Attachment 0003 - M and O Plan Guidance.xlsx
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- AH-64 Apache Accumulator, Hydraulic
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- W58RGZ-23-B-0025
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OPSHEET
| (Current Rev and Rev date) 2022 | Company Name | ||
| Full address, CAGE code, and plan number. | OPERATION SHOP TRAVELER |
WORK ORDER NO:
Date: ACFT: AH-64, OH-58, ETC SUBMITTED BY
Incoming Part Number: Outgoing Part Numbers:
AUTHORIZATION:
Date:
Approved by:
| Component Nomenclature | Outgoing NSN: | |
| S/N - |
| REFERENCES: 1. All references that are not referenced in the Depot Maintenance Work Requirements (DMWR, Usually Appendix A) will be annotated on the cover page, this includes Maintenance Engineering Orders (MEO's). MEO's will also be annotated in the affected step. 2. The current DMWR with date and changes will also be referenced on the cover page . | |
| REMARKS: |
CRITICAL SAFETY ITEM: The first page and then as applicable on each page of the plan, and any Subcontractor planning which affects a CSI CC, must contain a statement that is similar to the following: “This part is a Critical Safety Item (CSI) overhauled in accordance with QE-STD-2. Critical Characteristics (CC) must be 100% inspected and Engineering Services Activity (ESA) approval must be granted prior to implementing any change affecting a CC.”.
| STEP # | PROCEDURES/OPERATIONS | REFERENCE | ACTION TAKEN | MECH PID | TI STAMP |
| 1 | RECEIPT AND INITIAL INSPECTION |
QC: A. Record and/or verify serial number on tags are the same as on the component it is attached to.
B. Verify that all forms, records, tags, and other documents accompanying the Forward Longitudinal Bellcrank Assembly follow procedures prescribed by DA PAM 738-751.
| CC (CSI). Perform external inspection of Part for obvious damage. | LOCAL SHOP PRACTICES | ||||||
| 2 | Pre-Shop analysis, this will be conducted per chapter 3 in the DMWR. All forms must be completed including a component data form. MEO C4659D removes the Pre-Shop analysis, however, the component data form is still a requirement. Check MEO to see which is relevant. | Paragraph's 3-1 thru 3-7.1 pages 3-1 and 3-2 | Sign off for mechanic when applicable | Sign off for QA when applicable | |||
| REMOVAL OF Major Assemblies | |||||||
| 3 | Control of parts, and inspect for damage. | Para. 3-8 through 3-10.1, page 3-5 | |||||
| 4 | Removal of Linkage Assembly, figure 3-2 item 1. Remove Linkage assembly. NOTE: Do not remove Name plate (28) unless required. (notes in DMWR will be adhered to) | Para. 3-11.1 a., thru k. pages 3-5 through 3-13 | |||||
| 5 | Removal of Rod end Assembly, figure 3-7 item 1. Caution: To prevent damage to glands, pistons must be positioned at mid-stroke. | Para. 3-11.2 a. thru d. page 3-13 | |||||
| 6 | Removal of Piston. Figure 3-7 item 15. | Para. 3-11.3, a - j, pages 3-13 and 3-14. | |||||
| 7 | If there is a tolerance, shim measurement or anything that should be singled out that will require use later in the M&O that should be written as a write up of it's own. | ||||||
| 8 | Removal of Actuator assembly, Figure 3-2 item 29. | Para. 3-11.4, a. thru n. page 3-14 | |||||
| 9 | Pressure switch removal, figure 3-2 item 26. | Para. 3-11.5, a thru d. page 3-14 | |||||
| 10 | Screen removal, figure 3-2 item 42. | Para 3-11.6, a. thru c. page 3-14 | |||||
| DISASSAMBLEY GENERAL | |||||||
| 16 | Control of parts. | Para. 3-13, page 3-17 | |||||
| 17 | Inspect for damage. | Para. 3-14.1, page 3-17 | |||||
| DISSAMBLEY PROCEDURES | |||||||
| 18 | Servo Assembly procedures: Notes and Cautions WILL BE ADHERED to through this procedure. | Para 3-15.1, a. thru f. page 3-17 | |||||
| 19 | NOTE: Lap assembly (8) consisting of lap assembly (9), lap assembly (12) and manifold (15) is a matched set. Do not exchange similar parts with other sets. ● Do not disassemble manifold (15) unless required. (This must be a separate write up to ensure these parts are kept together) | Note page 3-17 | |||||
| 20 | Servo Assembly procedures: Notes and Cautions WILL BE ADHERED to through this procedure. | Para. 3-15 g. and h. page 3-17 | |||||
| 21 | Actuator Assembly. Install actuator assembly (Figure 3-7) in actuator assembly holding fixture (274040AT1) (Figure 3-8) using four 1/4-20 X 2-1/2 inch SCHS with four washers and four nuts. | Para. 3-15.2 page3-21 | |||||
| 22 | Feedback Link Assembly Disassembly. | Para. 3-15.3.1 Page 3-21 | |||||
| 23 | Feedback Lever Assembly and Summing lever assembly, Disassembly. | Para. 3-15.3.2, a thru l. page 3-21 | |||||
| 24 | Bracket disassembly. | Para. 3-15.3.3, page 3-24 | |||||
| 25 | Clevis Disassembly. | Para. 3-15.3.4, page 3-24 | |||||
| CLEANING | |||||||
| 28 | General Cleaning. All cleaning will be completed I/A/W DMWR. (Note, if specific cleaning of parts is mentioned, these parts should have separate entries) | Para 3-16, page 3-31 | |||||
| In-Process Inspections | |||||||
| 29 | In process inspection will be completed I/A/W DMWR, all notes and warnings will be complied with through out these inspections. | Para. 3-17 thru 3-17.5 pages 3-32 and 3-33 | |||||
| All OIPs should follow the examples below, they can vary, but must contain all OIP inspection steps and sign offs. | |||||||
| Overhaul Inspection Procedures (OIPs), All OIPs must be written individually for each part. | |||||||
| OIP 1, Linkage Assembly, PN 274060-103 or 107 | |||||||
| 30 | Serviceability, Visual inspection | Page 3-34, NO 1 | Inspection results here | Mech. Sign | QA as needed | ||
| 31 | Boost assembly condition (2 places), Visual, no cracks allowed. | Page 3-34, NO 2A | |||||
| 32 | Bearing Condition, (2 places), Manual, bearing should turn smoothly | Page 3-34, NO 3B | |||||
| 33 | Clevis threads (2 places), Visual, No stripped, crossed, flattened or missing threads allowed. | Page 3-34, NO 4C | |||||
| OIP 2, Rod Assembly, PN 274086-1 | |||||||
| 34 | Serviceability, Visual, Examine for corrosion, burrs or gouges. | Page 3-35, No. 1 | Inspection results here | Mech. Sign | QA as needed | ||
| 35 | Thread condition (Left hand thread), Visual, No stripped, crossed, flattened or missing threads allowed. | Page 3-35, No. 2A | |||||
| 36 | Thread Condition, Visual, No stripped, crossed, flattened or missing threads allowed. | Page 3-35, No. 3B | |||||
| 37 | Fractures and cracks, Visual inspect per Para 3-17.2. When cracks are suspected Fluorescent Penetrant per Para. 3-17.5 | Page 3-35, No. 4 | Visual, pass___ or Fail_____ If failed, FPI will be completed, see appendix (?) for results | ||||
| Below are example's of OIP's with different Critical Characteristic (CC). These examples may or may not pertain to this particular DMWR. | |||||||
| WARNING, CSI, Spring measurement is a CC. 100% inspection of all CCs prior to moving to subsequent operations is required. | |||||||
| 39 | ******WARNING, Spring measurement is a CC.****** Measure 0.745 - 0.780. The following information MUST be provided. PN_________________Part Serial Number___________ Inspection Date______________ Actual measurement _____________ TMDE _______________ Part Serial Number (SN), Part Number (PN), characteristic inspected, actual reading or dimension (torque, tolerance, etc.), date of inspection, identity of inspector, and calibrated tooling (name or SN) must be in that CC step CC's must stand out and be noticeable to ensure this is completed. | Page 3-60 | Results will be here | Mechanic signature | QA are required for CC's | ||
| 40 | ***Warning, Fluorescent Penetrant inspection is a CC*** Technique Sheet Control Number______________ | Page 3-60 | Pass_____ Fail ______ Technique sheets are found in appendix (?) | Mechanic signature | QA are required for CC's | ||
| 41 | Testing procedures (if applicable) should closely follow the assembly procedures. All testing producers must be incorporated, if a table for recording parameters is in the DMWR, that table's information must be incorporated in the plan. | ||||||
| Assembly procedures | |||||||
| 42 | General Assembly, ALL warning and note will be adhered to through out the assembly | Para. 3-20.1 page 3-99 | |||||
| 43 | Assemble Relief Valve | Para 3-21.1a. thru d. page 3-99 - 3-100 | results here (completed) | Mech sig. | QA if needed | ||
| 44 | Linkage Assembly | Para. 3-21.2, a and b. page 3-100 | results here (completed) | Mech sig. | QA if needed | ||
| Warning CSI, Verification of swagging of pin (28) and collar (27) is a CC. 100% inspection of all CCs prior to moving to subsequent operations is required. | |||||||
| 46 | Install new collar (figure 3-11, 27) on pin (28). | Para 3-21.2 c, page 3-101 | results here (completed) | Mech sig. | QA for CC | ||
| 47 | Install bracket (23) on other feedback lever assembly (12). Orient bracket similar to opposite bracket. | Para 3-21.2 d, page 3-101 | results here (completed) | Mech sig. | QA for CC | ||
| 48 | Install new pin (25) through bracket (23) and feedback lever assembly (12). | Para 3-21.2 e, page 3-101 | results here (completed) | Mech sig. | QA for CC | ||
| Warning CSI, Verification of proper swaging of pins (25 and |
31) and collars (24 and 30) is a CC. 100% inspection of all CCs prior to moving to subsequent operations is required.
| 50 | Install new collar (Figure 3-11, 24) on pin (25). | ||||||
| NOTE: Pin head must face out toward summing lever. | Para. 3-21.2 f, page 3-101 | ||||||
| 51 | Install one clevis (29) on summing lever assembly (15) with one new pin (31) and new collar (30). | Para. 3-21.2 g, page 3-101 | results here (completed) | Mech sig. | QA for CC | ||
| 52 | Install second clevis (29) on other summing lever assembly (15) with new pin (31) and new collar (30). | Para. 3-21.2 h, page 3-101 | |||||
| 53 | Install bushing (36) into summing lever assembly (15) as shown in Figure 3-11. | Para. 3-21.2 I, page 3-101 | |||||
| 54 | Install new pin (33) through feedback lever assembly (12), washer (35), and through bushing (36). | Para. 3-21.2 j, page 3-101 | |||||
| 55 | Install washer (35) on pin (33). | Para. 3-21.2 k, page 3-101 | |||||
| 56 | Warning CSI, Verification of proper swaging of pins (33) and |
(32) is a CC. 100% inspection of all CCs prior to moving to subsequent operations is required.
| 57 | NOTE: See Figure 3-17 and 3-18 for proper installation and verification procedures. Use pin/collar gage, (HG77-14A) for swage verification. | ||||
| 58 | Install one new collar (Figure 3-11, 32) on pin (33). | Para. 3-21.2 l, page 3-102 | results here (completed) | Mech sig. | QA for CC |
| 59 | Install second new pin (33) through second feedback lever assembly (12) and through second summing lever assembly (15). | Para. 3-21.2 m, page 3-102 | |||
| 60 | Install bushing (34) over pin (33) and into summing lever assembly (15). | Para. 3-21.2 n, page 3-102 | |||
| Warning CSI, |
Verification of proper swaging of pin (33) collar (32) is a CC. 100% inspection of all CCs prior to moving to subsequent operations is required. NOTE See Figure 3-17 and 3-18 for proper installation and verification procedures. Use pin/collar gage (HG77-14A) for swage verification.
| 61 | Install new collar (Figure 3-11, 32) on pin (33). | Para. 3-21.2 o, page 3-102 |
| WARNING If hydraulic fluid is decomposed by heat, toxic gases are released. Prolonged contact with liquid or mist can cause dermatitis and irritation. If there is any prolonged contact with skin, wash contacted area with soap and water. If liquid contacts eyes, flush eyes with water immediately for 15 minutes. Remove saturated clothing. If fluid is swallowed, do not induce vomiting. |
Get immediate medical attention. When handling liquid, wear rubber gloves. Inhalation of vapors should be avoided.
| 62 | Linkage Assembly, continued | Para 3-21.2, p. thru t. page 3-105 |
| 63 | Warning CSI, Verification of Installation of input linkage spacer is a CC. 100% inspection of all CCs prior to moving to subsequent operations is required. | |
| 64 | Linkage Assembly, continued | |
| 65 | Install one input linkage spacer (18) on outer |
stop bolt (22) next to summing lever assembly
| (15). | Para 3-21.2 u. Page 3-105 | |||
| 66 | Install input link assembly (19) on outer stop | |||
| bolt (22) next to input linkage spacer (18). | Para 3-21.2 v. Page 3-105 | |||
| 67 | Warning CSI, Verification of Installation of input linkage spacer is a CC. 100% inspection of all CCs prior to moving to subsequent operations is required. | |||
| 68 | Install second input linkage spacer (18) and second summing lever assembly (15) on outer stop bolt (22). | Para 3-21.2 w, page 3-105 | ||
| 69 | Install nut (11) on outer stop bolt (22). | Para 3-21.2 x, page 3-105 | ||
| 70 | Torque nut using linkage assembly tool (274060AT2) (Figure 3-12) to 70-80 inch pounds. Actual Torque____________ PN ___________________ Part Serial Number__________________ Inspection Date __________ TMDE _______________ | Para 3-21.2 y, page 3-105 | ||
| 71 | Linkage Assembly, continued | Para. 3-21.2 z thru an. pages 3-105 thru 3-107 | ||
| 72 | Install nut (3) on linkage retaining bolt. Torque nut to 20-25 inch-pounds. Actual Torque_______________ PN ______________________ Part Serial number_________________ Inspection Date ______________ TMDE ________________ | Para 3-21.2 ao., page 3-107 | ||
| 73 | Linkage Assembly, continued | Para 3-21.2, ap thru aq page 108 | ||
| 74 | Warning CSI, Verification of proper swaging of pin (2) and collar (1) is a **CC**. 100% inspection of all CCs prior to moving to subsequent operations is required. | |||
| 75 | NOTE: |
● See Figure 3-17 and 3-18 for proper installation and verification procedures. Use pin/collar gage (HG77-13A) for swage verification.
● Swage pin head must be on same side as bolt heads.
| 76 | Install new collar (Figure 3-11, 1) on swage pin (2). | Para 3-21.2, ar. page 108 | ||
| 77 | Linkage Assembly, continued | Para 3-21.2, as and at. page 108 | ||
| 78 | Testing procedures (if applicable) should closely follow the assembly procedures. All testing producers must be incorporated, if a table for recording parameters is in the DMWR, that table's information must be incorporated in the plan. Testing equipment must also have the Serial number and calibration due date. | |||
| 79 | Final Testing and Assembly | |||
| 80 | Make sure all parts are clean and that corrosion preventive materials have been removed. | Para 4-1.1 a, page 4-1 | ||
| 81 | Replace all parts listed in App. B, Table B-3. | Para 4-1.1 b, page 4-1 | ||
| 82 | NOTE: | |||
| Torque values given are in addition to rundown torque. Torques must be within specified limits. If part is to be safety tied, tighten to lowest recommended torque, then advance to line up for safety tying. Never go above highest recommended torque. Unless specified, do not drill a second cotter pin or lockwire hole in any part previously drilled. Replace part if holes cannot be lined up. | Para 4-1.1 c, page 4-1 | |||
| 83 | Install cotter pins and lockwire per NASM33540. | Para 4-1.1d, page 4-1 | ||
| Final Assembly | ||||
| 84 | General Assembly | Para. 4-2.1 | ||
| 85 | General Assembly continued | Para. 4-2.1, a, (1) - (6) | ||
| FINAL PAINT | ||||
| 89 | Clean, preparation, primer, paint. | Para. 4-4 | ||
| SHIPPING | ||||
| 90 | Part marking, IUID, Final inspection, Shipping documents. Container documents and marking. | Para. 4-4 |
01-242-1495 Repair Procedure I Removal and Installation Of Damaged or Worn Basic (production) Bushing/Bearing &"Arial,Bold"&12(PVA) WON_________ Critical Safety Item QE-ST-2 does apply
| Rev. 3 dated 21 June 2010 | SAMPLE MAINTENANCE AND OVERHAUL PLAN |
| **REFERENCE ONLY** | Critical Safety Item QE-STD-2 does apply |
&"Arial,Bold"&12PVA Page &P &"Arial,Bold"&12PVA
&"Arial,Bold"&12 Page &P &"Arial,Bold"&12
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