Attachment 1-12K Inspection Task Cards.pdf

Tail # : N57 Work Order # : 51827 Date :

Master Routine Index

Card Description

12000 HOUR AIRFRAME INSPECTION Req Labor Hours: 0

60-00001 PRELIMINARY RECORDS CHECK (ALL D CHECKS) *R407019_*

R407019

60-01002 PRE-INSPECTION CHECKLIST FOR 12,000 HOUR

INSPECTION - OPEN-UP

*R407034_* R407034

60-06002 PRE-INSPECTION CHECKLIST FOR 12,000 HOUR

INSPECTION - CLOSE-UP

*R407003_* R407003

60-13001R 12,000 HOUR FLUORESCENT PENETRANT NDI CHECK *R407002_*

R407002

60-43010 BAGGAGE FLOOR/OVER WING AREA - INSPECTION *R407024_*

R407024

60-43012 AFT PRESSURE BULKHEAD NDI INSPECTION *R406994_*

R406994

60-52001 UNDERWING KEELBEAM REMOVAL *R407004_*

R407004

60-52002 UNDERWING KEELBEAM INSTALLATION *R407028_*

R407028

60-53008 UNDERWING KEELBEAM VISUAL INSPECTION

(REMOVED)

*R407029_* R407029

60-53009 LONGITUDINAL SKIN SPLICES (PRESSURE CABIN)

X-RAY INSPECTION

*R407020_* R407020

60-53011L 12,000 HOUR ENGINE BEAM NDI AND VISUAL CHECK *R407021_*

R407021

60-53011R 12,000 HOUR ENGINE BEAM NDI AND VISUAL CHECK *R407027_*

R407027

60-53013 CIRCUMFERENTIAL SKIN SPLICES X-RAY

INSPECTION

*R407026_* R407026

60-71003 AUTOPILOT ROLL SERVO MOUNT CLUTCH TORQUE

- OPEN-UP

*R407035_* R407035

60-72001L FLAP INSTALLATION *R407036_*

R407036

60-72001R FLAP INSTALLATION *R407005_*

R407005

60-72002L AILERON - REMOVAL AND INSPECTION *R406997_*

R406997

60-72002R AILERON - REMOVAL AND INSPECTION *R406998_*

R406998

60-72003L AILERON - INSTALLATION *R407000_*

R407000

60-72003R AILERON - INSTALLATION *R406999_*

R406999

60-72004L FLAP REMOVAL *R407006_*

R407006

60-72004R FLAP REMOVAL *R406990_*

R406990

60-73012 AUTOPILOT ROLL SERVO MOUNT CLUTCH TORQUE

- CHECK

*R449270_* R449270

Master Routine Index

Card Description

60-73013L INSPECTION AND EDDY CURRENT OF

WING/FUSELAGE FITTINGS

*R406993_*

R406993

60-73013R INSPECTION AND EDDY CURRENT OF

WING/FUSELAGE FITTINGS

*R407025_* R407025

60-73014L NDI VISUAL INSPECTION OF WINGS *R407033_*

R407033

60-73014R NDI VISUAL INSPECTION OF WINGS *R407032_*

R407032

60-73015L NDI - FLAP INSPECTION *R407015_*

R407015

60-73015R NDI - FLAP INSPECTION *R407016_*

R407016

60-75001 SPOILER UP LIMIT SWITCH - FUNCTIONAL TEST *R406992_*

R406992

60-76003 AUTOPILOT ROLL SERVO MOUNT CLUTCH TORQUE

- CLOSE-UP

*R407022_* R407022

60-81002 RUDDER REMOVAL *R407007_*

R407007

60-81003 YAW DAMPER SERVO ACTUATOR/MOUNT CLUTCH

TORQUE - OPEN-UP

*R407009_* R407009

60-81004 PITCH SERVO MOUNT CLUTCH TORQUE - OPEN-UP *R407010_*

R407010

60-82001 RUDDER INSTALLATION *R407008_*

R407008

60-82002 HORIZONTAL STABILIZER REMOVAL *R407011_*

R407011

60-82003 HORIZONTAL STABILIZER INSTALLATION *R407013_*

R407013

60-82004 ELEVATOR REMOVAL *R407012_*

R407012

60-82005 ELEVATOR INSTALLATION *R407023_*

R407023

60-83008 HORIZONTAL STABILIZER ACTUATOR - INSPECTION *R407037_*

R407037

60-83009 VISUAL INSPECTION OF HORIZONTAL STABILIZER

ATTACHED TO VERTICAL STABILIZER

*R407030_* R407030

60-83010 VISUAL AND NDI INSPECTION OF HORIZONTAL

STABILIZER DETACHED FROM VERTICAL

STABILIZER

*R407031_* R407031

60-83012 VISUAL AND NDI OF ELEVATOR (REMOVED FROM

HORIZ. STAB.)

*R449269_* R449269

60-83013 VISUAL INSPECTION AND NDI OF VERTICAL

STABILIZER

*R406996_* R406996

60-83014 INSPECTION OF RUDDER *R407017_*

R407017

60-83015 YAW DAMPER SERVO ACTUATOR/MOUNT CLUTCH

TORQUE - CHECK

*R449268_* R449268

60-83016 PITCH SERVO MOUNT CLUTCH TORQUE - CHECK *R406991_*

R406991

Master Routine Index

Card Description

60-83017 VISUAL INSPECTION OF TAILCONE *R406995_*

R406995

60-86002 YAW DAMPER SERVO ACTUATOR/MOUNT CLUTCH

TORQUE - CLOSE-UP

*R407018_* R407018

60-86003 PITCH SERVO MOUNT CLUTCH TORQUE - CLOSE-UP *R407014_*

R407014

LEAR60 - 13001L 12,000 HOUR FLUORESCENT PENETRANT NDI CHECK *R407001_*

R407001

60-00001 Tail # : N57 (12000 HOUR AIRFRAME INSPECTION) Work Order # : 51827

Card #: 00001 Labor Hours: 0

Date :

Description: PRELIMINARY RECORDS CHECK (ALL D CHECKS)

*R407019_* R407019

Work Card Tasks TECH INSP Step Description

P 1 *Aircraft logbook and permanent records.

a. Review permanent records for service bulletins, MAD's, EO's, etc., that shall be accomplished on this inspection and assure that all items are on non-routine worksheets.

b. Determine the time change items (ADP run) that are due this inspection and assure that all items are recorded on non-routine maintenance worksheets.

c. Issue engine change and hot section inspection cards as applicable.

NOTE: The foregoing items may be accomplished by production controller (PC), project manager (PM), or leadman/foreman (L/F), or inspector (I) as dictated by local policy.

T 2 Check aircraft logbook and transfer all flight discrepancies and all carryover items to non-routine maintenance worksheets.

NOTE: Any discrepancy not cleared during the inspection will require quality control approval before being re-entered in the deferred discrepancy list.

NOTE: The foregoing items may be accomplished by inspector (I) or Technician (T) as dictated by local policy.

I 3a *Operations/normal checklist manuals update.

For aircraft located at Oklahoma City, Oklahoma, the inspector will remove the Operations Manual and the normal Checklist Manual from the aircraft for verification of current revision status and updating if required.

I 3b *Inspector will verify that all manuals are returned to the aircraft before next flight.

I 4 *If aircraft is assigned to a facility other than Oklahoma City, Oklahoma, the responsible facility will check the Operations Manual (TI 4040.25B), and normal Checklist Manual (TI 4040.25C) and make sure all current changes received have been inserted.

I 5 *Review interim maintenance/operations data in the alert envelope. If material has been issued to the effected manuals, remove data from the alert envelope; and, if applicable, remove related alert sticker from the logbook cover.

1 (Last)

60-01002

Card #: 01002 Labor Hours: 0

Date :

Description: PRE-INSPECTION CHECKLIST FOR 12,000 HOUR INSPECTION - OPEN-UP

*R407034_* R407034

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 if further information is necessary.

B NOTE: This checklist is intended to be used as a guide for preparing the aircraft for a 12000 Hour inspection when preparing the aircraft for a non destructive inspection (NDI).

C NOTE: Place all discrepancies on a non-routine card and in ILM.

T 1 Remove under wing keel beam from fuselage.

T 2 Remove wing from fuselage.

NOTE: Remove the main landing gear from the wings if a major landing gear inspection is going to be performed at this time.

T 3 Remove lower access panels from wing (BL 0.0 to WS 92.0).

T 4 Remove moveable surfaces from wings (flaps, Ailerons, and Spoilers). Perform flap removal task card 72004.

T 5 Remove rudder from vertical stabilizer.

T 6 Remove elevators from the horizontal stabilizer. And visually inspect elevators along spar and trailing edge for corrosion.

T 7 Perform task card 83009.

T 8 Remove horizontal stabilizer from the vertical stabilizer. And visually inspect the horizontal stabilizer along forward and aft spars and rib 4.5 for corrosion.

T 9 Remove engines.

T 10 After the wing is removed from the fuselage, remove the fuel pumps, major plumbing, electrical wiring and conduits from the lower wing.

T 11 Clean the upper and lower outside surface of the wing.

T 12 Clean the upper and lower dry bay skins.

T 13 Remove oblong or kidney shaped access panel just aft of the wing panel for accessibility.

T 14 Remove all cover plates inboard of WS92 for Eddy current inspection.

60-01002

Card #: 01002 Labor Hours: 0

Description: PRE-INSPECTION CHECKLIST FOR 12,000 HOUR INSPECTION - OPEN-UP

*R407034_* R407034

Work Card Tasks TECH INSP Step Description

T 15 Level wing and clear area around wing for free access. Jack the aircraft to the proper height. (Min. 36 inches floor to WS0.0).

T 16 Remove required cover plates to gain access to spars 5 and 7 for Eddy current inspection.

T 17 Remove access plates on the upper surface of the vertical stabilizer for Eddy current inspection.

T 18 On the fuselage, gain access to fuselage-to-wing fittings.

2 (Last)

60-06002

Card #: 06002 Labor Hours: 0

Date :

Description: PRE-INSPECTION CHECKLIST FOR 12,000 HOUR INSPECTION - CLOSE-UP

*R407003_* R407003

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 if further information is necessary.

T RII 1 Install the vertical stabilizer.

T RII 2 Install the horizontal stabilizer. And perform horizontal stabilizer actuator inspection task card 83008.

T RII 3 Install elevators on horizontal stabilizer.

T RII 4 Install the rudder.

T I 5 Install covers/plates removed to perform elevator and forward and aft horizontal stabilizer spars inspection.

T I 6 Install covers/plates removed on upper surface of vertical stabilizer for inspection.

T I 7 Install oblong/kidney shaped access panel removed just aft of wing panel.

T I 8 Install covers/plates removed on the wings to inspect spars 5 and 7.

T I 9 Install cover/plates removed from inboard of WS 92 for inspection.

T I 10 Level wings and install removed fuel pumps, major plumbing, electrical wiring and conduits removed from lower wings.

T RII 11 Install the main landing gear on to the wings, if removed.

T RII 12 Install the wings on to the fuselage and fuselage-to-wing fittings.

T RII 13 *Install Engines.

T RII 14 Install the flaps. Per task card 72001L/R.

T RII 15 Install the ailerons.

T RII 16 Install the spoilers.

T 17 Install the lower wing access panels from BL 0.0 to WS 92.0.

60-06002

Card #: 06002 Labor Hours: 0

Description: PRE-INSPECTION CHECKLIST FOR 12,000 HOUR INSPECTION - CLOSE-UP

*R407003_* R407003

Work Card Tasks TECH INSP Step Description

T RII 18 Install the under wing keel beam at the fuselage.

T 19 Perform the landing gear blow down and emergency brake functional tests after the systems are reconnected and can be safely operated.

60-13001R

Card #: 13001R Labor Hours: 0

Date :

Description: 12,000 HOUR FLUORESCENT PENETRANT NDI CHECK

*R407002_* R407002

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Sections 5-10-28 and NDI-2 Manual Part 5 71-20-01 thru -12 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL NUMBER

T 1 With the engine removed remove engine forward mount yoke, bolts for the fwd intermediate fitting and fitting, bolts for the fwd yoke to intermediate fitting and fitting, bolts for the fwd yoke isolators and isolators, aft engine isolators, aft mount links, bolts for the aft isolator mount links and bolts to mount links to case in accordance with the Learjet 60 Maintenance Manual.

(See Figures 1 thru 3)

T I 2 Perform a fluorescent penetrant inspection of the fwd engine beam intermediate fitting in accordance with NDI Manual Part 5, 71-20-01. Accomplish by method A, B, or D. (See Figure 1)

T I 3 Perform a fluorescent penetrant inspection of the fwd engine mount yoke in accordance with NDI Manual Part 5, 71-20-02. Accomplish by method A, B, C, or D. (See Figure 1)

T I 4 Perform a fluorescent penetrant inspection of the bolts to the fwd intermediate fitting to engine beam support fitting in accordance with NDI Manual Part 5, 71-20-03. Accomplish by method A, B, C, or D.

(See Figure 1)

T I 5 Perform a fluorescent penetrant inspection of the bolts and fwd yoke to intermediate fitting in accordance with NDI Manual Part 5, 71-20-04. Accomplish by method A, B, C, or D. (See Figure 1)

T I 6 Perform a fluorescent penetrant inspection of the bolts to the fwd engine mount yoke fitting isolator in accordance with NDI Manual Part 5, 71-20-05. Accomplish by method A, B, C, or D. (See Figure 2)

T I 7 Perform a fluorescent penetrant inspection of the fwd engine isolator to engine case bolts in accordance with NDI Manual Part 5, 71-20-06. Accomplish by method A, B, C, or D. (See Figure 2)

T I 8 Perform a fluorescent penetrant inspection of the fwd engine isolators in accordance with NDI Manual Part 5, 71-20-07. Accomplish by method C. (See Figure 2)

T I 9 Perform a fluorescent penetrant inspection of the aft engine isolator in accordance with NDI Manual Part 5, 71-20-08. Accomplish by method C. (See Figure 3)

T I 10 Perform a fluorescent penetrant inspection of the aft engine mount links in accordance with NDI Manual Part 5, 71-20-09. Accomplish by method A, B, C, or D. (See Figure 3)

Card #: 13001R Labor Hours: 0

Description: 12,000 HOUR FLUORESCENT PENETRANT NDI CHECK

*R407002_* R407002

Work Card Tasks TECH INSP Step Description

T I 11 Perform a fluorescent penetrant inspection of the bolts to the aft engine mount isolator to support fitting in accordance with NDI Manual Part 5, 71-20-10. Accomplish by method A, B, C, or D. (See Figure 3)

T I 12 Perform a fluorescent penetrant inspection of the bolts to the aft engine mount isolator links in accordance with NDI Manual Part 5, 71-20-11. Accomplish by method A, B, C, or D. (See Figure 3)

T I 13 Perform a fluorescent penetrant inspection of the bolts to the aft engine mount links to the engine case in accordance with NDI Manual Part 5, 71-20-12. Accomplish by method A, B, C, or D.

(See Figure 3)

Card #: 13001RDescription: 12,000 HOUR FLUORESCENT PENETRANT NDI CHECK

FIGURE 1

Card #: 13001RDescription: 12,000 HOUR FLUORESCENT PENETRANT NDI CHECK

FIGURE 2

Card #: 13001RDescription: 12,000 HOUR FLUORESCENT PENETRANT NDI CHECK

FIGURE 3

5 (Last)

60-43010

Card #: 43010 Labor Hours: 0

Date :

Description: BAGGAGE FLOOR/OVER WING AREA - INSPECTION

*R407024_* R407024

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL

NUMBER

T 1 Remove floorboards.

I 2a Baggage floor/over wing area:

Support structure for wing-to-fuselage fitting. At each location (spar/frame) 2/25, 5/27, 7/29, and 8/30 (8 locations total) visually inspect fuselage frame structure for cracks, corrosion, fastener condition, permanent deformation, and general security.

I 2b Lateral floor transition beam. Frame 26A, FS 378.05. (See Figure 1.) Visually inspect support structure at end of beam, for cracks, corrosion, fastener condition, and general security. Clean and visually inspect beam web and caps for cracks, corrosion, fastener condition, and general security.

I 2c Lower floor surface. (See Figure 2.) Clean and visually inspect lower surface of honeycomb floor panels from frame 24 to frame 31 for cracks, corrosion, segmented edge attachment condition, and general security.

I 2d Bulkheads at frame 24 and frame 31. Clean and visually inspect webs, stiffeners, and frame cap structure for cracks, corrosion, fastener condition, and general security. Upon inspection completion, clean and reprime as necessary.

I 2e Eddy current inspect lower cap-to-web attachment adjacent to fasteners. (Surface probe.) (Refer to Part 3, Chapter 53 of the NDI Manual.)

Card #: 43010Description: BAGGAGE FLOOR/OVER WING AREA - INSPECTION

Card #: 43010Description: BAGGAGE FLOOR/OVER WING AREA - INSPECTION

3 (Last)

60-43012

Card #: 43012 Labor Hours: 0

Date :

Description: AFT PRESSURE BULKHEAD NDI INSPECTION

*R406994_* R406994

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL NUMBER

T I 1 Gain access to and remove the aft pressure bulkhead.

T 2 Remove sealant from attaching screws, (perimeter and centerline), and fillet seal from around edge of bulkhead where it contacts frame 26A.

CAUTION: USE CARE TO AVOID DAMAGE TO BULKHEAD DURING REMOVAL FROM

FRAME 26A.

T 3 a. Remove bulkhead attaching screws and packing washers.

b. Remove bulkhead from aircraft.

I 4 Eddy current inspect the FWD frame flange of frame 26A AFT pressure bulkhead per the NDI manual Part 3 Chapters/Sections 53-20-01 and 53-20-05.

I 5 Eddy current inspect supporting structure along AFT pressure bulkhead lateral floor support angle and centerline beam upper and lower attachment for fatigue cracks, fastener security, corrosion, or other damage. Perform the NDI inspection per the NDI manual Parts 3, Chapters/Sections 53-20-02, 53-20-03, and 53-20-04.

I 6 Visually inspect periphery of bulkhead panel for signs of corrision, damage, or delamination.

60-43012

Card #: 43012 Labor Hours: 0

Description: AFT PRESSURE BULKHEAD NDI INSPECTION

*R406994_* R406994

Work Card Tasks TECH INSP Step Description

I 7 Visually inspect the cut-out in frame 26A for signs of corrision, damage, and cracks. Inspect the center post of the AFT pressure bulkhead along its length and at the attachments to the fuel cell floor and top.

I 8 Perform an X-ray inspection of the centerline beam, per the NDI manual Part 2 Chapter/Section 53-20-01.

T I 9 Install the AFT pressure bulkhead.

*a. Inspect each nutplate on frame 26A for condition of threads and security of mounting.

NOTE: Refer to M/M Chapter 20 for cleaning and sealant application procedures.

*b. Inspect and thoroughly clean mating surfaces of bulkhead and frame 26A.

T 10 Apply parting agent to mating surface of bulkhead, allow to dry 10 to 15 minutes or dry to touch.

T 11 Apply faying surface seal to mating surface of frame 28.

T 12 Install bulkhead and attachment screws with new packing washers. Apply Pro-Seal to all screwheads.

T 13 Install fillet seal around perimeter of bulkhead where it contacts frame 26A.

T I 14 After allowing sealant to cure, pressure test aircraft to 9.8 psi and check for leaks. Refer to M/M Chapter/Section 53-00-00 for Adjustment/Test.

60-52001

Card #: 52001 Labor Hours: 0

Date :

Description: UNDERWING KEELBEAM REMOVAL

*R407004_* R407004

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 and 57-00-00, if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

T 1 Defuel aircraft and purge fuel tanks. (Refer to Chapter 12.)

T 2 Remove engines from aircraft. (Refer to Chapter 71.) (See task card 1201.)

T 3 Install a jack pad and jack at LH and RH end of engine beam. Position jacks to obtain maximum clearance between the trailing edge of the wing and jacks.

T 4 Install jack pads and jacks under nose and wings of aircraft.

T 5 Raise aircraft until main landing gear tires are clear of the ground.

T 6 Relieve pressure from hydraulic system and drain reservoir.

T 7 Disconnect and remove batteries from aircraft.

T 8 Lower inboard main landing gear wheel well doors.

T 9 Identify, tag, disconnect and cap plumbing fittings and electrical connectors as required at both ends of keel beam.

T 10 Remove aileron aft control cable, aileron (wing inboard) control cables, and autopilot roll servo actuator cable. (Refer to Chapter 27.)

NOTE: Attach string to flight control cable terminals before pulling cables through structure. Pull cables clear of keel beam and secure string to structure. When reinstalling cables, use these strings as a guide to prevent misrouting cables.

T 11 Remove applicable cabin equipment and furnishings, between frames 24 and 28, as required to gain access to flight control cables.

T 12 Remove cabin center floorboards.

T 13 Remove lower antennas (as required).

T 14 Check that all plumbing and electrical wiring is disconnected between keel beam and wing.

T 15 Support keel beam and remove four bolts at each end of keel beam.

Card #: 52001 Labor Hours: 0

Description: UNDERWING KEELBEAM REMOVAL

*R407004_* R407004

Work Card Tasks TECH INSP Step Description

T 16 Remove keel beam vent hoses and sump.

T 17 Remove keel beam from aircraft and place on dolly.

T 18 After keel beam is removed from fuselage, install spreader bar between keel beam mounting pads.

CAUTION: THE SPREADER BAR MUST REMAIN INSTALLED AT ALL TIMES WHILE THE

KEEL BEAM IS REMOVED FROM THE AIRPLANE. THIS IS TO PREVENT STRUCTURAL

DAMAGE TO THE FUSELAGE.

Card #: 52001Description: UNDERWING KEELBEAM REMOVAL

60-52002

Card #: 52002 Labor Hours: 0

Date :

Description: UNDERWING KEELBEAM INSTALLATION

*R407028_* R407028

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 and 57-00-00, if further information is necessary.

PARTS RETURN ALL UNUSED PARTS TO THE STOCKROOM

C NOTE: Place all discrepancies on a non-routine card and in ILM.

D *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL

NUMBER

T 1 Remove spreader bar from fuselage.

T 2 Perform a dye penetrant check of keel beam attach fittings and apply epoxy primer on keel beam mounting pads as required.

T 3 Position keel beam under fuselage. Route vent tubes at aft end of keel beam into fuselage.

T I 4 Push keel beam in between mounting pads and secure keel beam using new bolts, nuts and washers.

Torque nuts 160 to 190 inch-pounds (16.93 Newton-meters to 21-45 Newton-meters).

NOTE: Forward keel beam attach bolts must be installed through frame 24. The forward keel beam fitting is accessible forward to frame 24 under floorboard.

T 5 Connect plumbing and electrical wiring between keel beam and wing.

CAUTION: CAREFULLY CHECK FOR THE CORRECT ROUTING OF FLIGHT CONTROL

CABLES; MISROUTING OF CABLES MAY RESULT IN WEAR OF COMPONENTS OR THE

BINDING OF CABLES.

T 6 Route flight control cables through frame 24 and keel beam. Connect turnbuckles and rig cables.

T 7 Route aileron cables in wing and connect turnbuckles. Install pulleys and guide pins. Rig cables.

T I 8 Install cable fairleads and pressure seals at frame 24.

Card #: 52002 Labor Hours: 0

Description: UNDERWING KEELBEAM INSTALLATION

*R407028_* R407028

Work Card Tasks TECH INSP Step Description

T 9 Install cabin floorboards.

T 10 Install applicable cabin equipment and furnishings, between frames 24 and 28, that were removed to gain access to flight control cables.

T 11 Check that all plumbing and electrical wiring is connected.

T 12 Install lower antennas (if removed).

CAUTION: CHECK THAT FLAPS, SPOILERS, AND LANDING GEAR ARE CLEAR OF

OBSTRUCTIONS PRIOR TO OPERATION.

T 13 Service hydraulic reservoir. (Refer to Chapter 12.)

T 14 Install and connect aircraft batteries.

T 15 Apply pressure to hydraulic system and perform leak check.

T I *16 Cycle flaps, spoilers and landing gear until air is bled from the hydraulic system.

T 17 Perform landing gear operational check. (Refer to Chapter 32.)

T 18 Position landing gear to down and locked.

CAUTION: ENSURE THAT LANDING GEAR IS DOWN AND LOCKED BEFORE PERFORMING

STEP (20).

T 19 Lower aircraft and remove jack and jack pads from aircraft.

T 20 Install engines. (Refer to Chapter 71.) (Refer to task card 1202.)

T RII 21 Perform flight controls operational check. (Refer to task card 3503.)

CAUTION: CHECK THAT CONTROL CABLES ARE CORRECTLY ROUTED AND ARE NOT

RUBBING OR BINDING.

T 22 Fuel aircraft and perform leak check and fuel system operational check.

T RII 23 Perform operational checks as required on all systems that were previously disconnected.

Card #: 52002Description: UNDERWING KEELBEAM INSTALLATION

60-53008

Card #: 53008 Labor Hours: 0

Date :

Description: UNDERWING KEELBEAM VISUAL INSPECTION (REMOVED)

*R407029_* R407029

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28, if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

T 1 Visually inspect removed assembly for corrosion, fatigue cracks, and general condition. Pay particular attention to end fittings common to beam assembly as well as those mating fittings forward of frame 24 and aft of frame 31.

T 2 Replace attachment tension bolts prior to installation. (Refer to task card 52002.)

60-53008

Card #: 53008Description: UNDERWING KEELBEAM VISUAL INSPECTION (REMOVED)

60-53009

Card #: 53009 Labor Hours: 0

Date :

Description: LONGITUDINAL SKIN SPLICES (PRESSURE CABIN) X-RAY INSPECTION

*R407020_* R407020

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL NUMBER

I 1 Perform a longitudinal skin splice (pressure cabin) x-ray inspection of the longitudinal skin splices along the main "T" stringers at stringers 4L, 6L, 18L, 23L, 2R, 6R, and 18R in accordance with Part 2, Chapter 53, of the NDI manual.

60-53011L

Card #: 53011L Labor Hours: 0

Date :

Description: 12,000 HOUR ENGINE BEAM NDI AND VISUAL CHECK

*R407021_* R407021

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 and NDI-2 Manual Part 3 53-40-01 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL NUMBER

T 1 With the engine removed, inspect the aft engine isolator and forward intermediate fitting in accordance with the Learjet 60 Maintenance Manual.

I 2 Perform an eddy current inspection of the forward beam support fitting in accordance with NDI Manual Part 3, 53-40-01.

(See Figure 1)

T 3 Visually check the forward engine beam assembly. And the forward engine beam stabilizer structure.

I 4 Perform an eddy current inspection of the aft beam support fitting in accordance with NDI Manual Part 3, 53-40-02. (See Figure 2)

T 5 Visually check the aft engine beam and the aft engine beam frame structure.

Card #: 53011LDescription: 12,000 HOUR ENGINE BEAM NDI AND VISUAL CHECK

Card #: 53011LDescription: 12,000 HOUR ENGINE BEAM NDI AND VISUAL CHECK

60-53011R

Card #: 53011R Labor Hours: 0

Date :

Description: 12,000 HOUR ENGINE BEAM NDI AND VISUAL CHECK

*R407027_* R407027

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 and NDI-2 Manual Part 3 53-40-01 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL NUMBER

T 1 With the engine removed aft engine isolator and forward intermediate fitting in accordance with the Learjet 60 Maintenance Manual.

I 2 Perform an eddy current inspection of the forward beam support fitting in accordance with NDI Manual Part 3, 53-40-01.

(See Figure 1)

T 3 Visually check the forward engine beam assembly. And the forward engine beam stabilizer structure.

I 4 Perform an eddy current inspection of the aft beam support fitting in accordance with NDI Manual Part 3, 53-40-02. (See Figure 2)

T 5 Visually check the aft engine beam and the aft engine beam frame structure.

Card #: 53011RDescription: 12,000 HOUR ENGINE BEAM NDI AND VISUAL CHECK

Card #: 53011RDescription: 12,000 HOUR ENGINE BEAM NDI AND VISUAL CHECK

60-53013

Card #: 53013 Labor Hours: 0

Date :

Description: CIRCUMFERENTIAL SKIN SPLICES X-RAY INSPECTION

*R407026_* R407026

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL NUMBER

I 1 Perform an x-ray inspection of the circumferental skin splices at frames 13 and 20B in the pressure cabin across the top of the fuselage from stringers 8L and 8R. Perform inspection in accordance with Part 2, Chapter 53, of the NDI manual.

60-71003

Card #: 71003 Labor Hours: 0

Date :

Description: AUTOPILOT ROLL SERVO MOUNT CLUTCH TORQUE - OPEN-UP

*R407035_* R407035

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Sections 5-10-28 and 22-10-11, if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

T 1 With flaps fully down, remove (3) fairings from L/H side of keel beam aft of wheel well to gain access to L/H autopilot roll servo access panel.

T 2 Remove roll servo access panel.

T I 3 Okay to close _________.

All panels used to facilitate the maintenance of this task, remove all unwanted tools and equipment.

60-72001L

Card #: 72001L Labor Hours: 0

Date :

Description: FLAP INSTALLATION

*R407036_* R407036

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual, Chapter/Section 27-50-01.

B WARNING: SPOILERS WILL SLAM DOWN WHEN ELECTRICAL POWER IS REMOVED FROM

THE AIRCRAFT WITH HYDRAULIC PRESSURE APPLIED. REMOVE HYDRAULIC POWER

FIRST AND THEN REMOVE ELECTRICAL.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL

NUMBER

T 1 Clean flap tracks and flat nose tracks.

T 2 Lubricate flap track rollers with MIL-G-81322 grease, using a zerk gun and an Alemite 90deg rubber tip adapter (P/N 327265).

T RII 3 Position flap assembly up to flap nose tracks, aligning flap with flap track rollers, and pushrod assembly with access hole in wing rear spar. Secure flap assembly with attaching parts.

T RII 4 Position flap pushrod assembly rod end up to sector assembly, and secure with attaching parts.

NOTE: Attach flap pushrod assembly to sector assembly by inserting bolt from bottom side of rod end and secure with attaching parts.

T I 5 Install attaching parts securing flap pushrod assembly bonding jumper to sector assembly. Check electrical bonding. (Refer to Wiring Manual, Chapter 20.)

T 6 Install attaching parts securing outboard and inboard bonding jumpers to flap assembly. Check electrical bonding. (Refer to Wiring Manual, Chapter 20.)

T 7 If required, replace protective tape on lower wing skin and upper wing skin lower surface.

T RII 8 Perform functional test of flap system. (Refer to 27-50-00, Adjustment/Test.)

Card #: 72001L Labor Hours: 0

Description: FLAP INSTALLATION

*R407036_* R407036

Work Card Tasks TECH INSP Step Description

T 9 Install sector assembly access cover.

Restore hydraulic power to aircraft.

Restore electrical power to aircraft.

Stow flaps and spoilers in full retract position.

Card #: 72001LDescription: FLAP INSTALLATION

Card #: 72001LDescription: FLAP INSTALLATION

Card #: 72001LDescription: FLAP INSTALLATION

60-72001R

Card #: 72001R Labor Hours: 0

Date :

Description: FLAP INSTALLATION

*R407005_* R407005

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual, Chapter/Section 27-50-01.

B WARNING: SPOILERS WILL SLAM DOWN WHEN ELECTRICAL POWER IS REMOVED FROM

THE AIRCRAFT WITH HYDRAULIC PRESSURE APPLIED. REMOVE HYDRAULIC POWER

FIRST AND THEN REMOVE ELECTRICAL.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL

NUMBER

T 1 Clean flap tracks and flat nose tracks.

T 2 Lubricate flap track rollers with MIL-G-81322 grease, using a zerk gun and an Alemite 90deg rubber tip adapter (P/N 327265).

T RII 3 Position flap assembly up to flap nose tracks, aligning flap with flap track rollers, and pushrod assembly with access hole in wing rear spar. Secure flap assembly with attaching parts.

T RII 4 Position flap pushrod assembly rod end up to sector assembly, and secure with attaching parts.

NOTE: Attach flap pushrod assembly to sector assembly by inserting bolt from bottom side of rod end and secure with attaching parts.

T I 5 Install attaching parts securing flap pushrod assembly bonding jumper to sector assembly. Check electrical bonding. (Refer to Wiring Manual, Chapter 20.)

T 6 Install attaching parts securing outboard and inboard bonding jumpers to flap assembly. Check electrical bonding. (Refer to Wiring Manual, Chapter 20.)

T 7 If required, replace protective tape on lower wing skin and upper wing skin lower surface.

T RII 8 Perform functional test of flap system. (Refer to 27-50-00, Adjustment/Test.)

Card #: 72001R Labor Hours: 0

Description: FLAP INSTALLATION

*R407005_* R407005

Work Card Tasks TECH INSP Step Description

T 9 Install sector assembly access cover.

Restore hydraulic power to aircraft.

Restore electrical power to aircraft.

Stow flaps and spoilers in full retract position.

Card #: 72001RDescription: FLAP INSTALLATION

Card #: 72001RDescription: FLAP INSTALLATION

Card #: 72001RDescription: FLAP INSTALLATION

60-72002L

Card #: 72002L Labor Hours: 0

Date :

Description: AILERON - REMOVAL AND INSPECTION

*R406997_* R406997

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Sections 5-10-28 and 27-10-02 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

T 1 Remove electrical power from aircraft.

T 2 Remove hinge bolt access covers from underside of aileron and aileron drive clevis bolt access door from wing.

T 3 Disconnect trim tab actuator/potentiometer wiring at electrical wiring splice inside wing and pull electrical wiring out through wing aft spar.

T 4 Disconnect bonding jumper from aileron at each hinge point.

T 5 Disconnect balance tab push-pull tubes from wing bracket. (Refer to Removal/Installation, 27-10-03.)

T 6 Remove nut, washers and clevis bolt connecting drive clevis to yoke. As bolt is removed, shims will be released. Save shims for reinstallation.

T 7 CAUTION: AILERON MUST BE SUPPORTED WHEN HINGE BOLTS ARE REMOVED OR

INSTALLED. SIDE LOADS ON HINGE BEARINGS DURING REMOVAL AND INSTALLATION

CAN DAMAGE HINGE BEARINGS.

Remove hinge bolts securing aileron to wing and remove aileron. If aileron is to be replaced, remove yoke bolt, yoke and shims from center hinge casting.

T 8 Clean and visually inspect aileron drive/actuation mechanism (yoke, clevis, etc.) using proper lighting and 10X magnification. Check for fatigue cracks, rust or corrosion, wear, and general condition. With yoke removed, inspect center hinge casting for corrosion, fatigue cracks, and general condition. (See Replacement Schedule for life limited parts.) Inspect other hinge locations for deformation, fatigue cracks, or general condition (includes wing and aileron hinge elements).

T 9 Conduct a general visual inspection of the aileron assemblies for permanent deformation, corrosion, cracks in skin, wear or chafing, and general condition.

Card #: 72002LDescription: AILERON - REMOVAL AND INSPECTION

Card #: 72002LDescription: AILERON - REMOVAL AND INSPECTION

60-72002R

Card #: 72002R Labor Hours: 0

Date :

Description: AILERON - REMOVAL AND INSPECTION

*R406998_* R406998

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Sections 5-10-28 and 27-10-02 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

T 1 Remove electrical power from aircraft.

T 2 Remove hinge bolt access covers from underside of aileron and aileron drive clevis bolt access door from wing.

3 N/A

T 4 Disconnect bonding jumper from aileron at each hinge point.

T 5 Disconnect balance tab push-pull tubes from wing bracket. (Refer to Removal/Installation, 27-10-03.)

T 6 Remove nut, washers and clevis bolt connecting drive clevis to yoke. As bolt is removed, shims will be released. Save shims for reinstallation.

T 7 CAUTION: AILERON MUST BE SUPPORTED WHEN HINGE BOLTS ARE REMOVED OR

INSTALLED. SIDE LOADS ON HINGE BEARINGS DURING REMOVAL AND INSTALLATION

CAN DAMAGE HINGE BEARINGS.

Remove hinge bolts securing aileron to wing and remove aileron. If aileron is to be replaced, remove yoke bolt, yoke and shims from center hinge casting.

T 8 Clean and visually inspect aileron drive/actuation mechanism (yoke, clevis, etc.) using proper lighting and 10X magnification. Check for fatigue cracks, rust or corrosion, wear, and general condition. With yoke removed, inspect center hinge casting for corrosion, fatigue cracks, and general condition. (See Replacement Schedule for life limited parts.) Inspect other hinge locations for deformation, fatigue cracks, or general condition (includes wing and aileron hinge elements).

T 9 Conduct a general visual inspection of the aileron assemblies for permanent deformation, corrosion, cracks in skin, wear or chafing, and general condition.

Card #: 72002RDescription: AILERON - REMOVAL AND INSPECTION

Card #: 72002RDescription: AILERON - REMOVAL AND INSPECTION

60-72003L

Card #: 72003L Labor Hours: 0

Date :

Description: AILERON - INSTALLATION

*R407000_* R407000

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Sections 5-10-28 and 27-10-02 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL

NUMBER

T RII 1 If any portion of an aileron has been repainted, repaired, or replaced, check aileron balance. (Refer to Control Surface Balancing, 27-00-00.)

NOTE: Ensure that aileron hinge bearings rotate smoothly and are correctly installed before installing aileron.

T RII 2 Align aileron on wing and connect aileron bonding jumpers to aileron hinge fittings in wing. Secure aileron to wing with hinge bolts and safety wire bolts. Check electrical bonding. (Refer to applicable wiring manual, Chapter 20.)

T RII 3 Align aileron drive yoke with aileron drive clevis. Shim as necessary between yoke and clevis to prevent bearing preloading when clevis bolt is installed. Install clevis bolt, nut and cotter pin.

T 4 Route aileron trim tab actuator and potentiometer electrical wiring through wing aft spare and splice at bundle.

T RII 5 Connect balance tab push-pull tubes to wing bracket. (Refer to Removal/Installation, 27-10-03.)

T RII 6 Rig aileron control system. (Refer to Adjustment/Test, 27-10-00.)

T RII 7 Check aileron control system for proper operation

T 8 Install remaining access covers.

Touch up paint as required.

Restore electrical power to aircraft. (If required.)

Card #: 72003LDescription: AILERON - INSTALLATION

Card #: 72003LDescription: AILERON - INSTALLATION

60-72003R

Card #: 72003R Labor Hours: 0

Date :

Description: AILERON - INSTALLATION

*R406999_* R406999

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Sections 5-10-28 and 27-10-02 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL

NUMBER

T RII 1 If any portion of an aileron has been repainted, repaired, or replaced, check aileron balance. (Refer to Control Surface Balancing, 27-00-00.)

NOTE: Ensure that aileron hinge bearings rotate smoothly and are correctly installed before installing aileron.

T RII 2 Align aileron on wing and connect aileron bonding jumpers to aileron hinge fittings in wing. Secure aileron to wing with hinge bolts and safety wire bolts. Check electrical bonding. (Refer to applicable wiring manual, Chapter 20.)

T RII 3 Align aileron drive yoke with aileron drive clevis. Shim as necessary between yoke and clevis to prevent bearing preloading when clevis bolt is installed. Install clevis bolt, nut and cotter pin.

4 N/A

T RII 5 Connect balance tab push-pull tubes to wing bracket. (Refer to Removal/Installation, 27-10-03.)

T RII 6 Rig aileron control system. (Refer to Adjustment/Test, 27-10-00.)

T RII 7 Check aileron control system for proper operation

T 8 Install remaining access covers.

Touch up paint as required.

Restore electrical power to aircraft. (If required.)

Card #: 72003RDescription: AILERON - INSTALLATION

Card #: 72003RDescription: AILERON - INSTALLATION

60-72004L

Card #: 72004L Labor Hours: 0

Date :

Description: FLAP REMOVAL

*R407006_* R407006

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual, Chapter/Section 27-50-01.

B WARNING: SPOILERS WILL SLAM DOWN WHEN ELECTRICAL POWER IS REMOVED FROM

THE AIRCRAFT WITH HYDRAULIC PRESSURE APPLIED. REMOVE HYDRAULIC POWER

FIRST AND THEN REMOVE ELECTRICAL.

CAUTION: WHEN NECESSARY TO DISCONNECT AN ELECTRICAL BONDING JUMPER,

ENSURE THAT IT IS CORRECTLY REINSTALLED. ELECTRICAL BONDING INTEGRITY IS

ESSENTIAL TO THE PROPER OPERATION AND SAFETY OF AIRCRAFT ELECTRICAL AND

AVIONICS EQUIPMENT.

NOTE: When installing a new flap, it is necessary to trim the flap fairing to a proper fit. Two installation procedures are provided, one for reinstalling a previously removed flap and one for installing a new flap.

T 1 With hydraulic and electrical power supplied to aircraft, fully extend spoilers and flaps.

Remove hydraulic power from aircraft.

Remove electrical power from aircraft.

T 2 Remove attaching parts securing outboard and inboard bonding jumpers to flap assembly.

Remove sector assembly access cover located on aft lower side of wing.

T 3 Remove attaching parts securing flap pushrod assembly rod end and flap pushrod assembly bonding jumper to sector assembly.

T 4 Remove attaching parts securing flap assembly to flap nose tracks and carefully remove flap assembly from wing structure, so as not to damage flap tracks or flap track rollers.

Card #: 72004LDescription: FLAP REMOVAL

Card #: 72004LDescription: FLAP REMOVAL

Card #: 72004LDescription: FLAP REMOVAL

4 (Last)

60-72004R

Card #: 72004R Labor Hours: 0

Date :

Description: FLAP REMOVAL

*R406990_* R406990

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual, Chapter/Section 27-50-01.

B WARNING: SPOILERS WILL SLAM DOWN WHEN ELECTRICAL POWER IS REMOVED FROM

THE AIRCRAFT WITH HYDRAULIC PRESSURE APPLIED. REMOVE HYDRAULIC POWER

FIRST AND THEN REMOVE ELECTRICAL.

CAUTION: WHEN NECESSARY TO DISCONNECT AN ELECTRICAL BONDING JUMPER,

ENSURE THAT IT IS CORRECTLY REINSTALLED. ELECTRICAL BONDING INTEGRITY IS

ESSENTIAL TO THE PROPER OPERATION AND SAFETY OF AIRCRAFT ELECTRICAL AND

AVIONICS EQUIPMENT.

NOTE: When installing a new flap, it is necessary to trim the flap fairing to a proper fit. Two installation procedures are provided, one for reinstalling a previously removed flap and one for installing a new flap.

T 1 With hydraulic and electrical power supplied to aircraft, fully extend spoilers and flaps.

Remove hydraulic power from aircraft.

Remove electrical power from aircraft.

T 2 Remove attaching parts securing outboard and inboard bonding jumpers to flap assembly.

Remove sector assembly access cover located on aft lower side of wing.

T 3 Remove attaching parts securing flap pushrod assembly rod end and flap pushrod assembly bonding jumper to sector assembly.

T 4 Remove attaching parts securing flap assembly to flap nose tracks and carefully remove flap assembly from wing structure, so as not to damage flap tracks or flap track rollers.

Card #: 72004RDescription: FLAP REMOVAL

Card #: 72004RDescription: FLAP REMOVAL

Card #: 72004RDescription: FLAP REMOVAL

60-73012

Card #: 73012 Labor Hours: 0

Date :

Description: AUTOPILOT ROLL SERVO MOUNT CLUTCH TORQUE - CHECK

*R449270_* R449270

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Sections 5-10-28, 22-10-11 and 22-10-06 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C *List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL

NUMBER

T 1a Check autopilot roll servo mount clutch torque.

Disconnect electrical connector (J604) from autopilot roll servo.

T 1b Disengage turnbuckle locking clip and loosen turnbuckle sufficiently to allow removal of cables from capstan.

T 1c Remove spacer post from servo mount.

T 1d Remove safety from cable retaining screws and remove screws and washers from capstan.

T 1e Remove safety wire from attaching parts securing mounting plate to mounting bracket.

T 1f Remove autopilot roll servo actuator, roll servo mount and mounting plate from aircraft.

T 1g Remove attaching parts securing autopilot roll servo actuator to roll servo mount.

T 1h Remove safety-wire, screws, and cover plate from servo mount. Loosen and remove spacer post. Remove servo mount from servo actuator.

T 1i Position servo mount on holding fixture with capstan thru hole. Install capstan locking pin.

T 1j Attach torque wrench to 3/8 inch output shaft and check breakaway torque six (6) different times, three (3) clockwise, and three (3) counterclockwise. Torque shall be 93 to 102 inch-pounds.

T 1k If torque is within tolerance, proceed with step m.

Card #: 73012 Labor Hours: 0

Description: AUTOPILOT ROLL SERVO MOUNT CLUTCH TORQUE - CHECK

*R449270_* R449270

Work Card Tasks TECH INSP Step Description

T 1l If torque is not within tolerance, adjust as follows:

(1) Remove torque wrench from 3/8 inch output shaft.

(2) Position clutch adjustment wrench on torque adjustment nut. Tighten to increase torque or loosen to decrease torque, as required, until proper torque is obtained.

T 1m Remove servo mount from holding fixture and check free wheeling torque as follows:

Attach torque wrench (inch-ounce) to 3/8 inch output shaft and check torque required to turn shaft clockwise then counterclockwise. Torque shall not exceed 10.5 inch-ounces in either direction.

T 2a Check magnetic clutch as follows:

Install servo mount on servo actuator.

T 2b Connect power supply number one, set to 0 vdc, positive (+) to pin A of servo actuator connector P1 and negative (-) to pin B of servo actuator connector P1.

T 2c Connect power supply number two, set to 28 vdc to P1, pin E and ground to pin F.

T 2d Attach torque wrench (0-500 in-lbs) to 3/8 inch output shaft.

T 2e Wait 10 minutes before verifying holding capabilities

T 2f After 10 minutes, slowly increase voltage on power supply one to develop a torque value of 90 inch-pounds. Clutch shall not ratchet.

T 2g If clutch ratchets, the servo and mount assembly must be replaced. If clutch does not ratchet, turn off power supply and disconnect leads from servo actuator connector (P1).

T 2h Connect power supply number one, set to 0 vdc, negative (-) to pin A of servo actuator connector P1 and positive (+) to pin B of servo actuator connector P1.

T 2i Repeat steps 2c. thru 2g. to check opposite direction.

T I 3a Roll servo mount installation.

Assemble autopilot roll servo actuator, roll servo mount, and mounting plate. Torque bolts securing mounting plate to servo mount 30 to 40 inch-pounds (3.39 to 4.52 Nm) and secure with MS20995NC32 safety wire.

T I 3b Position mounting plate with servo attached on mounting bracket. Torque bolts 30 to 40 inch-pounds (3.39 to 4.52 Nm) and safety-wire.

T 3c Connect electrical connector (J604) to autopilot roll servo.

Card #: 73012 Labor Hours: 0

Description: AUTOPILOT ROLL SERVO MOUNT CLUTCH TORQUE - CHECK

*R449270_* R449270

Work Card Tasks TECH INSP Step Description

T I 3d Position forward cable (without turnbuckle) on capstan as shown and secure with cable retaining screw and washer. Safety-wire screw.

T I 3e Position aft cable (with turnbuckle) on capstan as shown and secure with cable retaining screw and washer. Safety-wire screw.

NOTE: Adjust actuator cable to 75(+/-10) pounds (34[+/-5] kg). Cycle aileron system 25 times and then reduce tension to 45(+/-5) pounds (20[+/-2] kg) and safety-wire cable tension adjustment.

T 3f Install spacer post and capstan cover. Safety-wire capstan cover attaching parts.

T 4a Perform operational check of autopilot roll servo actuator. (Refer to 22-10-06, Inspection/Check.)

Connect external electrical power source to aircraft.

T 4b Set Battery, Inverter and AVIONICS LEFT and RIGHT MASTER Switches on.

T 4c Engage autopilot by depressing AP button on flight control panel.

T I 4d Operate Pilot's Wheel Trim Switch LWD unarmed. Observe control wheel rotates left. Center control wheel.

T I 4e Operate Pilot's Wheel Trim Switch RWD unarmed. Observe control wheel rotates right. Center control wheel.

T I 4f Repeat steps 4d. thru 4e. using copilot's Wheel Trim Switch.

T 4g Disengage autopilot by depressing the AP button on the flight control panel.

T 4h Set AVIONICS LEFT and RIGHT MASTER Switches off.

T 4i Battery and Inverter Switches off.

T 4j Disconnect external electrical power source from aircraft.

T 4k Connect external hydraulic power sources to aircraft.

T 4l Retract flaps to full up.

T 4m Remove external hydraulic power and external power sources from aircraft.

Card #: 73012 Labor Hours: 0

Description: AUTOPILOT ROLL SERVO MOUNT CLUTCH TORQUE - CHECK

*R449270_* R449270

Work Card Tasks TECH INSP Step Description

T I 4n Okay to close _________.

All panels used to facilitate the maintenance of this task, remove all unwanted tools and equipment.

Card #: 73012Description: AUTOPILOT ROLL SERVO MOUNT CLUTCH TORQUE - CHECK

60-73013L

Card #: 73013L Labor Hours: 0

Date :

Description: INSPECTION AND EDDY CURRENT OF WING/FUSELAGE FITTINGS

*R406993_* R406993

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL NUMBER

T 1 Clean and visually inspect all eight wing/fuselage fittings (four per side). Using 10X magnification and adequate lighting, visually inspect fittings and support structure for fatigue cracks, deformation, corrosion, marks, scratches, fastener working, and general security.

I 2 *Conduct eddy current inspection of lug areas at spars 2, 5, 7,and 8 for fatigue cracks.

(Refer to NDI Manual [NDI-2], Part 3,53-50-01.)

Card #: 73013LDescription: INSPECTION AND EDDY CURRENT OF WING/FUSELAGE FITTINGS

Card #: 73013LDescription: INSPECTION AND EDDY CURRENT OF WING/FUSELAGE FITTINGS

60-73013R

Card #: 73013R Labor Hours: 0

Date :

Description: INSPECTION AND EDDY CURRENT OF WING/FUSELAGE FITTINGS

*R407025_* R407025

Work Card Tasks TECH INSP Step Description

A Reference Maintenance Manual Chapter/Section 5-10-28 if further information is necessary.

B NOTE: Place all discrepancies on a non-routine card and in ILM.

C List of calibrated test equipment used to perform task card.

TEST EQUIPMENT USED PART NUMBER SERIAL NUMBER

T 1 Clean and visually inspect all eight wing/fuselage fittings (four per side). Using 10X magnification and adequate lighting, visually inspect fittings and support structure for fatigue cracks, deformation, corrosion, marks, scratches, fastener working, and general security.

I 2 *Conduct eddy current inspection of lug areas at spars 2, 5, 7,and 8 for fatigue cracks.

(Refer to NDI Manual [NDI-2], Part 3,53-50-01.)

Card #: 73013RDescription: INSPECTION AND EDDY CURRENT OF WING/FUSELAGE FITTINGS

Card #: 73013RDescription: INSPECTION AND EDDY CURRENT OF WING/FUSELAGE FITTINGS

60-73014L

Card #: 73014L Labor…