
Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16d
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16c
Rigid Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6a
Rotor Assemblies, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Rotor Blade Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
String Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14b
Telescopic Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14a
Rotor Blade Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Main Rotor Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13a
Refinishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13d
Spot Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13c
Tail Rotor Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13b
Rotor Blade Preservation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Rotor Blade Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Fiberglass Blade Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12b
Metal Blade Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12a
Rotor Blade Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17, F3-11
Electronic Blade Tracker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17b
Flag and Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17a
Tall Rotor Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17c
Rotor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4e, 4-5k

Index-72
 TM 1-1500-204-23-1
Rotor Hub, Main, and Blade Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-10
Rotor Maintenance Practices and Procedures, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Rotor Removal, Cleaning, and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11b
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11c
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11a
Rotor Systems, Principles of Operation and Design Features of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Rotor, Fully Articulated, Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Rotor, Main, Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Rotor, Single, Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Rotor, Tail, Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Rotor, Tail, Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Rotor, Tandem, Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
RPM Adjusting Screw Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-11

Scope (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Semi-Rigid Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6b
Shop Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b, 3-2b
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Shop Rules, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2, 3-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Shop Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c, 3-2c
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Shop Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d, 3-2d
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Single Capacity Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15c
Single Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
Single Rotor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10c
Spanwise Balance Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13c
Spot Painting (Rotors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13c
Square Tip, Damaged, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-5
Static Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13a
String Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14b
Surface Defects (Propeller), Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c

Index-73
TM 1-1500-204-23-1
T

Tail Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9c
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9b
Trammeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9d
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9a
Tail Rotor Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8a
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8b
Tail Rotor Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13b
Tall Rotor Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17c, F3-14
Tandem Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Tandem Rotor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Telescopic Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14a
Terms, Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1
Theory, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Thermal Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8b
Three-Blade Balance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-8
throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d
Tip Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12b
Tip, Damaged, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5e
Tracking Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10d
Tracking, Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-9
Tracking, Tail Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-14
Tractor Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a
Trammeling (of Tail Rotor Blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9d
Trim Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10e
Troubleshooting Procedures (Propeller System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Troubleshooting Procedures (Rotor Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15, T3-2
Troubleshooting Procedures for Hamilton Standard 53C51-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-3
Troubleshooting Procedures for Hartzell HC93Z20-2C Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-5
Troubleshooting Procedures for Hartzell HCB3TN-3 Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-5
Turboprop Overspeed Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15e
Turboprop Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15d
Turboprop Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6d
Two-Blade Balance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-7
Types (of Main Rotor Blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7a
Types (of Tail Rotor Blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9a
Types (of Tail Rotor Hubs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8b
Typical Anti-Icing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-12
Typical Electrical Deicing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-13

Index-74
 TM 1-1500-204-23-1
V

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5e
Vibrations, Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Volumetnc Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8c

Wood Propellers (Preservation and Storage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19a

Wood Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17a
Refinishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17d
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17c
Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17b
Woodward Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-10

Index-75
TM 1-1500-204-23-1
VOLUME 6

Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type II, Non-Solvent . . . . . . . . . . . . . . . . . . . . . . . . . 6-2c
Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type II, Non-Solvent, Shelf life . . . . . . . . . . . . . . . . T6-3
Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type I, Solvent Type . . . . . . . . . . . . . . . . . . . . . . . . . 6-2b
Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type I, Solvent Type . . . . . . . . . . . . . . . . . . . . . . . . . T6-1
Adhesive and Cements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Acrylic Monomer Base Adhesive, MIL-A-8576, Type I, Solvent Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2c
Cement Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Cement Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2a
Chemigum Coating Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 d
Colored Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2e
Composite Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2m
Deicer Repair Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2k
Deicer Shoe Electrical Conducting Neoprene Surface Coat Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2f
General Purpose Synthetic Rubber Base Cement MIL-Spec MMM-1617 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2g
Natural Base Rubber Adhesive, MIL-Spec MMM-A-139, Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2i
Neoprene Base Synthetic Rubber Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2j
Non-Hardening Distic Brand Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2h
Other Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2n
Adhesives and Cements, Specific Gravity Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6-2
Adhesives, Sealants, and Cements, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1d
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1c
Precautionary Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1a
Preparation of Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1b
Airframe Castle Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-22
Airframe Plain Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3j, F2-28
Alloys
Magnesium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5,T4-11
Titanium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Aluminum Alloy Designation Conversions (Old To New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-2
Aluminum Alloy Temper Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-3
Aluminum Alloy Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-6
Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Aluminum Alloys, Designation for Alloy Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Aluminum Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2n
Anaerobic Adhesive MIL-R-46082 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Anchor Nuts, Floating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-17
Application Time (Room Temperature), Sealing Compound PR-1826 B1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6-4

Index-76
 TM 1-1500-204-23-1
Assemblies, Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-19
Authority for Substitutions and Interchangeability of Material (Air Items) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
AVSCOM, Responsibilities of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Blind Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Bolt and Screw Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-1
Bolt Diameter by Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-2
Bolt, Drilled Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
Bolt Head Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
Bolt Hole Location by Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-4
Bolt Identification, Hexagon Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2
Bolt Length by Dash Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-5
Bolt Material by Letter Preceding Dash Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-3
Bolt Substitution, Huck and Hi-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-6
Bolt-End Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Bolted Joint with Oversize Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-13
Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Aluminum Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2n
Bolt Head Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
Clevis Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2j, F2-7
Close Tolerance Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2g
Drilled Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2f
External Wrenching Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21, F2-6
Eye Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2k, F2-8
Fitting Structural Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2q
Hexagon Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e
Huck Bolts (Lockbolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2p
Installation and End Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Internal Wrenching Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2h, F2-5
Jo-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2o
Locking or Safetying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c
Self-Locking Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21, F2-9
Substitutions for Huck, Hi-Lock, and NAS Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2r
Substitutions for Jo-Bolts and V-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2s, T2-7
Tee-Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2m

Camloc Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9b, F2-61

Castellated Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3b

Index-77
TM 1-1500-204-23-1
Castle Nut, Airframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-22
Castle Nut, Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-23
Cells, Fuel and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cement Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Cement Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2a
Cements and Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Changes to Department of Army Publications, Recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Channel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-19
Characteristics of Catalyst Cured Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3c
Characteristics of Drying Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3b
Characteristics of Pliable Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3a
Checknut, Plain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-24
Checknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3c
Chemigum Coating Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2d
Cherrylock Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-56
CherryMAX Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-55
Cross Reference (Part Number/Military Standard Part Number, CherryMAX Rivets . . . . . . . . . . . . . . . . . . . . . T2-11
Clamp Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Clamp, Loop-Type Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-42
Clamp, Loop-Type Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-45
Clamp Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b
Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Clamp Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Clamp Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b
Clamps, Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-43
Clamps, Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-44
Clevis Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2j, F2-7
Clevis Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7a, F2-46
Close Tolerance Bolt, Countersunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
Close Tolerance Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2g
Coding, Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1
Color Code (for Aluminum Alloys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-4
Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1
Colored Cements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2e
Common Solid Shank Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8a
Composite Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2m
Considerations to be Taken Before Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18b
Consumable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Consumable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Consumable Items Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3a
Consumable Items Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3b
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Cord Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a
Cord Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b

Index-78
 TM 1-1500-204-23-1
Cord Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d
Cord Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c
Cord, Test Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Corrosion Resistance (of Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8d
Cotter Pin Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17a, F2-77
Cotter Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7g, F2-52
Countersunk Close Tolerance Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
Countersunk Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-34
Cross Reference of Old and New Color Code (for Aluminum Alloys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-5
Cross Reference (Part Number/Military Standard Part Number) CherryMAX Rivets . . . . . . . . . . . . . . . . . . . . . . . T2-11
Cure Time (Room Temperature), Sealing Compound MIL-S-8802 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6-4
Curing (of Adhesives, Sealants, and Cements) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1d

Deicer Repair Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Deicer Shoe Electrical Conducting Neoprene Surface Coat Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2f
Description of Bolt-Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Designation Conversions (Old to New), Aluminum Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-2
Designation for (Aluminum) Alloy Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Diameter by Part Number, Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-2
Dill Lok-Skru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9c, F2-62
Drilled Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2f, F2-3
Dzus Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9a, F2-60

Electrical Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5f

Engine Self-Locking Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-20
Example of Color Marking (for Aluminum Alloys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1
External Wrenching Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2i, F2-6
Eye Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2k, F2-8

Fastener, Lockring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Camloc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9b, F2-61
Dill Lok-Skru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9c, F2-62
Dzus Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9a, F2-60
Interlocking Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9e, T2-12
Snap and Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9d

Index-79
TM 1-1500-204-23-1
Fillister Head Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-39
Fitting Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16a
Fitting Structural Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2q
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16, T2-18
Fitting Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16a
Special Fitting Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16b
Fitting Material Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-17
Fittings, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-76
Flat-Head Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-37
Floating Anchor Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-17
Flush Head Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-10
Forming Titanium and Titanium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5a
Fuel and Oil Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel Cell Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
Fuel Cell Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Oil Cell Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Oil Cell Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4d
Fuel Cell Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
Fuel Cell Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b

Gasket and Packing Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6b

Gasket and Packing Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6a
Gasket and Packings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Gasket and Packing Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6b
Gasket and Packing Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6a
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c
General
Adhesive Sealants, and Cements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Phenolic and Plastic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Rubber Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Purpose Synthetic Rubber Base Cement MIL-Spec MMM-A-1617 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2g
General Usage (of Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8c
Gnp Length (for Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a

Index-80
 TM 1-1500-204-23-1
H

Handling of Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b

Hardware General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Heat Treatment of Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8f
Helical Insert and Tools Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-15
Helical Insert National Fine Thread Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-14
Helical Insert Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-13
Helical Thread Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Insert Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11c
Inspection Criteria for Helical Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11d
Installation of Helical Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11e
Installation of Spark Plug Helical Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11h
Installation of Twinsert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11i
Oversize Insert and Twinsert Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11k
Removal of Helical Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11f
Removal of Twinsert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11j
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11a
Hexagon Head Bolt Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-11
Hexagon Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e
Hi-Shear Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8h, F2-54
High Tensile Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-33
Hinge Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7f
Hole Location by Letter, Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-4
Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-43
Huck and Hi-Lock Bolt Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Huck Bolts (Lockbolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2p
Huck Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-57

Identification
of Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a
of Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
of Magnesium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a, T4-7
of Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
of Phenolic Compositions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2a
of Plastic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3a, T5-1
of Rubber Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-3
of Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-10
of Steel Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4a
of Steels, SAE Numbers Used in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-8
of Tie Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13a
of Titanium and Titanium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5c
Insert Tolerance (for Helical Inserts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-l11c
Inspection Criteria for Helical Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11d

Index-81
TM 1-1500-204-23-1
Inspection of Rubber Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1b
Inspection of Titanium and Titanium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Installation Data, Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-69
Installation of Helical Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11e
Installation of Spark Plug Helical Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11h
Installation of Twinsert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11i, F2-66
Installation, Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-65
Installation, Stud and Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-59
Installing New Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10b
Interlocking Slide Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9e, T2-12
Internal Wrenching Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -2h, F2-5
Internal Wrenching Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3h

Jamnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3d
Jo-and V-Bolts Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2s, T2-7
Jo-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Flush Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-10
Hexagon Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-11
Millable Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-12
Joint with Oversize Hole, Bolted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-13

Length by Dash Number, Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-5

Length Measurement (of Screws) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b
Light Hexagon Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3e, F2-25
Locking of Safetying Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Lockpins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7e, F2-51
Lockring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-74
Lockring Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Lockring Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-75
Lockwasher, Spit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-30
Lockwashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Lockwashers, Teeth-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-31
Lockwire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17b
Lockwiring Oil Caps, Drain Cocks, and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-79
Lockwiring Screws, Nuts, and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-78
Lockwiring, Speed Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-81
Lockwiring Turnbuckes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17f
Loop-Type Bonding Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-42
Loop-Type Support Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-45

Index-82
 TM 1-1500-204-23-1
M

Machine Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-38

Magnesium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a, T4-7
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b
Maintenance Activities, Responsibility of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Marking Steel Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4b
Marking Titanium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5d
Markings, Bolt and Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-1
Material, by Letter Preceding Dash Number, Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-3
Materials, Consumable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Materials Used in Fabrication (of Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Metals, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Millable Hexagon Head Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-12
Minimum Breakaway Torque for Used All-Metallic and Nonmetallic Self-Locking Nuts . . . . . . . . . . . . . . . . . . . . . . T2-8
Mixing (Adhesives, Sealants, and Cements) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 c

National Fine Thread Sizes (for Helical Inserts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-14

Natural Rubber Adhesive, MIL-Spec MMM-A-139, Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2i
Neoprene Base Synthetic Rubber Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2j
Non-Hardening Distic Brand Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2h
Numbering System, CherryMAX Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-10
Nut Installation Limits, Self-Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-21
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Airframe Plain Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3j, F2-28
Castellated Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3b
Checknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3c
Identification of Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3i
Internal Wrenching Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3h
Jamnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3d
Light Hexagon Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3e, F2-25
Self-Locking Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3a
Sheet Spring Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3g, F2-27
Wingnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3f, F2-26

Oil Caps, Drain Cocks, and Valves, Lockwiring of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-79

Oil Cell Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4c
Oil Cell Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4d
Old and New Color Code (for Aluminum Alloys), Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-5

Index-83
TM 1-1500-204-23-1
Other Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 n
Oversize Insert and Twinsert Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11k

Packings, Gaskets and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Part Number Breakdown, Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-68
Part Numbers, Helical Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-13
Phenolic and Plastic Materials, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Phenolic Compositions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2a
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2c
Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2b
Pin, Threaded Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-48
Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Clevis Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7a, F2-46
Cotter Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7g, F2-52
Hinge Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7f
Lockpins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7e, F2-51
Safety Retaining Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7c, F2-49
Spring Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7d, F2-50
Taper Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7b
Pins, Plain Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-47
Plain Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a, F2-29
Plastic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3a, T5-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3c
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3b
Plate Nut, Self-Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-16
Practices for Installation of Cotter Pins and Lockwire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Cotter Pin Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17a, F2-77
Double-Twist Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17b
Lockwire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17c
Lockwiring Turnbuckles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17f
Rod End Safetying (Key Type NAS 559) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17h, F2-82
Safetying Emergency Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17e
Securing Electrical and Electronic Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-171
Single-Wire Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17d
Speed Rig Safetying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17g
Precautionary Measures (for Adhesives, Sealants, and Cements) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1a
Preload Indicating Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-35
Preparation of Surface (for Adhesives, Sealants, and Cements) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1b
Principle of Lockring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-75
Purpose (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Index-84
 TM 1-1500-204-23-1
R

Recommended Changes to Department of the Army Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18c
Recommended Torque Values, Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-9
Removal of Bent, Damaged, or Broken Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10a
Removal of Helical Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11f
Removal of Twinsert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11j
Removal, Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-64
Repair of Damaged Spark Plug Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11g
Responsibilities
of AVSCOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
of Maintenance Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Rivet, Cherry MAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-55
Rivet, Huck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-57
Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8, F2-53
Blind Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8i
Common Solid Shank Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8a
Corrosion Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8d
General Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8c
Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8f
Hi-Shear Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8h, F2-54
Materials Used in Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8b
Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8j
Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8e
Rivets, Cherrylock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-56
Rivnut Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-58
Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8j
Rod End Safetying (Key Type NAS 559) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17h, F2-82
Rubber Materials
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1b
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1a

SAE Numbers Used in Identification of Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-8

Safety Retaining Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7c, F2-49
Safetying Emergency Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17e
Scope (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Screw Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Electrical Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5f
Length Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b

Index-85
TM 1-1500-204-23-1
Machines Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5d,F2-38
Screw Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5e,F2-40
Self-Tapping Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5e,F2-36
Structural Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3l
Screws, Fillister Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-39
Screws, Flat-Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-37
Screws, Nuts, and Bolts, Lockwiring of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-78
Screws, Round-Head Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-41
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Anaerobic Adhesive MIL-R-46082 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Characteristics of Catalyst Cured Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3c
Characteristics of Drying Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3b
Characteristics of Pliable Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3a
Sealing Compound, MIL-S-7126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3f
Sealing Compound, MIL-S-8784 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3d
Sealing Compound, PR-1826 B1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3e
Semi-Solid Synthetic Rubber Sealant for Engine Firewalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3h
Semi-Solid Synthetic Rubber Sealant, MIL-A-7126, for Hot-Air Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3g
Sealing Compound, MIL-S-7126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3f
Sealing Compound, MIL-S-8784 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3d
Sealing Compound, PR-1826 B1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3e
Application Time (Room Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6-4
Cure Time (Room Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6-5
Securing Electrical and Electronic Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17i
Selection of Helical Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11b
Self-Locking Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21, F2-9
Self-Locking Engine Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-20
Self-Locking Nut Installation Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-21
Self-Locking Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3a
Self-Locking Plain Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-15
Self-Locking Plate Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-16
Self-Locking Thin Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-14
Self-Tapping Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5e,F2-40
Semi-Solid Rubber Sealant, for Engine Firewalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3h
Semi-Solid Rubber Sealant, Mil-A-7126, for Hot-Air Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3g
Shear Castle Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-23
Sheet Spring Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3g, F2-27
Shelf Life (of Adhesive, Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type II, Non-Solvent) . . . T6-3
Shelf Life (of Adhesive, Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type I, Solvent Type) . . . T6-1
Shock Absorber and Elastic Exerciser Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cord Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a
Cord Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b

Index-86
 TM 1-1500-204-23-1
Cord Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d
Cord Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c
Single-Wire Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17d
Snap and Curtain Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9d
Spacer Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12a
Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12b
Spacer Installation Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-69
Spacer Part Number Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-68
Special Fitting Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16b
Special Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Specific Gravity Ranges (for Adhesives and Cements) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6-2
Speed Rig Lockwiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-81
Speed Rig Safetying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17g
Split Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-30
Spring Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7d, F2-50
Steel Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4a
Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4b
Steel, Identification of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-10
Storage
of Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
of Gaskets and Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c
of Magnesium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c
of Phenolic Compositions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2c
of Plastic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3c
of Rubber Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1a
Strength (of Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8e
Structural Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5c, F2-36
Stud and Grommet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-59
Stud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-65
Stud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-64
Stud Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-63
Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Installating New Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10b
Removal of Bent, Damaged, or Broken Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10a
Styles of Plate Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-18
Substitution and Interchangeability of Material (Air Items), Authority for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Substitution and Interchangeability (of Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8g
Substitutions for Huck, Hi-Lok, and NAS Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2r
Substitutions for Jo-Bolts, and V-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2s, T2-7

Index-87
TM 1-1500-204-23-1
T

Taper Pin Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-32

Taper Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7b
Tee-Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2m
Teeth-Type Lockwashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-31
Temper Designations (of Aluminum Alloys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-3
Terminals, Turnbuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-72
Test Loads (of Cords) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Testing of Magnesium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b
Thin Nut, Self-Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-14
Threaded Taper Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-48
Tie Rod Terminal Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13b, F2-71
Tie Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13a
Tie Rod Terminal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13b, F2-71
Tire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Tire Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Tire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Tire Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Titanium and Titanium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5, T4-11
Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5a
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5c
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5d
Tools Data, Helical Insert and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-15
Tools Data, Metri-Thread Insert and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-16
Tools Data, Twinsert and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-17
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Considerations to be Taken Before Torquing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18b
Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18c
Torque Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18a
Torque Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18a
Torque for Used All-Metallic and Nonmetallic Self-Locking Nuts,
Minimum Breakaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-8
Torque Values, Nut, Recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-9
Tube Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-44
Tube Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a
Tube Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Tube Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a
Tube Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Turnbuckle Assemblies, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-80
Turnbuckle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14b
Turnbuckle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14a

Index-88
 TM 1-1500-204-23-1
Turnbuckle Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-72
Turnbuckles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Turnbuckle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14b
Turnbuckle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14a
Twinsert and Tools Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-16
Twinsert Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-66
Types of Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-6
Types of Helical Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11a
Types of Plastic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3b
Types of Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-58
Typical Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-76
Typical Turnbuckle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-80

Usage (of Phenolic Compositions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2b

Washer, Countersunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-34

Washer, High Tensile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-33
Washer, Taper Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-32
Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lockwashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
Plainwashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a, F2-29
Special Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Washers, Preload Indicating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-35
Wingnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3f, F2-26

Index-89
TM 1-1500-204-23-1
VOLUME 7

Advantages (of Radiography) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Advantages (of Ultrasonic Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Amperage (Circular Magnetization) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9b
Amperage (Longitudinal Magnetization) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10b
Angle Beam Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9b
Application, Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Application of Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14b
Application of Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14e
Applications (of Longitudinal Magnetization) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10c
Applications (of Radiography) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Applying Transparent Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12b
Availability of Penetrants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8b

Basic Principles of Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Basic Terminology (of Magnetism) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Ferromagnetic Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a
Leakage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b
Magnetic Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3d
Magnetic Flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3e
Magnetism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c
Permeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3f
Residual Magnetism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3g
Retentivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3h
Basic Testing Methods (Ultrasonics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Beam Divergence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7c
Best Access to Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6f
Black Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11d

Calibration of Ultrasonic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Capabilities and Limitations (Magnetic Particle Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Changing Magnitude of Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5c
Characteristics, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Circular Magnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9b
Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9a
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8a
Conditions Not Requiring Demagnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13b
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Continuous Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8b

Index-90
 TM 1-1500-204-23-1
Couplants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8d
Current and Particle Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Continuous Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8b
Field Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8c
Field Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8d
Residual Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8a
Sensitivity Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8e
Currents, Eddy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Data, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Defects, Honeycomb, Fiberglass, and Composite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-2
Definitions (Magnetic Particle Inspection Terms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11a
Degree of Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6d
Demagnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Conditions Not Requiring Demagnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13b
Limits of Demagnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13d
Reasons for Demagnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13a
Techniques for Demagnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13a
Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a
Detection Standards (Radiation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-1
Detection, Flaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7, T2-1
Developer Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10j
Developer Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10k
Developer Dwell Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Disadvantages (of Radiography) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Disadvantages (of Ultrasonic Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10e
Dry Particle Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12c
Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10c

Eddy Current Inspection, Uses of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-1

Eddy Current Test Set Model ED-520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Changing Magnitude of Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5c
Needle Defections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5d
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5a
Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5b
Eddy Currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Electrical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11d
Electromagnetic Inspections, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Index-91
TM 1-1500-204-23-1
Emulsifier Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10g
Emulsifier Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10h
Emulsifier Dwell Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Equipment (Longitudinal Magnetization) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10d
Evaluate Discontlnuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14g
Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8a
Exposure and Processing, Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Exposure Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 b

Ferromagnetic Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a

Field Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Field Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8c
Field Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8d
Filing Radiographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Film Exposure and Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8a
Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8b
Film Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6b
Film Processing, Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
Fixing Indications with Lacquer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12a
Flaw Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7, T21
Fluorescent Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12e
Fluorescent Penetrant Inspection, Specific Procedures for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Fluorescent Penetrant Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Fluoroscopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7a
Fundamentals of Magnetic Particle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

General (Inspection Techniques) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6a

General Penetrant Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Procedures for Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
General Shop Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Maintenance of Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a
Shop Housekeepin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Shop Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c
Shop Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
General, Electromagnetic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General, Magnetic Particle Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General, Nondestructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Index-92
 TM 1-1500-204-23-1
General, Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General (Radiography Safety and Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11a
General (Ultrasonic Inspection Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8a
General, Ultrasonic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Honeycomb, Fiberglass, and Composite Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-2

Importance of Skilled Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Indicators, Magnetic Particle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Inspection (Penetrant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12a
Inspection and Interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12a
Interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12b
Inspection Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11a
Inspection of Bar Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9f
Inspection of Metal Plates and Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9e
Inspection of the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14f
Inspection of Tubes and Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9g
Inspection Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Inspection Process, Selection of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Inspection Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Best Access to Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6f
Degree of Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6d
Film Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6b
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6a
Source-to-Film Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6c
Thickness Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6e
Inspection, Penetrant, Types and Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Inspection, Ultrasonic, Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Inspection, Ultrasonic, Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Inspections, Types of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Interpretation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Interpretation (Penetrant Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12b
Interpretation (Radiographic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9, 5-9a

Index-93
TM 1-1500-204-23-1
L

Lamb Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6d

Leakage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b
Lighting and Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11c
Limitations (Penetrant Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Limitations and Capabilities (Magnetic Particle Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Limits of Demagnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13d
Longitudinal Magnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10b
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10c
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10d
Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10a
Longitudinal Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6a

Magnetic Flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3e

Magnetic Particle Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11a
Steps of Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11b
Magnetic Particle Inspection, Fundamentals of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Magnetic Particle Inspections, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Magnetic Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3d
Magnetism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c
Magnetism, Theory of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Magnetization, Circular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Magnetization, Longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Maintenance of Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2e
Manual Film Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
Materials, Consumable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Methods of Application (Magnetic Particles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7b
Methods of Application, Particles and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Methods of Recording Indications (Magnetic Particle Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Applying Transparent Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12b
Dry Particle Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12c
Fixing Indications with Lacquer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12a
Fluorescent Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12e
Photographing Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12f
Wet Particle Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12d
Minimum Penetration Time For Penetrants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1
Misinterpretation (Radiographic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9b
Modes of Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Lamb Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6d

Index-94
 TM 1-1500-204-23-1
Longitudinal Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6a
Rayleigh Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6c
Transverse Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6b

Nature of Sound Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

NDI Shop Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Need for Both Types of Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Needle Deflections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5d
Nondestructive Inspection, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Nondestructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b

Operation (Eddy Current Test Set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5a

Operative Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7b

Particle Application, Current and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7a
Particles and Methods of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Methods of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7b
Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7a
Penetrant Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10d
Penetrant Application (Type I, Method C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14c
Penetrant Inspection, Basic Principles of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Penetrant Inspection, General Procedures for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Penetrant Inspection, Type I, Method C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Penetrant Inspection Types and Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Penetrant Inspections, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Penetrant Inspections, Precautions in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Penetrants, Minimum Penetration Time for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1
Penetrants, Quality Control of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Penetration Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10f
Permeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3f
Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Photographing Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12f
Portable X-Ray Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7b
Pre-operative Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7a
Precautions in Penetrant Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Index-95
TM 1-1500-204-23-1
Operative Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7b
Pre-operative Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7a
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7d
Temperature Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7c
Precleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10b
Precleaning Process (for Type C Penetrant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14a
Preparation, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pretesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10a
Pretesting, Precleaning, Drying, Application, and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Developer Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10j
Developer Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10k
Developer Dwell Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10e
Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10c
Emulsifier Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10g
Emulsifier Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10h
Emulsifier Dwell Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10i
Penetrant Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10d
Penetration Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10f
Precleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10b
Pretesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10a
Removal Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10m
Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8b
Purpose (of Electromagnetic Inspections) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Purpose (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Purpose (of Penetrant Inspections) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Purpose (of Radiography) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Quality Control of Penetrants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8b
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8a

Index-96
 TM 1-1500-204-23-1
R

Radiation Detection Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-1

Radiation Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11c
Radiographic Interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9a
Misinterpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9b
Radiographs, Filing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Radiographs, Filing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Radiography Safety Precautions and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Electrical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11d
Exposure Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11b
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11a
Radiation Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11c
Rayleigh Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6c
Reasons for Demagnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13a
Recording Indications, Methods of (Magnetic Particle Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Reflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7a
Refraction and Mode Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7b
Relative Response of Survey Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-2
Removal of Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14h
Removal of Excess Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14d
Removal Methods (Penetrants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10m
Requirements, Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Residual Magnetism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3g
Residual Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8a
Responsibility (for Shop Rules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a
Retentivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3h

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7d

Safety Precautions and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Scope (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Search Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8b
Selection of Inspection Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Sensitivity Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8e
Shop Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Shop Requirements, NDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Shop Rules, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Shop Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c
Shop Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
Skilled Operators, Importance of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Sound Waves, Nature of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Source-to-Film Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6c
Special Techniques (Radiography) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Index-97
TM 1-1500-204-23-1
Fluoroscopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7a
Portable X-Ray Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7b
Specific Procedures for Fluorescent Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Black Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11d
Inspection Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11a
Lighting and Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11c
Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11b
Steps of Inspection (Magnetic Particle Inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11b
Straight Beam Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9a
Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11b, 6-9d
Surface Wave Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9c
Survey Meters, Relative Response of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-2

Technique (of Circular Magnetization) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9a

Technique (of Longitudinal Magnetization) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10a
Techniques for Demagnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13c
Techniques, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Techniques, Special (Radiography) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Temperature Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7c
Terminology, Basic (of Magnetism) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Test Set, Eddy Current, Model ED-520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Testing Methods, Basic (Ultrasonics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Testing Procedure (Eddy Current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5b
Theory of Magnetism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Thickness Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7e
Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8c
Transmission Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Beam Divergence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7c
Reflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7a
Refraction and Mode Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7b
Transverse Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6b
Type I, Method C Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Application of Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14b
Application of Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14e
Evaluate Discontinuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14g
Inspection of the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14f
Penetrant Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14c
Precleaning Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14a
Removal of Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14h
Removal of Excess Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14d

Index-98
 TM 1-1500-204-23-1
Types of Fluorescent Penetrant Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Types of Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a
Need for Both Types of Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Nondestructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b

Ultrasonic Equipment, Calibration of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Ultrasonic Inspection Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8a
Search Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8b
Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8c
Ultrasonic Inspection Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Angle Beam Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9b
Inspection of Bar Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9f
Inspection of Metal Plates and Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9e
Inspection of Tubes and Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9g
Straight Beam Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9a
Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9d
Surface Wave Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9c
Ultrasonic Inspections, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Use of Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Uses of Eddy Current Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-1

Vibration, Modes of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Wet Particle Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12d

Index-99
TM 1-1500-204-23-1
VOLUME 8

Aluminum Alloys, Typical Machine Setting for Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-4

Aluminum Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d
Aluminum Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c
Aluminum Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5e
Aluminum Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b
Gas Weldin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c
Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5e
Types of Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a
Arc Welding Defects, Causes, and Remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-3
Arc Welding Magnesium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-6

Bandsaws
Care and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
Cutoff-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
Vertical-Contour Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2
Bearing Roll Staking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6e
Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9a
Brazing and Silver Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9a
Post Brazing and Silver Soldering Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9c
Silver Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9b
Brush Method of Starting Electric Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5

Care and Use of Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Bandsaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4b
Drilling Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a
Grinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4f
Lathes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Milling Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4d
Shapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4e
Cleaning
Aluminum Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b
Magnesium Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6a
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Corrosion-Resistant Steel and Nickel Chromium Alloy Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Index-100
 TM 1-1500-204-23-1
Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7d
Distinguishing Corrosion-Resistant Steels and Nickel-Base Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7a
Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7c
Special Welding Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7b
Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7e
Welding Stresses and Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7f
Corrosion-Resistant Steel Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7d
Corrosion-Resistant Steel Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7c
Corrosion-Resistant Steel Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7e
Corrosion-Resistant Steels and Nickel Alloys, Relation Between Sheet Thickness and Current Required for Metallic
Arc Welding of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-8
Corrosion-Resistant Steels and Nickel-Base Alloys, Relation Between Sheet Thickness and Current Required for
Inert-Arc Welding of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-9
Counterboring and Spotfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6c
Cut-off Type Bandsaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3

Distinguishing Corrosion-Resistant Steels and Nickel-Base Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7a

Drill Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Drilling Machines
Care and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4a
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3a
Special Operations on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Electric Arc Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b

Electric Arc Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a ,T3-1
Equipment Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c

Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d

Flames, Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Fluxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4c

Index-101
TM 1-1500-204-23-1
G

Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a

Gas Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Gas Welding Equipment, Guide to Regulation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-5
Gas Welding Flames................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
General
Machine Shop Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Weld Shop Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Layout Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a
Grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-7
Grinder Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-8
Grinding Machines Care and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4f
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3b
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-8
Guide to Regulation of Gas Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-5

Inert-Arc Welding of Corrosion-Resistant Steels and Nickel- Base Alloys, Relation Between Sheet Thickness and
Current Required for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-9
Introduction
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Lapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6d
Lathes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-4
Care and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4c
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3c
Laying Out and Mounting Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General Layout Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5a
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b

Machine Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Drilling Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3a
Grinding Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3b
Lathes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3c
Milling Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3d

Index-102
 TM 1-1500-204-23-1
Miscellaneous Machine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3f
Portable Machine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Shapers and Planers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3e
Machine Settings for Arc Welding Magnesium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-6
Machine Shop Practices
Care and Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Laying Out and Mounting Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Machine Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Shop Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Special Operations on Drilling Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Magnesium Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c
Magnesium Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6b
Magnesium Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6d
Magnesium Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6a
Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6b
Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6d
Metallic Arc Welding of Corrosion-Resistant Steels and Nickel Alloys, Relation Between Sheet Thickness and Cur-
rent Required for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-8
Milling Machines
Care and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4d
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3d
Miscellaneous Machine Tools, Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3f
Mounting Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5b

Portable Machine Tools, Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3g

Post Brazing and Silver Soldering Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9c
Purpose of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Relation Between Sheet Thickness and Current Required for Inert-Arc Welding of Corrosion-Resistant Steels and
Nickel-Base Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-9
Relation Between Sheet Thickness and Current Required for Metallic Arc Welding of Corrosion-Resistant Steels and
Nickel Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-8

Index-103
TM 1-1500-204-23-1
Responsibility
Machine Shop Rules, for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a
Welding Shop Rules, for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Rod Information, Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2

Safety, Welding Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c

Schematic, Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Shaper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6
Shapers and Planers, Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3e
Shapers, Care and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4e
Shop Housekeeping
Machine Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Welding Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Shop Rules, Machine Shop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Equipment Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2c
Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2d
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2a
Shop Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2b
Shop Rules, Welding Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c
Shop Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Silver Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9b
Special Operations on Drilling Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Bear Roll Staking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6e
Counterboring and Spotfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6c
Lapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6d
Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6b
Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Special Welding Considerations, Corrosion-Resistant Steel and Nickel Chromium Alloy Welding . . . . . . . . . . . . 3-7b
Starting Electric Arc, Brush Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Stress Relieving Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-7

Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6a
Treatment, Stress Relieving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-7
Types of Alloys, Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a

Index-104
 TM 1-1500-204-23-1
Types of Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Electric Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a
Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3c
Typical Machine Setting for Spot Welding Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-4

Vertical-Contour Bandsaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2

Welding Equipment
Electric Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Welding, Arc; Defects, Causes, and Remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-3
Welding Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
Fluxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4c
Welding Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Welding on Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Welding Rod Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Welding Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Welding Shop Practices
Aluminum Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Brazing and Silver Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Corrosion-Resistant Steel and Nickel Chromium Alloy Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Magnesium Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Shop Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Types of Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Welding Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Welding on Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Welding Stresses and Distortion, Corrosion-Resistant Steels and Nickel Chromium Alloy Welding . . . . . . . . . . . 3-7f

Index-105
TM 1-1500-204-23-1
VOLUME 9

Accuracy Limits, Torque Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-1

Action of Preload Indicating Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-30
Adjustable Hook Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-39
Adjustable Reamer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-92
Adjustable Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-25
Adjusting the Snap Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-65
Adjustment of Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-4
Air Blow Cleaning Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-13
Air Compressors, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-14
Aircraft Landing Gear Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-10
Aircraft Pre-Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-15
Alternate Method for Tightening to 15 Degree Wrench Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-25
Angle Extension Torque Wrench Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-20
Angle, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-19
Application of Blade Pitch for Certain Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-98
Application of Force, Improper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-19
Applying Paint at an Angle, Effect of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-6
Army Aviation, Types of Tools Used in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Attachment - Offset Reverse Extension, Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-17
Audible-Indicating Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-4
Automatic Center Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-60
Awl 4-6, F4-48
Awl, Scribing with an . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-49

Ball Peen Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1

Beading Large Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-124
Bench Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8a, F4-53
Bench Vise, Using a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Bender, Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-117
Bending Tube Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123
Bending Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-118
Bevel Protractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-12
Bits, Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Blade Set, Hacksaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-97
Bobs, Plumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3, F3-6
Body Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Box-End Wrench Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-23
Box-End Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-22
Boxes, Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Boxes, Typical Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Breast Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-80
Brown and Sharpe Tapered Reamer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-94

Index-106
 TM 1-1500-204-23-1
C

Cable Rigging Tension Chart, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-7

Cable Tensionmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Calibration, Repair and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-28
Vernier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-29
Calipers, Hermaphrodite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-27
Calipers, Simple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-24
Calipers, Spring-Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-25
Calipers, Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-26
Care of Torque Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Carpenters Square . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-10
Carriage Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-55
Carriage Clamp, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-56
Center Head, Setting the . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-14
Center Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-50
Center Punch for Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-84
Check and Chuck Key, Three-Jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-3
Checkered Flags, Reflectorizing and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Checking Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-19
Checking Diameters, Snap Gauge for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-64
Checking Dimension Between Surfaces, Snap Gauge for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-62
Checking Flat or Cylindrical Work, Snap Gauge for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-63
Checking Propeller Shaft Run Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-76
Chisels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-57
Chisels, Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Clamp, Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-55
Clamping Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Bench Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-53
Cleaner, File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-79
Cleaning Gun, Air Blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-13
Cleaning Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning Solvent Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-12
Cold Chisels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Combination Flaring Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-120
Combination Square . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-11
Combination Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-24
Common Screwdriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-13
Concentric Torque Wrench Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-15
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Control Surface Angle, Measuring at Full Throw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-3
Conversion of Tensiometer Reading in Pounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-6
Correct and Incorrect Stroke Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-5

Index-107
TM 1-1500-204-23-1
Correct Drill Sizes for Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-102
Correct GO Dimension for Cylindrical Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-68
Correct NO-GO Dimension for Cylindrical Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-69
Cotter Pin Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7, F7-11
Cranes and Hoists, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-18
Crossfiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-76
Crowfoot Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-20
Crowfoot Wrench, Using a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-21
Crowfoot Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Curved Tooth File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-74
Cutters, Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-114
Cutters, Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-115
Cutting Edge and Heel Angles, Usual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-86
Cutting Edge, Hand Grinding of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-87
Cutting Edge, Hand Grinding of Heel to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-88
Cutting, Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-113
Cutting Tube with Tube Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Cutting Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-112
Cylinder, Locating Diameter of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-15
Cylinder, Marking Diameter of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-16
Cylindrical Part, Correct GO Dimension for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-68
Cylindrical Part, Correct NO-GO Dimension for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-69
Cylindrical Part, Placing Snap Gauge on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-67

Deflecting Beam Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-2

Deicer Boot Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Deicer Boot Pliers, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-19
Deicer Boot Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Depth Gauge, Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-48
Depth Gauge, Rule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-47
Depth Gauge, Vernier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-49
Depth Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Depth Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-36
Description
Leather Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Determining Correct Torque Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Determining Depth with the Square Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-20

Index-108
 TM 1-1500-204-23-1
Diagonal Cutting Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-42
Dial Indicator Installed on Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-75
Dial Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-104
Dies, Taps and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Diestock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-105
Divider, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-21
Divider, Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-22
Dividers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Dividers, Scribing a Circle with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-23
Double Cutting Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Double-Flaring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-122
Drawfiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-78
Dressing a Grinding Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-6
Drill Bit, Machine Grinding a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-85
Drill Bit, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-83
Drill Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Drill Grinding Gauge, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-89
Drill Jaws, V-Grooves in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-82
Drill Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-2
Drill, Breast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-80
Drill, Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-81
Drill, Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Drilling, Center Punch for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-84
Drills, Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Drills, Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Drills, Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-15
Drive Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-61

Index-109
TM 1-1500-204-23-1
E

Effect of Applying Paint at an Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-6

Electric Drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3, F6-2
Electric Grinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Engine Maintenance Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-3
Engine Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-12
Equipment, Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-20
Extension Rods for Inside and Depth Micrometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-37
Extension, Proper Application of Force When Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-18
Extractor, Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7, F7-11
Extractor, Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-109
Extractors, Spiral Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-108
Extractors, Straight Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-107

Face Pin Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-38

Faulty Patterns and Suggested Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-10
File Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-79
File Handle, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-75
File Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-65
File Teeth Spacing and Fineness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-67
File Teeth, Single- and Double-Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-66
File, Curved Tooth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-74
File, Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-70
File, Half-Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-73
File, Mil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-69
File, Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-72
File, Square . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-71
File, Triangular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-68
Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Filing for a Flat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-77
Fillet and Radius Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-73, 3-19
Fillet and Radius Gauges, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-74
Fingers, Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8, F7-12
Fishing Tool, Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5, F7-9
Flanged Ring Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-56
Flares, Single and Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-119
Flaring Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Index-110
 TM 1-1500-204-23-1
Flat File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-70
Flat Parts, Gauging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-66
Flat Surface, Filing for a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-77
Flat-Nose Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F444
Flush Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-113
Flushing Paint Gun with Thinner or Solvent (Cup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-7
Flushing Paint Gun with Thinner or Solvent (Pressure Tank or Gravity Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-8

Gauge Tolerances, Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1

Gauge Tolerances, Snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Gauge Types, Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-57
Gauge, Flanged Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-56
Gauge, Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Gauge, Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-45, 3-10
Gauge Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-52
Gauges, Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-55, 3-15
Gauges, Snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-59, 3-16
Gauges, Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Gauging Flat Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-66
General
Electrical Power Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General Maintenance Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Ground Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Measuring Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Special Aircraft Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Storage of Ground Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Tool Procedures and Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Torque Tools and Torque Principles and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Use Torque Multiplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-21
General, Ground Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Grinder, Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Grinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-4
Grinding Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-5
Grinding Wheel, Dressing a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-6
Grinding, Screwdriver Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-19
GSE - Three Color Camouflage Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-1
Guns, Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Index-111
TM 1-1500-204-23-1
H

Hacksaw Blade Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-97

Hacksaw Blade, Installing a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-99
Hacksaw, Proper Way to Hold a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-100
Hacksaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17, F4-96
Half-Pound File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-73
Hammer Face Substances, Soft-Faced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Hammer, Ball Peen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Hammer, Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Hammer, Lead or Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-5
Hammer, Riveting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Hammer, Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-4
Hammer, Soft-Faced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-6
Hammers and Mallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-81
Hand Drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Hand Grinding of Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-87
Hand Grinding of Heel to Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-88
Hand Seamer and Groover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Handle and Wedges, New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-11
Handle, Hinged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-29
Handle, Ratchet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-27
Handle, Removing Broken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-10
Handle, Sliding T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-28
Handle, Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-30
Heel Angle, Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-90
Height Gauge, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-51
Height Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-51
Hermaphrodite Calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-27
Hexagonal Setscrew Wrench (Allen Wrench) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-31
Hinged Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-29
Hole Gauges, Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22, F3-79
Hollow Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-64
Hook Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-36
Hub Nut Torque Multiplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-22

Index-112
 TM 1-1500-204-23-1
I

Identification of Parts of Reamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-91

Improper Application of Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-19
Individual Flaring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-121
Inside Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-35
Installation of Preload Washer on a Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-32
Installation of Preload Washers on a Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-31
Installing a Hacksaw Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-99
Installing Protractor Head on Rule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-17
Installing Wooden Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-12

Jack Hydraulic Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-6

Jack, 3-Ton, Tripod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-9
Jack, 5-Ton, Tripod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-8
Jack, 10-Ton, Self-Contained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-11
Jack, 12-Ton, Tripod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-7
Jack, Aircraft Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-10
Jobber’s (Machine) Reamer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-93

Knife, Putty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-52

Knife, Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-50
Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Knives, Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-51

Laying Out Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-24

Lead or Copper Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-5
Leather Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Level Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Level
Machinist’s Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Master Precision Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Mechanic’s Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Striding Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Locating Diameter of Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-15
Lockwire Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11, F7-16

Index-113
TM 1-1500-204-23-1
Long-Nose Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-43
Loosening Protractor Adjustment Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-18
Lubricants for Tapping and Die-Cutting Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-3
Lubricating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-20

Machine Grinding a Drill Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-85

Magnet, Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9, F7-14
Maintenance Platform, Type B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-1
Maintenance Stand, Type B-4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-2
Maintenance Stand, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-3
Mallet, Rawhide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-7
Mallet, Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Mallet, Tinner’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-9
Mallets, Hammers and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Marking a Square Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-13
Marking Diameter of Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-16
Master Precision Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Materials, Consumable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Measuring Control Surface Angle at Full Throw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-3
Measuring Heel Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-90
Measuring Hole with a Small Hole Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-80
Measuring Hole with Telescoping Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-78
Measuring Sheet Metal and Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-72
Mechanic’s Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Mechanical Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8, F7-12
Mechanist’s Scribers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7
Micrometer Depth Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-48
Micrometer with Extension Rod, Using Inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-40
Micrometer, Reading a Vernier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-43
Micrometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-36
Extension Rods for Inside and Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-37
Inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-35
Outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-34
Parts of a Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-41
Reading a Measurement on a Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-42
Reading a Metric Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9f, F3-44
Using Inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-38
Using Outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-39

Index-114
 TM 1-1500-204-23-1
Mill File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-69
Mixing, Painting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Multipliers, Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

New Handle and Wedges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-11

Nippers and Pincers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-111, 4-22
Nitrogen Servicing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-17
Nomenclature, File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-65
Nonconcentric Attachments to Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-16
Nozzle Position to Produce Vertical Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-3

Offset Screwdriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15

Oil Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-11
Oil Spray Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Open-End Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-20
Open-End Wrench Jaw Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-21
Operation and Use, Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Operation of Vernier Calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-31
Outside Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-34
Oxygen Servicing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-24

Paint Gun with Thinner or Solvent (Cup), Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-7

Paint Gun with Thinner or Solvent (Pressure Tank or Gravity Bucket), Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-8
Paint Gun, Soaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-9
Paint Gun, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
Paint Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Painting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Parts of a Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-41
Pattern, Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-2
Phillips Screwdriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-14
Pickler, Pre-Oiler and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-19
Pin Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-62
Pin Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-37
Pinchers, Nippers and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22, F4-111

Index-115
TM 1-1500-204-23-1
Pipe and Tube Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Pipe Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-114
Placing Snap Gauge on Cylindrical Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-67
Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Deicer Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Lockwire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11, F7-16
Pliers, Diagonal Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-42
Pliers, Flat Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-44
Pliers, Long-Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-43
Pliers, Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-40
Pliers, Round-Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-45
Pliers, Slip-Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-41
Pliers, Vise-Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-47
Pliers, Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-46
Plug Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-54, 3-14
Plug, Three-Prong Grounded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-1
Plumb Bobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3, F3-6
Plumb Bobs, Polished Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Plumb Bobs, Solid Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Pneumatic Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Pneumatic Drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-15
Pneumatic Grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8, F5-16
Pneumatic Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9, F5-17
Pneumatic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Pneumatic Vacuum Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6, F5-14
Pocket Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-51
Polished Brass Plumb Bobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Portable Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-23
Power Application of Force When Using Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-18
Power Supply, Portable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-23
Power Wrench Torque Multiplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-23
Practices and Procedures, Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Practices, Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Pre-Oiler and Pickler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-19
Precautions, Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Preload Indicating Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-29
Preload Indicating Washers, Torque Procedures Without a Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Preset Torque Screwdriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-1
Prick Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-58
Progressive Snap Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-61
Propeller Shaft Runout, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-76
Propeller Shaft, Dial Indicator Installed on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-75
Proper Fit of Screwdrivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17

Index-116
 TM 1-1500-204-23-1
Proper Procedure for Pulling Adjustable Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-35
Proper Way to Hold a Hacksaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-100
Protractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2, F7-1
Protractor Adjustment Screws, Loosening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-18
Protractor Head on Rule, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-17
Protractor, Bevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-12
Protractor, Setting, with Flight Control Surface in Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-2
Punch, Automatic Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-60
Punch, Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-59
Punch, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-61
Punch, Hollow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-64
Punch, Leather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Punch, Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-62
Punch, Prick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-58
Punch, Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-63
Punches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Purpose of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Putty Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-52
Tools on Army Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Radius Gauges, Fillet and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Ratchet Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-27
Ratchet Screwdrivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-16
Rawhide Mallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-7
Reading a Measurement on a Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-42
Reading a Measurement on a Vernier Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-32
Reading a Metric Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-33
Reading a Metric Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-44
Reading a Vernier Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-43
Reamer, Adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-92
Reamer, Brown and Sharpe Tapered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-94
Reamer, Jobber’s (Machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-93
Reamer, Repairman’s Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-95
Reamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Reamers, Identification of Parts of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-91
Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-2
Reflectorizing and Checkered Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Removing Broken Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-10

Index-117
TM 1-1500-204-23-1
Repair
and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Tool, Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6, F7-10
Rigid Frame Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-3
Ring Gauge Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-57
Ring Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-1
Ring Gauges, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-58
Riveting Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Roller, Deicer Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Round File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-72
Round-Nose Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-45
Rubber Mallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Rule Depth Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-47
Rule, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-9
Rules, Tapes and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Safety
Electrical Power Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Safety Practices and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Schematic Diagram, Jack Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-6
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Screwdriver Tip Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-19
Screwdriver, Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15
Screwdriver, Phillips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-14
Screwdriver, Preset Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-1
Screwdrivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Screwdrivers, Common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-13
Screwdrivers, Proper Fit of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17
Screwdrivers, Ratchet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-16
Scribers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Scribers, Mechanist’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7
Scribing a Circle with Dividers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-23
Scribing with an Awl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-49
Selection, Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Self-Contained Jack, 10-Ton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-11
Servicing Unit, Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-17
Servicing Unit, Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-24

Index-118
 TM 1-1500-204-23-1
Setscrew Wrench (Allen Wrench) Hexagonal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-31
Setting Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-4
Setting Height on a Surface Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10c, F3-46
Setting Protractor with Flight Control Surface in Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-2
Setting the Center Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-14
Shears and Double Flares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-119
Shears, Double Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Sheet Metal and Wire Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-72, 3-18
Sheet Metal and Wire, Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-72
Shop Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Simple Calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-24
Single- and Double-Cut File Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-66
Sizes, Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-2
Slide Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-28
Sliding T-Bar Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-28
Slip-Joint Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-41
Small Hole Gauge, Measuring Hole with a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-80
Small Hole Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-79, 3-22
Snap Gauge for Checking Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-64
Snap Gauge for Checking Dimension Between Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-62
Snap Gauge for Checking Flat or Cylindrical Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-63
Snap Gauge, Adjusting the . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-65
Snap Gauge, Progressive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-61
Snap Gauge, Solid Nonadjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-60
Snap Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-59, 3-16
Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Soaking a Paint Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-9
Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-26
Soft-Faced Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-6
Soft-Faced Hammer Face Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-1
Soldering Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-22, 7-16
Solid Nonadjustable Snap Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-60
Solid Steel Plumb Bobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Solvent, Cleaning Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-12
Spacing and Fineness, File Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-67
Special Aircraft Tools, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Speed Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-30
SPEM Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-4
Spiral Screw Extractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-108
Spray Gun, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-11
Spray Guns, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-2
Spray Pattern, Adjustment of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-4

Index-119
TM 1-1500-204-23-1
Spring Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-21
Spring-Joint Calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-25
Square
Carpenter’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-10
Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-11
Square File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-71
Square Head, Determining Depth with the . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-20
Square Line, Marking a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-13
Squares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Stand, SPEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-4
Stand, Type D5B Hydraulic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-5
Storage of Ground Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Straight Screw Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-107
Striding Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Stroke Technique, Correct and Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-5
Suggested Corrections, Faulty Pattern and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-10
Surface Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Setting Height on a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-46

Tap Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-109

Tap Extractor, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-110
Tap Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-103
Tapes and Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Tapes, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-8
Tapping and Die-Cutting Threads, Lubricants for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-3
Tapping, Correct Drill Sizes for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-102
Taps and Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-101
Telescoping Gauge, Measuring Hole with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-78
Telescoping Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21, F3-77

Index-120
 TM 1-1500-204-23-1
Telescoping Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9, F7-14
Tensiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-4
Tensiometer Reading in Pounds, Conversion of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-6
Tensiometer, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Tensiometer, Using a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-5
Testing of Torque Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Thickness Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17, F3-70
Thread Chasers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19, F4-106
Thread Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-52
Thread Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Three-Jaw Chuck and Chuck Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-3
Three-Prong Grounded Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-1
Tightening Preload Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-33
Tightening to 15-Degree Wrench Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-24
Tightening to 30-Degree Wrench Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-27
Tightening to 60- or 120-Degree Wrench Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-26
Tightening to 90- or 180-Degree Wrench Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-28
Tinner’s Mallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-9
Tolerances
Ring Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15, T3-1
Snap Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-2
Tool Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Tool Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Tool Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2f
Tool Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Tool, Double Flaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-122
Tool, Individual Flaring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-121
Tool, Tube Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Tools, Combination Flaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-120
Tools, Flaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Tools, Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Tools, Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-22, 7-16
Torque Multiplier Power Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10, F8-23
Torque Multiplier, General Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-21
Torque Multiplier, Hub Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-22
Torque Multipliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Torque Procedures Without a Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Torque Tool Accuracy Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-1
Torque Tools, Care of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Index-121
TM 1-1500-204-23-1
Torque Tools, Testing of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Torque Tools, Types of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Torque Value, Determining Correct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Torque Values, Recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-2
Torque Wrench Attachment - Offset Reverse Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-17
Torque Wrench Attachment, Angle Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-20
Torque Wrench Attachments, Concentric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-15
Torque Wrench Operation and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Torque Wrench Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Torque Wrench - Deflecting Beam with Indicating Dial (Direct Reading with Audible Signal), Type I, Class 2, Style
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-8
Torque Wrench - Deflecting Beam with Indicator Plate (Direct Reading with Feel Impulse and Audible Signal), Type
I, Class 1, Style B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-6
Torque Wrench - Deflecting Beam with Indicator Plate (Direct Reading), Type I, Class 1, Style A . . . . . . . . . . . . F8-5
Torque Wrench - Rigid Case with Indicator Dial (Direct Reading) Type II, Style A . . . . . . . . . . . . . . . . . . . . . . . . . . F8-9
Torque Wrench - Rigid Case with Indicator Dial, Presetting Torque Dial (Direct Reading with Audible Signal),Type II,
Style B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-10
Torque Wrench - Rigid Case with Presetting Dial (Direct Reading with Flashlight Signal), Type II, Style C . . . F8-11
Torque Wrench - Rigid Case, Micrometer-Style Torque Presetting, Audible Signal, Plain Head Type Ill, Class
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-12
Torque Wrench - Rigid Case, Micrometer-Style Torque Presetting, Audible Signal, Ratchet Reversible Head, Type
III, Class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-13
Torque Wrench - Rigid Case, Preset Torque, Audible Signal, Type V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-14
Torque Wrench, Audible-Indicating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-4
Torque Wrench, Deflecting Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-2
Torque Wrench, Nonconcentric Attachments to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-16
Torque Wrench, Rigid Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-3
Torque Wrenches - Deflecting Beam with Indicating Dial (Direct Reading), Type I, Class 2, Style A . . . . . . . . . . F8-7

Index-122
 TM 1-1500-204-23-1
Tow Vehicle, Type MB-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-21
Towbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-16
Trailer, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-12
Trammel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-30
Transfer Calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-26
Transfer Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-63
Triangular File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-68
Tripod Jack, 3-Ton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-9
Tripod Jack, 5-Ton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-8
Tripod Jack, 12-Ton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-7
Tube Beading Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26, F4-123
Tube Bender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-117
Tube Benders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Tube Cutter, Cutting Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-116
Tube Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-115
Tube Cutters, Pipe and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Tube, Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-118
Tubing, Beading Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-124
Turnbuckle Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4, F7-8
Type I, Class 1, Style A Torque Wrench - Deflecting Beam with Indicator Plate (Direct Reading) . . . . . . . . . . . . F8-5
Type I, Class 1, Style B Torque Wrench - Deflecting Beam with Indicator Plate (Direct Reading and Feel Impulse
and Audible Signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-6
Type I, Class 2, Style A Torque Wrenches - Deflecting Beam with Indicating Dial (Direct Reading) . . . . . . . . . . F8-7
Type I, Class 2, Style B Torque Wrench - Deflecting Beam with Indicating Dial (Direct Reading with Audible Sig-
nal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-8
Type II Style A Torque Wrench - Rigid Case with Indicator Dial (Direct Reading) . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-9
Type II, Style B Torque Wrench - Rigid Case with Indicator Dial, Presetting Torque Dial (Direct Reading with Audible
Signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-10
Type II, Style C Torque Wrench - Rigid Case with Presetting Dial (Direct Reading with Flashlight Signal) . . . . F8-11
Type III, Class 1 Torque Wrench Rigid Case, Micrometer-Style Torque Presetting, Audible Signal, Plain Head F8-12
Type III, Class 2 Torque Wrench - Rigid Case, Micrometer-Style Torque Presetting, Audible Signal, Ratchet Re-
versible Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-13
Type B-1 Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-1
Type B-4A, Maintenance Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-2
Type D5B Hydraulic Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-5

Index-123
TM 1-1500-204-23-1
Type MB-4 Tow Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-21
Type V Torque Wrench - Rigid Case, Preset Torque, Audible Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-14
Types of Ground Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Types of Tools Used in Army Aviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Types of Torque Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Typical Air Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-14
Typical Aircraft Pre-Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-15
Typical Cable Rigging Tension Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-7
Typical Cranes and Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-18
Typical Drill Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-83
Typical Height Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-51
Typical Paint Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
Typical Rule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-9
Typical Tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-8
Typical Tool Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1

Use of Tap Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-110

Using a Bench Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-54
Using a Crowfoot Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-21
Using a File Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-75
Using a Tensiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-5
Using a Thickness Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-71
Using a Vernier Depth Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-50
Using Carnage Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-56
Using Deicer Boot Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-17
Using Deicer Boot Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-19
Using Drill Grinding Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-89
Using Fillet and Radius Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-74
Using Inside Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-38
Using Inside Micrometer with Extension Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-40
Using Leather Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-18
Using Offset Screwdriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-18
Using Outside Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-39
Using Ring Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-58
Using Thread Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-53
Usual Cutting Edge and Heel Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-86

Index-124
 TM 1-1500-204-23-1
V

V-Grooves in Drill Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-82

Vacuum Cleaner, Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Valve Repair Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6, F7-10
Valve Stem Fishing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5, F7-9
Vernier Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-29
Vernier Caliper, Operation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-31
Vernier Caliper, Reading a Measurement on a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-32
Vernier Depth Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-49
Vernier Depth Gauge, Using a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-50
Vertical Fan, Nozzle Position to Produce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-3
Vise, Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-53
Vise-Grip Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-47

Washer on a Bolt, Installation of Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-32

Washers on a Stud, Installation of Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-31
Washers, Action of Preload Indicating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-30
Washers, Preload Indicating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-29
Washers, Tightening Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-33
Water Pump Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-46
Wedge, Installing Wooden . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-12
Wing Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-22
Wire Gauge, Sheet Metal and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18, F3-72
Wire, Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-112
Wrench Arc, Alternate Method for Tightening to 15 Degree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-25
Wrench Arc, Tightening to 15-Degree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-24
Wrench Arc, Tightening to 30-Degree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-27
Wrench Arc, Tightening to 60- or 120-Degree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-26
Wrench Arc, Tightening to 90- or 180-Degree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-28
Wrench Jaw Offset, Open-End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-21
Wrench, Adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-25

Index-125
TM 1-1500-204-23-1
Wrench, Adjustable Hook Spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-39
Wrench, Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-24
Wrench, Crowfoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-20
Wrench, Face Pin Spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-38
Wrench, Hook Spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-36
Wrench, Open-End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-20
Wrench, Pin Spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-37
Wrench, Torque Multiplier Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Wrench, Turnbuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4, F7-8
Wrench, Use of Box-End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-33
Wrench, Use of Open-End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-32
Wrench, Use of Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-34
Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Wrenches, Box-End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-22
Wrenches, Crowfoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Wrenches, Proper Procedure for Pulling Adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-35
Wrenches, Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-103

Index-126
 TM 1-1500-204-23-1
VOLUME 10

Abrasion Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2l

Acceptability Limits, Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-22
Acceptable Spotweld Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6a
Access Door, Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-8
Acrylic Plastic, Minimum Annealing Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-4
Acrylic Plastics, Drill for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-3
Acrylic Plastics, Oven Temperatures for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-1
Addition of Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4c
Adhesives and Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4e
Combination or Two-Step Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4b
High-Temperature Setting Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4a
Room Temperature Setting Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4c
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4d
After Deburring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-50
Aging Time and Temperature (Aluminum Alloys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7f
Aircraft Mating Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-1
Aircraft Metals, Shaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Aircraft Plastics, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Aircraft Structures, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Airframe Sheet Metal Repair, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Airframe Sheet Metal, Basic Principles of Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Airplane Structural Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-5
Airplanes (Fuselage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Alclad Alloys, Reheat Treatment of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-12
Alclad Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-8
Allowable Percentage of Defective Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6b
Allowance, Bend, 90-Degree Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-3
Allowance, Bend, Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6-1
Alloy Characteristics and Uses (Aluminum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7b
Alloying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4a
Alloying Elements (for Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6b
Alloying Elements, Major . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-5
Alloys, Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Alloys, Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Alloys, Magnesium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Alloys, Metals and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Alloys, Titanium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Alternate Transparent Plastic Plug Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13b
Aluminum Alloy Designations and Conversions to 4 Digit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-6
Aluminum Alloy Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3a
Aluminum Alloy Rivets, Single Shear, Strength of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-2
Aluminum Alloy Sheet Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7i

Index-127
TM 1-1500-204-23-1
Aluminum Alloy, Hardness Conversion for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-16
Aluminum and Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Aging Time and Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7f
Alloy Characteristics and Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7b
Aluminum Alloy Sheet Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7i
Corrosion Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7c
Heat-Treatment Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7e
Heat-Treating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7g
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7a
Insulation of Dissimilar Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7h
Material Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7j
Shop Working Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7d
Aluminum, Bare, Sheet, Plate, Extrusions, and Forgings, Rockwell Hardness Values for . . . . . . . . . . . . . . . . . T5-21
Aluminum Identification Marking Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-7
Aluminum Lockbolt Rivet Gun, Pull- and Blind-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-73
Aluminum Sheet and Plate, 0.050 Inch Minimum, Rockwell Hardness Values for . . . . . . . . . . . . . . . . . . . . . . . . T5-20
Aluminum, Model B, Hardness Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-13
Aluminum-Alloy Sheet Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-14
Annealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10c
Application (of Adhesives and Resins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4e
Approved Edge Attachment for Laminated Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-19
Approved Edge Attachment for Monolithic Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-18
Ashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14b
Assembling (Joined Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9h
Assembly Tools, Cherry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-45
Assembly, Empennage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-14
Automatic Center Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-18
Aviation Snips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4f, F3-12

Balance Considerations, Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Balanced and Unbalanced Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-4
Balancing Jig, Field-Expedient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-6
Balancing Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Effects of Moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3a
Effects of Weight and Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3b
Band Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d
Band Saw, Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-27
Bandsaw Widths for Various Radii of Cuts (of Plastic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-3
Bar Folding Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6a, F3-31
Bars, Bucking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-6
Basic Part Numbers, Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-81
Basic Principles of Repair (of Airframe Sheet Metal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Index-128
 TM 1-1500-204-23-1
Maintaining Original Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2b
Maintaining Original Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2a
Minimizing Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2c
Beaded Skin, Patch Repairs to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-57
Beads, Crimps, Relief Holes, and Riveted Angles, Nose Rib Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-22
Bearing Strength (Pounds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-3
Bench Grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-30
Bench Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4e, F3-11
Bend Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3b
Bend Allowance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6-1
Bend Allowance, 90-Degree Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-3
Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3e, F5-5
Bending Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Bend Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3b
Brake or Sight Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3d
Duplicating Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3g
Flat Pattern Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3e
Locating Brake or Sight Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3f
Radius of Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3a
Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3c
Blanket and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9e
Blind-Type Lockbolt Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-24
Blind-Type Lockbolt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-77
Blind-Type Lockbolts, Drilling Procedures for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-30
Blind-Type Lockbolts, Grip Range for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-27
Block, Bumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-26
Blocks, Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-23
Bolt and Rivet Mounting (on Transparent Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16c
Bolt Installation, Typical (in Transparent Plastic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-17
Bonded Former Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6p
Bonded Former Repair (Cap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-13
Bonded Former Repair (Web) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-14
Bonded Magnesium Panel Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-3
Bonded Magnesium Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6d
Bonded Stiffeners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6c
Bonding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Bonding Procedures for Acrylic Plastic MIL-P-5425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11a
Bonding Procedures for Acrylic Plastic MIL-P-8184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11b
Bonding Procedures for Acrylic Plastic MIL-P-5425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11a
Bonding Procedures for Acrylic Plastic MIL-P-8184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11b
Bowed Steel Tubes, Straightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-64
Box Beam Wing Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-10
Brake Line, Locating, in the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-11
Brake or Sight Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3d, F6-5

Index-129
TM 1-1500-204-23-1
Brake or Sight Line of Flange, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-10
Brake, Cornice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-32
Brass and Mild Steel, Hardness Conversion for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-15
Bucking Bar Weights, Recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-6
Bucking Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-6
Buckles, Working Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-17
Bulkhead and Skin Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-28
Bulkhead Flanged Member Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-26
Bulkhead Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-18
Bulkhead Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9i
Bulkheads, Frames, and Formers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8a
Bumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4a
Bumping Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-26
Bumping, Sandbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-29
Burning (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4b
Burrs After Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-49

Cabin and Tail Cone Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-4

Calculation Method (of Balancing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-8
Camlock Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-107
Camlock Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15b
Camlock Punch, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-109
Camlock Stud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-112
Capacity, Tool, Chart (for Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-14
Catcher Bag, Stem 670A20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-44
Cemented Assemblies, Jigs for Holding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-9
Cemented Joint, Effect of Heat Treating on a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-10
Cemented Plastic Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 10-4
Cementing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9h
Direct Application Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9d
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9e
Glue Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9c
Jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9i
Masking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9f
Soak Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9b
Soaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9g
Type of Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9a
Center Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-17
Center Punch for Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-15
Center Punch, Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-18
Centering Inner Sleeve in Steel Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-68

Index-130
 TM 1-1500-204-23-1
Chamfered Flanging Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-32
Channel Repair by Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-30
Channel Repair by Patching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-29
Channel, Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-6
Characteristics (of Aircraft Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Characteristics (of Titanium Alloys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9b
Chart, Setback - K- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6-2
Chem-Milled Skin Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6k, F8-2
Chem-Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2b
Chemical Composition (Copper Alloys) by Trade Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-16
Chemical Reaction (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4e
Cherry Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-45
Cherry Grip Gauge 269C3, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-36
CherryMax Blind Heads, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-53
CherryMAX Cross Reference (Part Number/Military Standard Part Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-9
CherryMAX Drilling Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-15
CherryMAX Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8e
CherryMAX Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8d
CherryMAX Part Number Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-10
CherryMAX Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8g
CherryMAX Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-55
CherryMAX Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-31
CherryMAX Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
CherryMAX Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8e
CherryMAX Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8d
CherryMAX Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8g
CherryMAX Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8c
CherryMAX Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8f
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8a
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8b
CherryMAX Rivet Shaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-51
CherryMAX Sleeve Stretch Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-54
CherryMAX Stem and Collar Flushness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-52
CherryMAX Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8c
CherryMAX Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8f, T7-17
CherryMAX, Countersinking Dimensions for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-46
Circle Snips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4h, F3-14
Circular Damage Repair for Lightly Stressed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-46
Circular Damage Repair in Heavily Stressed Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-51
Circular External Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8b, F8-11
Clamp Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-9
Classification of Damage (to Sandwich Construction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Coin-Tapping Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5a
Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5e

Index-131
TM 1-1500-204-23-1
Double Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5h
Large Single Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5g
Missing Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5b
Scotchply Edge Member and Corfil Edge Filler Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5i
Skin Core Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5c
Skin Doubler Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5d
Small Single Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5f
Unbonding and Ply Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5j
Class I Damage (of Fiber Laminate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-19
Class I Repair (of Radomes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9i
Class II Damage (of Fiber Laminate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-20
Class II or Class III Repair to Plastic with Fluted Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9m
Class II or Class III Repair to Plastic with Foamed-In Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9l
Class II Repair (of Radomes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9j
Class II Repair (of Radomes), Typical Scarf Method for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-26
Class III Damage (of Fiber Laminate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-21
Class III Repair (of Radomes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9k
Classes of Repair (of Fiber Laminate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9c
Classification of Damage (Impregnated Glass Cloth Parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8a
Classification, of Damage (Airframe Sheet Metal Repair) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Cleaning (of Glass Windshields) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17b
Cleaning (Plastic Enclosures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15a
Cleanliness of Repair Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6a
Cleco Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7
Cleco Fasteners Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-8
Codes, Color (for Aluminum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-7
Coin Dimpling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-10
Coin-Tapping Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5a
Cold Climate Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 5e
Cold Forming (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7a
Cold-Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5c
Collar Numbering System, Lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-25
Color Codes (for Aluminum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-7
Combination or Two-Step Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4b
Commonly Used Alloys (Magnesium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8b
Completed Double Face Patch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-27
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-2
Compressive Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2c
Concave Flange, Forming a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-24
Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2m
Construction (Sandwich) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1a
Construction Materials (Fuselage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Construction, Alclad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-8
Construction, Monocoque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1

Index-132
 TM 1-1500-204-23-1
Construction, Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-13
Construction, Semi-Monocoque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Construction, Spar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-12
Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Contour Band Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-27
Contraction and Expansion Allowances (for Transparent Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-5
Control Surface, Establishing Neutral Position of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-7
Control Surfaces, Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7, F4-16
Control Surface Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-1
Conversions to 4 Digit System, Aluminum Alloy Designations and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-6
Convex Flange, Forming a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-25
Copper and Copper Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10a
Major Alloying Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10b
Copper, Model BB-75, Hardness Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-14
Core Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Foamed-In-Place Core Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2c
Foamed or Cellular Core Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2b
Honeycomb Core Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2d
Natural Core Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2a
Cornice Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6b, F3-32
Correcting Oval Shaped Steel Tubing Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-63
Correctly and Incorrectly Driven Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5a, F7-20
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3a
Corrosion Resistance (of Aluminum Alloys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7c
Corrosion Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2k
Corrosion Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6h
Countersink, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-7
Countersink, Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-8
Countersinking Dimensions (100 Degrees) for CherryMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-46
Countersinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-17
Countersinking Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-18
Countersinking, Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-47
Countersinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4i, F3-15
Countersinks for Shaving, Recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-16
Countersunk Head Nominal Diameter CherryMAX Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-32
Countersunk Head Oversize Diameter, CherryMAX Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-34
Countersunk Head Rivet, Removal of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-24
Countersunk-Head Rivet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6b
Crack or Scratch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-5
Crack Repair for Lightly Stressed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-47
Cracking, Rivet Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-21
Cracks (in Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12d

Index-133
TM 1-1500-204-23-1
Crazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12c
Crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64b, F6-12
Crimps and Beads, Nose Rib with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-21
Cross Reference of Old and New Color Code (for Aluminum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-8
Cross Reference, Old Color Code (Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-3
Cross Reference, CherryMAX (Part Number/Military Standard Part Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-9
Curing and Heat Treatment (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Annealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10c
Further Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10b
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10a
Curved Formed or Extruded Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5b
Cushion Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-8
Cushion, Formation of, on Acrylic Plastic by Immersion in Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-5
Cutout Repair, Rectangular Damage (Lightly Stressed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-44
Cutting Acrylic Plastic Sheets, Types of Circular Saw Blades for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-2
Cutting Techniques (for Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8f
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8a
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8b
Routers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8d
Saws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8c
Scribing and Sanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8a

Damage (to Sandwich Construction), Classification of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Damage Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Damage Repairable by Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5c
Damage Repairable by Patching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5b
Damage Requiring Replacement of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5d
Negligible Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5a
Damage Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6b
Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Damage Near Existing Structure (Lightly Stressed), Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-45
Damage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6c
Damage Repair (Impregnated Glass Cloth Parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8b
Damage Repair Near Adjacent Member in Heavily Stressed Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-52
Damage Repair Near Existing Structure in Heavily Stressed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-49
Damage Repair Near Primary Horizontal Member in Heavily Stressed Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-50
Damage Repairable by Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5c
Damage Repairable by Patching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5b
Damage Requiring Replacement of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5d
Damage, Class I (of Fiber Laminate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-19
Damage, Class II (of Fiber Laminate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-20

Index-134
 TM 1-1500-204-23-1
Damage, Class III (of Fiber Laminate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-21
Damaged Face Plies, Removal of, by Scarf Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-25
Damaged Honeycomb Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-1
Damaged Swage in Aileron and Flap Skin, Patch Repair to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-58
Deburring, After . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-50
Deep Scratches, Sanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-11
Delamination and Discoloration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12e
Dent at a Steel Tube Cluster Joint, Reinforcing a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-65
Dent or Crack, Sharp, in Length of Steel Tubing, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-66
Dents (in Sandwich Construction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5e
Dents and Creases, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-32
Design (Sandwich Construction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 b
Determining Rivnut Grip Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-57
Die, Joggling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-30
Dimensions, Drill Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-16
Dimpling and Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-48
Dimpling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-9
Dimpling, Coin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-10
Direct Application Method (Cementing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9d
Double Face Patch Repair, Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-27
Double Row of Rivets, Rivet Spacing for Repair with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-42
Double Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5h
Double Skin Repair (Flush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-10
Double Skin Repair (Nonflush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-11
Drill Angle for Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-1
Drill Bit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-16
Drill for Acrylic Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-3
Drill Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-29
Drill Sizes for Various Diameter Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-4
Drill Sizes, Hole and, for Self-Plugging (Friction Lock) Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-8
Drilling (for Olympic Blind Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11d
Drilling (Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8f
Drilling Dimensions, CherryMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-15
Drilling Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-68
Drilling Procedures for Blind-Type Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-30
Drilling Procedures for Pull- and Stump-Type Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-29
Drilling Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Drilling, Burrs After . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-49
Drilling, Center Punch for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-15
Drills and Drill Presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5e
Drive Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-19
Driving Hi-Shear Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-63
Ductility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2f

Index-135
TM 1-1500-204-23-1
Duplicating Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3g
Dynamic Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2b
Dzus Fastener (Stud, Grommet, and Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-95
Dzus Fastener (Stud, Grommet, and Receptacle), Installation Tools for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-104
Dzus Fastener (Stud, Grommet, and Spring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-96
Dzus Fastener Head Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-97
Dzus Fastener Installation Secondary Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-103
Dzus Fastener Installation, Wing-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-102
Dzus Fastener Receptacle, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-105
Dzus Fastener Stud and Grommet, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-106
Dzus Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15a
Dzus Fasteners, Installation of Type A-AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-100
Dzus Fasteners, Installation of Type F-FA-FJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-101
Dzus Fasteners, Installation Tools for Type A-AJ and F-FA-FJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-98

Edge Attachment, Typical Sighting Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-20

Edge Band Sealing, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-29
Edge Distance, Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-4
Edge Preparation, Edge Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-6
Effect of Heat Treating on a Cemented Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-10
Effects of Moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3a
Effects of Weight and Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3b, F11-3
Elasticity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2d
Eliminating Gaps and Leveling Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9aa, F8-59
Empennage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Empennage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-14
Enclosure, Laminated, Approved Edge Attachment for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-19
Enclosure, Monolithic, Approved Edge Attachment for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-18
Enclosures, Acrylic Plastic, Maintenance of on Army Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Engine Mount (Tubing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11a
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-6
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c
Piston-Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a
Turbine-Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b
Equipment, Shop (Sheet Metal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2, 3-1
Establishing Neutral Position of a Control Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-7
Example of Structural Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-62
Expansion and Contraction Allowances (for Transparent Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-5
Expansion and Contraction Allowances (of Transparent Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16b
External and Internal Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
External Repair, Circular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-11

Index-136
 TM 1-1500-204-23-1
F

Face Plies, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-24

Facing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Aluminum Alloy Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3a
Glass Fiber Mat Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3f
Magnesium Alloy Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3c
Plywood Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3d
Resin-Impregnated Glass Cloth Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3e
Steel Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3b
Factors in Determining Rivet Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-3
Failure, Spotweld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Failure, Spotweld, with No Skin Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Fastener, Camlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-107
Fastener, Cleco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7
Fastener, Dzus (Stud, Grommet, and Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-95
Fastener, Dzus (Stud, Grommet, and Spring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-96
Fastener, Dzus, Head Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-97
Fasteners, Hi-Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Fasteners, Turn-Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Fiber Laminate Material Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Blanket and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9e
Class I Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9i
Class II Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9j
Class II or Class III Repair to Plastic with Foamed-In Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9l
Class II or Class III Repair to Plastic with Fluted Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9m
Class III Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9k
Classes of Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9c
General Principles of Materials and Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9d
General Repair Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9g
General Repair Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9a
Inspection after Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9r
Materials Used in Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9b
Parting Films and Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9f
Procedure for Edge Band Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9q
Procedure for Obtaining Void-Free Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9p
Procedure for Preventing Moisture and Oil Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9o
Repair of Pre-Drilled Attachment Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9n
Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9h
Field-Expedient Balancing Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-6
Finishing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Ashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14b
Machine Buffing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14c
Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14d
Sanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14a
First Flange, Layout of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-7

Index-137
TM 1-1500-204-23-1
Fishmouth Splice, Steel Tube, Using Large Diameter Replacement Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-70
Fitting (Cementing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9e
Flanged Member Repair, Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-26
Flanging Block, Chamfered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-32
Flat Pattern Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3e
Flexing (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4d
Flight Control Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7, F4-16
Floor Channel Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9o, F8-36
Floor Repair, Metal-Covered Wooden . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Flush Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-8
Flush Head Jo-Bolts, Grip Ranges, Sizes, and Diameters of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-83
Flush Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-5
Flush Patch Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-7
Flush-Head Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-78
Foamed or Cellular Core Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2b
Foamed-In-Place Core Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2c
Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4e
Forces, Stress and Strain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Forgings, Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-21
Formation of Cushion on Acrylic Plastic by Immersion in Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-5
Formed Angle, Stringer Repair with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-17
Formed Patch, Rivet Spacing for Repair Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-43
Formed Sections (of Stored Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5d
Former and Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17
Former Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9h, F8-25
Former Repair, Bonded (Cap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-13
Former Repair, Bonded (Web) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-14
Former, Slip Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-33
Forming (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Forming (of Aircraft Metals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2a
Forming a Concave Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-24
Forming a Convex Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-25
Forming a Flanged Angle by Shrinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-16
Forming a Flanged Angle by Stretching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-18
Forming Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4k, F3-23
Forming Blocks, Metal and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-23
Forming by Bumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5e
Forming Curved Flanged Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5d
Forming Flanged Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5c
Forming Methods (for Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7d
Forming of Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Cold Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7a
Forming Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7d
Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7c

Index-138
 TM 1-1500-204-23-1
Heating for Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7b
Forming Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46-4
Bumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4a
Crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4b
Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4e
Shrinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4d
Stretching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4c
Forming Procedures, Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Forms (for Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7c
Frame and Former Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17
Frame and Nonstressed Skin Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-38
Frame and Skin Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-27
Frame and Stringer Joint, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-35
Friction Lock (Self-Plugging Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Further Treatment (of Heat-Treated Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10b
Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2b
Construction Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2c
Helicopters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a

Gauge, Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6

General Precautions (Cutting Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8a
General Principles of Materials and Repair Procedures (with Fiber Laminate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9d
General Repair Consideration (for Radome Repair) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9g
General Repair Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Chem-Milled Skin Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6k
Corrosion Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6h
Damage Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6b
Damage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6c
Repair Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6d
Repair Parts Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6e
Rivet Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6f
Rivet Spacing and Edge Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6g
Riveting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6i
Structural Support During Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6a
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6j
General Repair Requirements (Fiber Laminate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9a
General Shop Rules (Sheet Metal Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1a
Shop Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1b
Shop Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1c

Index-139
TM 1-1500-204-23-1
Shop Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1d
General, Aircraft Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
General, Aircraft Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General, Airframe Sheet Metal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
General, Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General, Rebalancing Movable Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
General, Rivets and Riveting Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General, Sandwich Construction Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
General, Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General, Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
General, Structural Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Glass Cloth Repair of Lack-of-Material Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-18
Glass Cloth Repair of Large Crack or Perforation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-17
Glass Cloth Repair of Small Crack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-16
Glass Fiber Mat Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3f
Glass Windshields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17b
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17a
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17c
Glue Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9c
Grinder, Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-30
Grinding and Sanding Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5f
Grip Lengths for Solid Shank Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-1
Grip Lengths, Hi-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-90
Grip Lengths, Jo-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-82
Grip Range (CherryMAX Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-11
Grip Range (Olympic Blind Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11b
Grip Range for Blind-Type Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-27
Grip Range for Olympic Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-20
Grip Range for Pull- and Stump-Type Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-26
Grip Ranges, Sizes, and Diameters of Flush Head Jo-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-83
Grip Ranges, Sizes, and Diameters of Hex Head Jo-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-84
Grip Ranges, Sizes, and Diameters of Millable Hex Head Jo-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-85

Hammers, Peening with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-110

Hand Forming Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Curving Formed or Extruded Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5b
Forming by Bumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5e
Forming Curved Flanged Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5d
Forming Flanged Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5c

Index-140
 TM 1-1500-204-23-1
Joggling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5f
Lightening Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5h
Relief Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5g
Straight Line Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5a
Hand Router Template for Milling Plug Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-15
Hand Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4d, F3-10
Hand Tools (for Riveting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4a
Hand-Type Tester, Webster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-10
Handling and Storage (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Hand Tools and Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Aviation Snips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4f
Bench Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4e
Circle Snips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4h
Countersinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4i
Forming Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4k
Hand Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4d
Micrometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
3-43-4Punches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4j
Radius Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b
Sheet Metal Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4c
Straight Snips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hardness Conversion for Aluminum Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-16
Hardness Conversion for Brass and Mild Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13e
Hardness Conversion for Brass and Mild Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-15
Hardness Range (for Aluminum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13c
Hardness Range (for Copper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13d
Hardness Range, Aluminum, Model B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-13
Hardness Range, Copper, Model BB-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-14
Hardness Tester, Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-12
Hardness Testing of Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Hardness Conversion for Brass and Mild Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13e
Hardness Range for Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13c
Hardness Range for Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13d
Hardness Values for Clad Aluminum Sheet and Plate, and Bare Aluminum Sheet, Plate, Extrusions, and Forg-
ings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13f
Rockwell Hardness Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13b
Webster Hardness Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13a
Hardness Values, Rockwell, for 0.050 Inch Minimum Thickness Class Aluminum Sheet and Plate . . . . . . . . . T5-20
Hardness Values, Rockwell, for Bare Aluminum Sheet, Plate, Extrusions, and Forgings . . . . . . . . . . . . . . . . . . T5-21
Hardness Values for Clad Aluminum Sheet and Plate, and Bare Aluminum Sheet, Plate, Extrusions, and Forg-
ings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13f
Hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2i
Hat and Longeron Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-21

Index-141
TM 1-1500-204-23-1
Hat Sect ion, Splice Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-37
Hatch Seal, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-60
Head Radius, Hi-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-92
Head Types (Jo-Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13a
Heat Treating (Soaking) Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-10
Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cold-Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5c
Hot Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5b
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5a
Heat Treatment, Curing and (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Heat-Treatable Rivet Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-9
Heat-Treatment Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7e
Heat-Treatment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7g
Heating for Forming (Acrylic Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7b
Heavily Stressed Area, Circular Damage Repair in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-51
Heavily Stressed Area, Damage Repair Near Adjacent Member in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-52
Heavily Stressed Area, Insertion Skin Repair Across Stiffeners in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-53
Heavily Stressed Areas, Damage Repair Near Existing Structure in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-49
Heavily Stressed Areas, Rectangular Damage Repair for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-48
Helicopter Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15
Helicopters (Fuselage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a
Hex Head Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-79
Hex Head Jo-Bolts, Grip Ranges, Sizes, and Diameters of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-84
Hi-Lok Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Hole Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14c
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14a
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14f
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14e
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-149
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14b
Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14d
Hi-Lok Grip Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-90
Hi-Lok Head Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-92
Hi-Lok Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-93
Hi-Lok Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-32
Hi-Lok Protrusion Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-94
Hi-Shear Rivet Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-64
Hi-Shear Rivet Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-60
Hi-Shear Rivet Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-61
Hi-Shear Rivet, Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-63
Hi-Shear Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10a
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10e
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10d

Index-142
 TM 1-1500-204-23-1
Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10c
Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10f
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10b
Hi-Shear Rivets, Removal of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-65
High-Temperature Setting Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4a
Hold-Down Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-28
Hole and Drill Sizes for Self-Plugging (Friction Lock) Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-8
Hole Finder, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-10
Hole Preparation (for Hi-Lok Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14c
Hole Preparation (for Jo-Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13e
Hole Size Limits (Olympic Blind Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11c
Hole Size Limits for Olympic Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-21
Hole Sizes and Countersink Diameters, Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-31
Holes, Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-31
Honeycomb Core Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2d
Honeycomb Panel Edge, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-12
Honeycomb Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-2
Honeycomb Skin, Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-1
Hot Climate Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15d
Hot Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5b
Huck Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12d
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12h
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12g
Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12f
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12b
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12i
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12e
Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12c
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12a

Identification and Types (of Aircraft Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Identification Marking Code (Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-2
Identification of Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7a
Identification of CherryMAX Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8a
Identification of Copper Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10a
Identification of Hi-Lok Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14a
Identification of Hi-Shear Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10a
Identification of Huck Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12d
Identification of Inconel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12a, T5-18
Identification of Jo-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13b
Identification of Magnesium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8a

Index-143
TM 1-1500-204-23-1
Identification of Monel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 a, T5-17
Identification of Olympic Blind Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 a
Identification of Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9a
Identification of Self-Plugging Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7a
Identification of Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6a
Identification of Terms and Symbols (Balancing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-2
Identification of Titanium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9a
Identification, Penetrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-11
Inconel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12a
Methods for Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12b
Inconel, Identification of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-18
Incorrect Countersinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-47
Industrial Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4b
Inner Sleeve in Steel Tube, Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-68
Inner Sleeve Splice, Steel Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-67
Insertion Skin Repair Across Stiffeners in Heavily Stressed Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-53
Inspection after Repair (of Radomes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9r
Inspection of Glass Windshields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17a
Inspection of Hi-Lok Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14f
Inspection of Hi-Shear Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10e
Inspection of Huck Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12h
Inspection of Jo-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13h
Inspection of Olympic Blind Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11f
Inspection of Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Inspection of Self-Plugging Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7f
Inspection, Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Inspection, Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Installation Considerations (for Transparent Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16a
Installation of Blind-Type Lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-77
Installation of Dzus Fastener Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-105
Installation of Dzus Fastener Stud and Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-106
Installation of Hi-Lok Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14e
Installation of Huck Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12g
Installation of Jo-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13g
Installation of Olympic Blind Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11e
Installation of Olympic Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-70
Installation of Pull-Type Lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-75
Installation of Stump-Type Lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-76
Installation of Type A-AJ Dzus Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-100
Installation of Type F-FA-FJ Dzus Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-101
Installation Procedure, Rivnut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-59
Installation Procedures for Hi-Shear Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10d
Installation Procedures for Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9d

Index-144
 TM 1-1500-204-23-1
Installation Procedures for Self-Plugging Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7e
Installation Tools for Dzus Fastener (Stud, Grommet, and Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-104
Installation Tools for Hi-Shear Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10c
Installation Tools for Huck Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12f
Installation Tools for Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9c
Installation Tools for Self-Plugging Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7d
Installation Tools for Type A-AJ and F-FA-FJ Dzus Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-98
Installation Tools, Rivnut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-58
Installation Tools, Self-Plugging Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-28
Installation, Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-18
Installation, Hi-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-93
Installation, Self-Plugging Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-29
Insulation of Dissimilar Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7h
Internal and External Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Bulkhead Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9i
Eliminating Gaps and Leveling Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9aa
Floor Channel Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9o
Former Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9h
Longeron Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9b
Longitudinal Skin Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9r
Nonstressed Skin and Frame Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9q
Patch Repair to Damaged Swage in Aileron and Flap Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9z
Patch Repairs to Beaded Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9y
Repair for Damaged Skin Close to a Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9x
Repair of C rack by Stop-Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9k
Repair of Damaged Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9j
Repair of Damaged Frame or Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9m
Repair of Dents and Creases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91
Repair of Heavily Stressed Support and Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9v
Repair of Frame and Stringer Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9n
Rib Repair by Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9g
Rib Repair by Patching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9f
Rivet Spacing, Selection and Acceptability Limits for a Nonstressed Skin Patch . . . . . . . . . . . . . . . . . . . . . . . . . 8-9t
Skin and Web Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9u
Spar Angle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9d
Spar Repair by Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9c
Spar Web Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9e
Splice Repair of Hat Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9p
Stressed Skin Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9w
Stringer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9a
Transverse Skin Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9s
Internal Construction, Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b, F4-11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Index-145
TM 1-1500-204-23-1
J

J-Section Stringer Splice Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-16

Jigs (Cementing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9i
Jigs for Holding Cemented Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-9
Jo-Bolt Basic Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-81
Jo-Bolt Grip Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-82
Jo-Bolt Hole Sizes and Countersink Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-31
Jo-Bolt Stem Break-Off Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-87
Jo-Bolt Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-86
Jo-Bolt, Flush-Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-78
Jo-Bolt, Hex Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-79
Jo-Bolt, Hex Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-80
Jo-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Head Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13a
Hole Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13e
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13b
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13h
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13g
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13i
Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13c
Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13f
Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13d
Joggling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5f
Joggling Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-30
Joint Allowable Loads (Pounds) Per MIL-HDKB-5 (Rivet) Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-13

Ketts Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b, F3-25

Lacing Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-12

Lack-of-Material Damage, Glass Cloth Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-18
Lap or Scab Patch (Crack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-3
Lap or Scab (Hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-4
Lap Patch Edge Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7d
Lap Patch Edge Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-6
Large Crack or Perforation, Glass Cloth Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-17
Large Single e Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-59
Layout (for Cutting Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8b
Layout of First Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-7
Layout of Third Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-9
Layout of Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-8
Layout, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Leveling Installations, Eliminating Gaps and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-59

Index-146
 TM 1-1500-204-23-1
Lightening Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5h
Lightly Stressed Areas, Circular Damage Repair for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-46
Lightly Stressed Areas, Crack Repair for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-47
Lightly Stressed Areas, Crack Repair for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2e
Loads, Joint Allowable, (Pounds) Per MIL-HDBK-5 (Rivet) Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-13
Locating Brake Line in the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-11
Locating Brake or Sight Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3f
Locating Brake or Sight Line of Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-10
Location (of Stored Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5a
Lockbolt Collar Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-25
Lockbolt, Blind-Type, Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-24
Lockbolt, Pull-Type, Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-22
Lockbolt, Stump-Type, Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-23
Lockbolts, Huck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Lockbolts, Types of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-72
Longeron and Hat Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-21
Longeron and Stringer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-19
Longeron Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9b
Longitudinal Skin Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9r, F8-39
Loose Jo-Bolt, Removal of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-89

Machinability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2j
Machine Buffing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14c
Machine Screw Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-14
Machine Screw Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-13
Machine, Bar Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-31
Magnesium Alloy Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3c
Magnesium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Commonly Used Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8b
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8a
Methods of Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8c
Maintaining Original Contour (Airframe Sheet Metal Repair) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2b
Maintaining Original Strength (Airframe Sheet Metal Repair) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2a
Maintenance of Acrylic Plastic Enclosures on Army Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15a
Cold Climate Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15e
Hot Climate Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15d
Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15b
Waxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15c
Maintenance of Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3c
Maintenance of Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Major Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b

Index-147
TM 1-1500-204-23-1
Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Storage of Tools, Equipment, and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c
Major Alloying Elements (for Copper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10b
Major Alloying Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-5
Major Repair (of Shop Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Malleability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2g
Marking Code (Steel), Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-2
Marking Example, Aluminum Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-7
Marking Example, Steel Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-6
Masking (Cementing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9f
Masking (Paper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6a
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6b
Masking Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5c
Material Substitution (of Metals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7j
Material Thickness Variation (and Hi-Lok Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-91
Material, Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-68
Material, Patch, Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-5
Materials (Huck Lockbolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12b
Materials and Use (Solid Shank Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2a
Materials Used In Repair (of Fiber Laminate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9b
Materials, Core (Sandwich Construction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Materials, Facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Materials, Substitute (Aluminum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-15
Mating Jig, Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-1
Members, Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Metal and Forming Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-23
Metal Forming Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Bar Folding Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6a
Cornice Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6b
Shrinking and Stretching Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6d
Slip Roll Former . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c
Metal-Covered Wooden Floor Panels, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-15
Metal-Covered Wooden Floor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Negligible Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7a
Patching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7b
Metals and Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Alloying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4a
Industrial Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4b
Preparing Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4c
Metals, Hardness Testing of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Metals, Properties of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Method, Calculation (of Balancing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-8
Method, Lacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-12

Index-148
 TM 1-1500-204-23-1
Method, Scale (of Balancing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-9
Method, Soak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-6
Methods (of Rebalancing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4b
Methods for Working (of Inconel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12b
Methods for Working and Uses (of Monel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 b
Methods of Working (Magnesium Alloys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8c
Methods of Working (Titanium Alloys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9c
Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Micrometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4a
Microshaver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-14
Military Specification Number (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104a
Millable Hex Head Jo-Bolts, Grip Ranges, Sizes, and Diameters of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-85
Millable Hex Head Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-80
Minimizing Weight (Airframe Sheet Metal Repair) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2c
Minimum Annealing Time for Acrylic Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-4
Minimum Rivet Edge Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-1
Minimum Rivet Shear and Tensile Strength (Pounds) in Steel Coupons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-12
Missing Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5b
Modern Use (Sandwich Construction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1c
Moisture and Contamination, Preventing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-28
Monel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 a
Methods for Working and Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 b
Monel, Identification of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-17
Monocoque Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-1
Monospar Wing Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Mount, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-6
Mounts, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
MS 20600 Protruding-Head Rivet Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-26
MS 20601 Countersunk-Head Rivet Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-27
Multispar Wing Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-9

Nacelle Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-7

Nacelles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Natural Core Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2a
Nearest Corresponding Numbers, Specifications, Cross Reference of (Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-4
Negligible Damage (of Metal-Covered Wooden Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7a
Negligible Damage (to Airframe Sheet Metal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5a
Neutral Axis and Stresses Resulting from Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-2
Nicks and Dents (in Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12a
Nominal Diameter, Countersunk Head, CherryMAX Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-32
Nominal Diameter, Protruding Head, CherryMAX Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-33

Index-149
TM 1-1500-204-23-1
Non-Destructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3f
Non-Powered Metal Cutting Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Rotary Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3d
Scroll Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b
Squaring Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a
Throatless Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3c
Nonstressed Frame Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-33
Nonstressed Skin and Frame Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9q, F8-38
Nose Rib Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-22
Nose Rib Using Beads, Crimps, Relief Holes, and Riveted Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-22
Nose Rib with Crimps and Beads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-21
Nose Rib with Relief Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-20
Nose Rib, Plain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-19
Numbering System, Hi-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-32

Old and New Color Code (for Aluminum), Cross Reference of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-8
Old Color Code (Steel) Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-3
Olympic Blind Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11d
Grip Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11b
Hole Size Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11c
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11a
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11f
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11e
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11g
Olympic Rivet Grip Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-67
Olympic Rivet Material Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-18
Olympic Rivet Part Number Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-19
Olympic Rivet Pulling Head Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-69
Olympic Rivet Stem Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-66
Olympic Rivet, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-71
Olympic Rivets, Grip Range for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-20
Olympic Rivets, Hole Size Limits for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-21
Olympic Rivets, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-70
Open and Closed Skin Area Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7b
Operations, Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Operator Maintenance, (Sheet Metal) Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Optical Quality (of Aircraft Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Outer Sleeve Splice, Steel Tube Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-69
Oven Temperature for Acrylic Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-1
Overlay Patch to Reinforce a Crack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-16
Oversize Diameter, Countersunk Head, CherryMAX Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-34

Index-150
 TM 1-1500-204-23-1
Oversize Diameter, Protruding Head, CherryMAX Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-35

Pan Void, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-7

Panel Repair, Bonded Magnesium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-3
Part Number Breakdown, CherryMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-10
Part Number Cross Reference, Olympic Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-19
Parting Films and Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9f
Parts Repair, Spotwelded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Patch Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-5
Patch Repairs to Beaded Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9y, F8-57
Patch Repair to Damaged Swage In Aileron and Flap Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9z, F8-58
Plywood Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3d
Patch, Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-5
Patch, Flush, Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-7
Patch, Machine Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-14
Patch, Overlay, to Reinforce a Crack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-16
Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7a
Patching (of Metal-Covered Wooden Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7b
Patching Procedures (for Metal-Covered Wooden Floors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7c
Patching Procedures (for Acrylic Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Alternate Transparent Plastic Plug Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13b
Transparent Overlay Plastic Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13c
Transparent Plastic Plug Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13a
Peening with Hammers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-110
Penetrator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-11
Pin Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-20
Piston-Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3a
Plain Nose Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-19
Plastic Joint, Cemented . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-4
Plastics, Forming of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Plate, Hold-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-28
Pliers and Strip Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-111
Pliers, Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-9
Pliers, Cleco Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-8
Plies and Core, Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-23
Pneumatic Rivet Gun Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-12
Pneumatic Rivet Gun, Riveting Procedures Using a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-19
Pneumatic Rivet Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-11
Polishing (of Acrylic Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14d, 10-15b
Portable Power Drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-28
Position (of Stored Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5b
Power Drills, Portable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-28

Index-151
TM 1-1500-204-23-1
Power Tools (for Riveting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4b
Powered Metal Cutting Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Band Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d
Drills and Drill Presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5e
Grinding and Sanding Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5f
Ketts Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5b
Reciprocating Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5a
Practices, Countersinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-18
Precipitation (Aging) Treating Temperatures, Times, and Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-9
Preparing Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4c
Preparing Materials for Spotwelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6d
Press, Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-29
Preventing Moisture and Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-28
Prick Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-16
Primary Horizontal Member in Heavily Stressed Area, Damage Repair Near . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-50
Principles, Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Procedure for Edge Band Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9q
Procedure for Obtaining Void-Free Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9p
Procedure for Preventing Moisture and Oil Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90
Procedures, Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Procedures, Cementing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Procedures, Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Procedures, Patching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Properties of Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Abrasion Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Compressive Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2c
Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2m
Corrosion Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2k
Ductility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2f
Elasticity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2d
Hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2i
Linear Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2e
Machinability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2j
Malleability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2g
Shear Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2b
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2n
Tensile Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2a
Toughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2h
Protective Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3e
Protruding Head Nominal Diameter CherryMAX Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-33
Protruding Head Oversize Diameter CherryMAX Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-35
Protruding Head Rivets, Removal of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6a, F7-23
Protrusion Limits, Hi-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-94

Index-152
 TM 1-1500-204-23-1
Pull- and Blind-Type Aluminum Lockbolt Rivet Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-73
Pull- and Blind-Type Steel Lockbolt Rivet Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-4
Pull- and Stump-Type Lockbolts, Drilling Procedures for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-29
Pull- and Stump-Type Lockbolts, Grip Range for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-26
Pull-Type Lockbolt Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-22
Pull-Type Lockbolt, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-75
Punch, Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-17
Punch, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-19
Punch, Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-20
Punch, Prick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-16
Punch, Rotary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
Punch, Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-21
Punches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4j
Purposes (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Quality Assurance for Repair (of Sandwich Construction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6q

Quality, Optical (of Aircraft Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Quency Delay, Recommended Maximum, Wrought Alloys (for Immersion Type Quenching) . . . . . . . . . . . . . . T5-13

Radii of Cuts (of Plastic), Various, Bandsaw Widths for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-3

Radius Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4b, F3-6
Radius of Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3a
Range, Grip (CherryMAX Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-11
Reaming, Dimpling and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-48
Rebalancing Movable Surfaces, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Reciprocating Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5c, F3-26
Recommended Bucking Bar Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-6
Recommended Countersinks for Shaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-16
Recommended Installation Procedures for Transparent Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Bolt and Rivet Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16c
Expansion and Contraction Allowances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16b
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16a
Recommended Maximum Quench Delay, Wrought Alloys (for Immersion Type Quenching) . . . . . . . . . . . . . . . T5-13
Rectangular Damage Cutout Repair (Lightly Stressed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-44
Rectangular Damage Repair for Heavily Stressed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F848
Reheat Treatment of Alclad Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-12
Reinforced Shell Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Reinforcing a Dent at a Steel Tube Cluster Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-65
Relief Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59, F6-31
Relief Holes, Nose Rib with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-20

Index-153
TM 1-1500-204-23-1
Removal (of Hi-Lok Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14g
Removal (of Huck Lockbolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12i
Removal (of Jo-Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13i
Removal (of Masking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6a
Removal (of Olympic Blind Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11g
Removal and Installation (of Glass Windshields) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17c
Removal of Countersunk Head Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-24
Removal of Damaged Face Plies by Scarf Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-25
Removal of Hi-Shear Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-65
Removal of Loose Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-89
Removal of Protruding Head Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-23
Removal of Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Removal of Self-Plugging Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-30
Removal of Tightly Installed Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-88
Removal Procedures (Hi-Shear Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10f
Removal Procedures (Rivnuts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9e
Removal Procedures (Self-Locking Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7g
Removal, CherryMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-55
Removing Damaged Face Plies Using Step Joint Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-22
Removing Olympic Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair by Insertion, Stringer, When Damage Affects More than One Stringer . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-15
Repair by Insertion, Stringer, When Damage Affects Only One Stringer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-14
Repair by insertion, Stringer, When Damage Exceeds Two Thirds of One Leg in Width . . . . . . . . . . . . . . . . . . . F8-13
Repair by Patching, Stringer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-12
Repair for Damaged Skin Close to a Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9x, F8-56
Repair for Heavily Stressed Support and Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-54
Repair for Short Edge Distance and Broken Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F12-7
Repair Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Rivet Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3a
Rivet Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3c
Rivet Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3b
Rivet Substitutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3d
Repair Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6d
Repair Methods for Specified Defects (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12d
Crazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12c
Delamination and Discoloration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12e
Nicks and Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12a
Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12b
Repair of Cracks by Stop-Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9k, F8-31
Repair of Damage Near Existing Structure (Lightly Stressed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-45
Repair of Damaged Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9j
Repair of Damaged Frame or Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9m
Repair of Defective Spotwelds Exceeding Allowable Percentage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6c

Index-154
 TM 1-1500-204-23-1
Repair of Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6i
Repair of Dents and Creases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91, F8-32
Repair of Double-Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6m
Repair of Frame and Stringer Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9n, F8-35
Repair of Heavily Stressed Support and Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9v
Repair of Honeycomb Panel Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-12
Repair of Honeycomb Panel Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
Repair of Impregnated Glass Cloth Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Repair of Large, Single-Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-61
Repair of Metal-Covered Wooden Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-15
Classification of Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8a
Damage Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8b
Repair of Missing Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6f
Repair of Pan Void . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-7
Repair of Pre-Drilled Attachment Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9n
Repair of Sandwich Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Bonded Former Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6p
Bonded Magnesium Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6d
Bonded Stiffeners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6c
Cleanliness of Repair Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6a
Quality Assurance for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6q
Repair of Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6i
Repair of Double-Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6m
Repair of Honeycomb Panel Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
Repair of Large, Single-Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-61
Repair of Missing Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6f
Repair of Scotchply Edge Member and Corfil Edge Filler Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6n
Repair of Skin Core Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6g
Repair of Skin Doubler Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6h
Repair of Skin Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6e
Repair of Small, Single-Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6j
Repair of Small, Single-Skin Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5f
Sample Honeycomb Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6b
Repair of Scotchply Edge Member and Corfil Edge Filler Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6n
Repair of Sharp Dent or Crack in Length of Steel Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-66
Repair of Skin Core Doubler Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6h
Repair of Skin Core Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6g, F9-6
Repair of Skin Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6e
Repair of Small, Single-Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6j
Repair of Small, Single-Skin Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6k
Repair Parts Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6e
Repair Practices, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Repair Procedures (for Radome Repair) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Repair, Channel, by Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-30

Index-155
TM 1-1500-204-23-1
Repair, Channel, by Patching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-29
Repair, Floor Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-36
Repair, Former . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-25
Repair, Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-2
Repair, Machine Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-13
Repair, Nonstressed Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-33
Repair, Nose Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-22
Repair, Rib, by Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-24
Repair, Spar Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-20
Repair, Spar, by Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-19
Repair, Stressed Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-34
Repair, Trailing Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-4
Repair, Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Repair, Wing Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-23
Repairing Aluminum Alloy Parts, Rivet Selection and Spacing When . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-2
Repairing Corrosion-Resistant Steel Parts, Rivet Selection and Spacing When . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-3
Repairing Magnesium Alloy Parts, Rivet Selection and Spacing When . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-4
Repairs for Cracks in Radius of Stringer End, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-18
Replaced Plies and Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-23
Replacement (of Masking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6b
Replacement and Repair, Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-8
Replacing Face Plies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-24
Requirements (for Rebalancing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -4a
Resin-Impregnated Glass Cloth Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3e
Resins, Adhesives and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Responsibility for Shop Rules (Sheet Metal Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1a
Retainer, Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-61
Rib Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-13
Rib Repair by Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9g, F8-24
Rib Repair by Patching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9f
Right and Wrong Methods of Horizontal Stacking of Small (Plastic) Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-1
Rivet Acceptability Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-22
Rivet Edge Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-4
Rivet Edge Distances, Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-1
Rivet Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5b
Rivet Grip Length, Olympic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-67
Rivet Gun, Pneumatic, Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-12
Rivet Guns, Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-11
Rivet Head Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-21
Rivet Head Markings, Solid Shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-2
Rivet Heat-Treating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2c
Rivet Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2b
Rivet Identification, MS 20600 Protruding-Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-26
Rivet Identification, MS 20601 Countersunk-Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-27

Index-156
 TM 1-1500-204-23-1
Rivet Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Correctly and Incorrectly Driven Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5a
Rivet Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5b
Rivet Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5c
Rivet Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5c
Rivet Inspection, Hi-Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-64
Rivet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4a
Power Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4b
Riveting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4c
Rivet Length, Factors in Determining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-3
Rivet Material Codes, Olympic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-18
Rivet Parts, Hi-Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-60
Rivet Pulling Head Operation, Olympic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-69
Rivet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Countersunk-Head Rivet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6b
Protruding-Head Rivet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6a
Rivet Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73a, 8-6f
Rivet Selection and Spacing When Repairing Aluminum Alloy Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-2
Rivet Selection and Spacing When Repairing Corrosion-Resistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-3
Rivet Selection and Spacing When Repairing Magnesium Alloy Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-4
Rivet Sets, Hi-Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-61
Rivet Shaving, CherryMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-51
Rivet Shear, Minimum, and Tensile Strength (Pounds) in Steel Coupons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-12
Rivet Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3c, F7-5
Rivet Spacing and Edge Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6g
Rivet Spacing for Repair Using Formed Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-43
Rivet Spacing for Repair with Double Row of Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-42
Rivet Spacing for Repair with Single Row of Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-41
Rivet Spacing, Selection and Acceptability Limits for a Nonstressed Skin Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9t
Rivet Squeezers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-13
Rivet Stem Styles, Olympic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-66
Rivet Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3b
Rivet Styles and Materials, Solid Shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-1
Rivet, CherryMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-31
Rivet, Heat-Treatable, Identification of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-9
Riveting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6i
Riveting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4c
Riveting Procedures Using a Pneumatic Rivet Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-19
Rivets and Riveting Techniques, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Rivets Substitutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3d
Rivets, CherryMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Rivets, Correctly and Incorrectly Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-20
Rivets, Hi-Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

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Rivets, Olympic Blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Rivets, Solid Shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Rivnut Grip Length, Determining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-57
Rivnut Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-59
Rivnut Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-58
Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9, F7-56
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9a
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9d
Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9c
Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9e
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9b
Rockwell Hardness Scales, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-19
Rockwell Hardness Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13b
Rockwell Hardness Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-12
Rockwell Hardness Values for 0.050 Inch Minimum Thickness Clad Aluminum Sheet and Plate . . . . . . . . . . . T5-20
Rockwell Hardness Values for Bare Aluminum Sheet, Plate, Extrusions, and Forgings . . . . . . . . . . . . . . . . . . . T5-21
Room Temperature Setting Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4c
Rotary Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3d, F3-4
Router Cutter, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-2
Routers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8d

SAE Numbers, Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-1

Safety of Powered Metal Cutting Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Sample Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-6
Sample Honeycomb Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6b
Sandbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-24
Sandbag Bumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-29
Sanding (Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14a
Sanding Deep Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-11
Sandwich Construction Repair, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1a
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1b
Modern Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1c
Sandwich Construction, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Saw, Ketts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-25
Saw, Reciprocating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-26
Saws (Used to Cut Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8c
Scab or Lap Patch (Crack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-3
Scab or Lap Patch (Hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-4
Scale Method (of Balancing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-9
Scope (of Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Scotchply Edge Member and Corfil Edge Filler Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5i

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 TM 1-1500-204-23-1
Scratch or Crack Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-5
Scratches (in Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12b
Scribing and Edge Sanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8e
Scroll Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3b, F3-2
Seal Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61
Sealant Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10c
Sealant Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10d
Sealing of Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10e
Sealing, Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Secondary Procedures, Dzus Fastener Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-103
Selection of CherryMAX Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8b
Selection of Hi-Lok Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14b
Selection of Hi-Shear Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10b
Selection of Huck Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12e
Selection of Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9b
Self-Plugging Rivet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-29
Self-Plugging Rivet Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-28
Self-Plugging Rivet Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7c
Self-Plugging Rivet Stem Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-25
Self-Plugging Rivets (Friction Lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7a
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7f
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7e
Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7d
Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7g
Self-Plugging Rivet Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7c
Substitution for Common Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7b
Self-Plugging Rivets, Removal of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-30
Semi-Monocoque Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3c, F64
Setback - K - Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6-2
Shaping Aircraft Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Chem-Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2b
Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2a
Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3d, F5-4
Shear Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2b
Shear, Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-10
Shear, Scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Shearing Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Shears, Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-11
Shears, Squaring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1
Shears, Throatless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Sheet and Plate, Rockwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-20
Sheet Metal Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4c

Index-159
TM 1-1500-204-23-1
Sheet Metal, Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Sheet Substitution, Aluminum Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-14
Shell, Reinforced, Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-3
Shop Equipment (Sheet Metal Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Shop Housekeeping (Sheet Metal Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1b
Shop Rules, General (Sheet Metal Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Shop Safety (Sheet Metal Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 e, 2-1c
Shop Tools and Materials (Sheet Metal Shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1d
Shop Working Practice (Aluminum Alloys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7c
Shrinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4c, F6-14
Shrinking and Stretching Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6d, F3-34
Shrinking by V-Block Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-15
Shrinking, Forming a Flanged Angle by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-16
Sight Line, Brake or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-5
Single Row of Rivets, Rivet Spacing for Repair with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F841
Single Shear Strength of Aluminum Alloy Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-2
Sizes (of Jo-Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13c
Sizes of Twist Drills with Decimal Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-5
Skin and Bulkhead Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-28
Skin and Frame Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-27
Skin and Web Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9u
Skin Core Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5c
Skin Core Voids, Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-6
Skin Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3d
Skin Cutout Patching Using Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6f
Skin Cutout Repair Near Stiffener Using Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6g
Skin Doubler Void Repair (0.255 Inch or Greater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-8
Skin Doubler Void Repair (Less Than 0.255 Inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-9
Skin Doubler Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5d
Skin Joint, Longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-39
Skin Joint, Transverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-40
Skin Patch, Nonstressed, Rivet Spacing, and Acceptability Limits for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9t
Skin Repair, Chem-Milled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-2
Skin Repair, Double (Flush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-10
Skin Repair, Double (Nonflush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-11
Skin Repair, Stressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8a
Skin Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Circular External Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8b
Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8a
Temporary Patch Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8c
Skin Wrinkles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3c
Skin, Damaged, Close to a Frame, Repair for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-56
Skin, Stressed, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-55

Index-160
 TM 1-1500-204-23-1
Sleeve Stretch Marks, CherryMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-54
Slip Roll Former . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6c, F3-33
Small Crack, Glass Cloth Repair of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-16
Small Single Skin Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5f
Snips, Aviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-12
Snips, Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-14
Snips, Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-13
Soak Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9b, F10-6
Soaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9g
Soaking (Heat Treating) Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-10
Soaking Time for Solution Treatment of Cast Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-11
Solid Shank Rivet Head Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-2
Solid Shank Rivet Styles and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-1
Solid Shank Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Materials and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2a
Rivet Heat-Treating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2c
Rivet Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2b
Solid Shank Rivets, Grip Lengths for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-1
Solution Treatment of Cast Alloys, Soaking Time for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-11
Spacing, and Rivet Selection, When Repairing Corrosion-Resistant Steel Parts . . . . . . . . . . . . . . . . . . . . . . . . . . T5-11
Spacing, Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-5
Spar Angle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9d, F8-20
Spar Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-12
Spar Repair by Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9c, F8-19
Spar Web Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9e, F8-21
Specifications, Cross Reference of Nearest Corresponding Numbers (Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-4
Specified Defects (of Plastics), Repair Methods for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Splice Repair of Hat Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9p, F8-37
Spotfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-62
Spotweld Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Spotweld Failure with No Skin Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Spotweld Repair to Crack in Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6i
Spotweld Repair to Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6h
Spotwelded Parts Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Acceptable Percentage of Defective Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6b
Acceptable Spotweld Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6a
Preparing Materials for Spotwelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6d
Repair for Short Edge Distance and Broken Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6e
Repair of Defective Spotwelds Exceeding Allowable Percentage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6c
Skin Cutout Patching Using Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6f
Skin Cutout Repair Near Stiffener Using Spotwelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6g
Spotweld Repair to Crack in Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6i
Spotweld Repair to Hole in Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6h

Index-161
TM 1-1500-204-23-1
Spotwelds, Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Spotwelds, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Spotwelds, Shearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Spring Installation, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-99
Squaring Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3a, F3-1
Squeezers, Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-13
Stabilizer, Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15
Stacking, Horizontal, of Small (Plastic) Sheets, Right and Wrong Methods of . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-1
Stainless Steel, Drill Angle for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-1
Standard Countersink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-7
Standard Rockwell Hardness Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-19
Standard Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-99
Standard Tools for Stump-Type Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-28
Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2a
Static Balance, Control Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl1-1
Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Alloying Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6b
Identification of Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6a
Types of Steels and Their Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6c
Steel Facing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3b
Steel Identification Marking Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-6
Steel Lockbolt Rivet Gun, Pull- and Blind-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-74
Steel SAE Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-1
Steel Tube Fishmouth Splice Using Large Diameter Replacement Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-70
Steel Tube Inner Sleeve Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-67
Steel Tube Using Outer Sleeve Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-69
Steel Tubing Distortion, Correcting Oval Shaped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-63
Stem and Collar Flushness, CherryMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-52
Stem Break-Off Limits, Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-87
Stem Catcher Bag 670A20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-44
Stem Features, Self-Plugging Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-25
Step Joint Method, Removing Damaged Face Plies Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-22
Stop Countersink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-8
Stop-Drilling, Repair of Cracks by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-31
Storage (of Adhesives and Resins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4d
Storage and Handling (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Formed Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5d
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5a
Masking Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5c
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5b
Storage of Tools, Equipment, and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c
Straight Line Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5a
Straight Snips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4g, F3-13
Straightening Bowed Steel Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ F8-64

Index-162
 TM 1-1500-204-23-1
Strength, Bearing (Pounds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-3
Stress and Strain Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3e
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3b
Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3d
Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3a
Torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3c
Stressed Beam Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-34
Stressed Skin Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7, 8-9w, F8-55
Flush Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7d
Open and Closed Skin Area Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7b
Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7a
Patching Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7c
Stresses Resulting from Bending, Neutral Axis and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-2
Stretching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4d, F6-13
Stretching Machine, Shrinking and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-34
Stretching, Forming a Flanged Angle by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-18
String Repair by Insertion When Damage Affects Only One Stringer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-14
Stringer and Longeron Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-19
Stringer Cross-Section, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-20
Stringer Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9a
Stringer Repair by Insertion When Damage Affects More than One Stringer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-15
Stringer Repair by Insertion When Damage Exceeds Two Thirds of One Leg in Width . . . . . . . . . . . . . . . . . . . . F8-13
Stringer Repair by Patching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-12
Stringer Repair with Formed Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-17
Stringer Splice Repair, J-Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-16
Stringers and Longerons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8b
Strip Extractor, Pliers and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-111
Structural Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3a
Non-Destructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3f
Protective Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3e
Skin Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3d
Skin Wrinkles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3c
Surface Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3b
Structural Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Bulkheads, Frames, and Formers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8a
Stringers and Longerons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8b
Structural Metals, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Structural Parts, Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-5
Structural Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Sealant Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10c
Sealant Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10d
Sealing of Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10e

Index-163
TM 1-1500-204-23-1
Types of Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10a
Wires and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10b
Structural Support During Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6a
Structural Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 b
Structural Tubing, Example of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-62
Structure, Nacelle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-7
Stud, Camlock, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-112
Stump-Type Lockbolt Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-23
Stump-Type Lockbolt, Installation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-76
Stump-Type Lockbolts, Standard Tools for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-28
Substitute Materials (Aluminum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5-15
Substitution (by Huck Lockbolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12c
Substitution (of Self-Plugging Rivets) for Common Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7b
Support and Stiffener, Heavily Stressed, Repair for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-54
Supporting Ring, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-108
Surface Balance Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Addition of Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2c
Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2b
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2a
Surface Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3b
Surface Rebalancing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Dynamic Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2b
Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2a
Terms and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2c

Tail Cone and Cabin Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-4

Techniques, Cutting (for Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Temperature (for Heat Treatment of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10a
Template, Hand Router, for Milling Plug Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-15
Temporary Patch Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-&
Tensile Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2a
Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3a, F5-1
Terms and Symbols (Balancing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2c
Terms and Symbols (Balancing), Identification of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fll11-2
Thickness Variation, Material (and Hi-Lok Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-91
Thickness, Cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-8
Throatless Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3c, F3-5
Tightly Installed Jo-Bolt, Removal of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-88
Titanium and Titanium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9b
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9a
Methods of Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9c

Index-164
 TM 1-1500-204-23-1
Tolerance (for Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6j
Tool Capacity Chart (for Rivets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-14
Tooling (for Hi-Lok Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Tooling (for Jo-Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13f
Tooling, Jo-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-86
Torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3c, F5-3
Toughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2h
Trailing Edge Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-4
Transfer Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-21
Transfer Punch, Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-9
Transparent Overlay Plastic Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13c
Transparent Plastic Plug Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13a
Transparent Plastics, Recommended Installation Procedures for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Transverse Skin Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9s, F840
Treatment, Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Troubleshooting, CherryMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-17
Tubing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11a
Structural Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11b
Turbine-Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3b
Turn-Lock Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Camlock Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15b
Dzus Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15a
Twist Drills with Decimal Equivalents, Sizes of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-5
Type of Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9a
Types and Identification (of Aircraft Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Burning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4b
Chemical Reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4e
Flexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4d
Military Specification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4a
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4c
Types of Circular Saw Blades for Cutting Acrylic Plastic Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T10-2
Types of Design (Wing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5a
Types of Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5a
Types of Lockbolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-72
Types of Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10a
Types of Steel and Their Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6c
Typical Bolt Installation (in Transparent Plastic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-17
Typical CherryMAX Blind Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-53
Typical Edge Band Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-29
Typical Hatch Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-60
Typical Repairs for Cracks in Radius of Stringer End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-18
Typical Router Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-2
Typical Scarf Method for Class II Repair (of Radomes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-26

Index-165
TM 1-1500-204-23-1
Typical Sighting Dome Edge Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10-20
Typical Stringer Cross Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-20

Unbalanced and Balanced Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl11-4

Unbonding and Ply Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5j
Use of Camlock Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-109
Use of Hole Finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-10
Use of Supporting Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-108
Use of Transfer Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-9
Use of 269C3 Cherry Grip Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-36
Uses (of Jo-Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13d

V-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-22
Various Diameter Rivets, Drill Sizes for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7-4
Visual Inspection (of Plastics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4c
Void Repair, Skin Doubler (Less Than 0.255 Inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-9
Void Repair, Skin Doubler (0.255 Inch or Greater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-8

Waxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15c
Web Repair, Spar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-21
Webster Hardness Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13a
Weight and Distance, Effects of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-3
Windshields, Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Wing Construction, Box Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-10
Wing Construction, Monospar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Wing Construction, Multispar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-9
Wing Internal Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-11
Wing Rib Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-23
Wing-Type Dzus Fastener Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-102
Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Internal Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5b
Types of Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5a
Wires and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10b

Index-166
 These are the instructions for sending an electronic 2028
The following format must be used if submitting an electronic 2028. The subject line must be
exactly the same and all fields must be included; however only the following fields are
mandatory: 1, 3, 4, 5, 6, 7, 8, 9, 10, 13, 15, 16, 17, and 27.
From: “Whomever” [email protected]
To: [email protected]
Subject: DA Form 2028
1 From: Joe Smith
2 Unit: home
3 Address: 4300 Park
4 City: Hometown
5 St: MO
6 Zip: 77777
7 Date Sent: 19-OCT-93
8 Pub no: 55-2840-229-23
9 Pub Title: TM
10 Publication Date: 04-JUL-85
11 Change Number: 7
12 Submitter Rank: MSG
13 Submitter FName: Joe
14 Submitter MName: T
15 Submitter LName: Smith
16 Submitter Phone: 123-123-1234
17 Problem: 1
18 Page: 2
19 Paragraph: 3
20 Line: 4
21 NSN: 5
22 Reference: 6
23 Figure: 7
24 Table: 8
25 Item: 9
26 Total: 123

27 Text:
This is the text for the problem below line 27.
 DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS
For use of this form, see AR 25-30; the proponent agency is OAASA. 20160610
INSTRUCTIONS FOR SUBMITTING THE DA FORM 2028
After completing the DA Form 2028 (Recommended Changes to Publications and Blank Forms), you may send it via Mail, Email, or Web.
Preferred methods of submission are Web and Email. A reply will be furnished directly to you. To submit via the World Wide Web use
https://amcom2028.redstone.army.mil. E-mail directly to [email protected] or by fax (256) 842-6546 or DSN 788-6546. Mail directly to
Commander, U.S. Army Aviation and Missile Command, ATTN: AMSAM-MSS-LP, Redstone Arsenal, AL, 35898-5230. Part II (page 2) is for
changes to Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DETERMINING AND SELECTING THE PROPER PROPONENT

You can identify the proper proponent for any publication or form by searching for the its title using DA Pam 25-30, which can be accessed at:
http://www.apd.army.mil/pamdocs/APD_Search.asp
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
COMMANDER MSG, JANE Q. DOE
U.S. ARMY AVIATION AND MISSILE COMMAND 1234 ANY STREET
ATTN: AMSAM-MSS-LP NOWHERE TOWN, AL 34567
REDSTONE ARSENAL, AL 35898

PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
Machine Gun, .50 Caliber M3P and M3P Machine
TM 9-1005-433-24 20020916 Gun Electrical Test Set Used on Avenger Air Defense
PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
ITEM
NO. GRAPH NO.* NO. NO. (Provide exact wording of recommended changes, if possible).
1 WP 2 Test or Corrective Action column should identify a different WP number.
0005-3

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE

MSG, JANE Q. DOE AUTOVON, PLUS EXTENSION
788-1234

APD LC v1.00ES
DA FORM 2028, SEP 2015 PREVIOUS EDITIONS ARE OBSOLETE.
Page 1 of 2
TO: (Forward direct to addressee listed in publication) FROM: Activity and location) (Include ZIP Code) DATE
COMMANDER MSG, JANE Q. DOE
U.S. ARMY AVIATION AND MISSILE 1234 ANY STREET
COMMAND NOWHERE TOWN, AL 34567 20160610
ATTN: AMSAM-MSS-LP
PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE
TM 9-1005-433-24 Machine Gun, .50 Caliber M3P and M3P Machine
20020916 Gun Electrical Test Set Used on Avenger Air Defe
TOTAL NO.
PAGE COL. LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
NO. RECOMMENDED ACTION
NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED

PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

MSG, JANE Q. DOE PLUS EXTENSION
788-1234

DA FORM 2028, SEP 2015 Page 2 of 2

 DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS
For use of this form, see AR 25-30; the proponent agency is OAASA.
INSTRUCTIONS FOR SUBMITTING THE DA FORM 2028
After completing the DA Form 2028 (Recommended Changes to Publications and Blank Forms), you may send it via Mail, Email, or Web.
Preferred methods of submission are Web and Email. A reply will be furnished directly to you. To submit via the World Wide Web use
https://amcom2028.redstone.army.mil. E-mail directly to [email protected] or by fax (256) 842-6546 or DSN 788-6546. Mail directly to
Commander, U.S. Army Aviation and Missile Command, ATTN: AMSAM-MSS-LP, Redstone Arsenal, AL, 35898-5230. Part II (page 2) is for changes
to Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DETERMINING AND SELECTING THE PROPER PROPONENT

You can identify the proper proponent for any publication or form by searching for the its title using DA Pam 25-30, which can be accessed at:
http://www.apd.army.mil/pamdocs/APD_Search.asp
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
COMMANDER
U.S. ARMY AVIATION AND MISSILE COMMAND
ATTN: AMSAM-MSS-LP
REDSTONE ARSENAL, AL 35898

PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON

ITEM
NO. GRAPH NO.* NO. NO. (Provide exact wording of recommended changes, if possible).

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE

AUTOVON, PLUS EXTENSION

APD LC v1.00ES
DA FORM 2028, SEP 2015 PREVIOUS EDITIONS ARE OBSOLETE.
Page 1 of 2
TO: (Forward direct to addressee listed in publication) FROM: Activity and location) (Include ZIP Code) DATE
COMMANDER
U.S. ARMY AVIATION AND MISSILE
COMMAND
ATTN: AMSAM-MSS-LP
PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COL. LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
NO. RECOMMENDED ACTION
NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED

PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

DA FORM 2028, SEP 2015 Page 2 of 2

 The Metric System and Equivalents
Linear Measure Liquid Measure
1 centimeter = 10 millimeters = .39 inch 1 centiliter = 10 milliters = .34 fl. ounce
1 decimeter = 10 centimeters = 3.94 inches 1 deciliter = 10 centiliters = 3.38 fl. Ounces
1 meter = 10 decimeters = 39.37 inches 1 liter = 10 deciliters = 33.81 fl. ounces
1 dekameter = 10 meters = 32.8 feet 1 dekaliter = 10 liters = 2.64 gallons
1 hectometer = 10 dekameters = 328.08 feet 1 hectoliter = 10 dekaliters = 26.42 gallons
1 kilometer = 10 hectometers = 3,280.8 feet 1 kiloliter = 10 hectoliters = 264.18 gallons
Weights Square Measure
1 centigram = 10 milligrams = .15 grain 1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 decigram = 10 centigrams = 1.54 grains 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 gram = 10 decigram = .035 ounce 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 decagram = 10 grams = .35 ounce 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 hectogram = 10 decagrams = 3.52 ounces 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 kilogram = 10 hectograms = 2.2 pounds 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons

Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. Inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. Inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet

Approximate Conversion Factors

To change To Multiply by To change To Multiply by
inches centimeters 2.540 ounce-inches Newton-meters .007062
feet meters .305 centimeters inches .394
yards meters .914 meters feet 3.280
miles kilometers 1.609 meters yards 1.094
square inches square centimeters 6.451 kilometers miles .621
square feet square meters .093 square centimeters square inches .155
square yards square meters .836 square meters square feet 10.764
square miles square kilometers 2.590 square meters square yards 1.196
acres square hectometers .405 square kilometers square miles .386
cubic feet cubic meters .028 square hectometers acres 2.471
cubic yards cubic meters .765 cubic meters cubic feet 35.315
fluid ounces milliliters 29,573 cubic meters cubic yards 1.308
pints liters .473 milliliters fluid ounces .034
quarts liters .946 liters pints 2.113
gallons liters 3.785 liters quarts 1.057
ounces grams 28.349 liters gallons .264
pounds kilograms .454 grams ounces .035
short tons metric tons .907 kilograms pounds 2.205
pound-feet Newton-meters 1.356 metric tons short tons 1.102
pound-inches Newton-meters .11296

Temparature (Exact)

°F Fahrenheit 5/9 (after Celsius °C

temperature subtracting 32) temperature
PIN: 070482-000