35D6-1-106.pdf

TO 35D6-1-106

TECHNICAL MANUAL

PERIODIC AND MAINTENANCE INSTRUCTIONS

AIRCRAFT AND ENGINE SLINGS (GENERAL) AND

RESTRAINING DEVICES

FOR AEROSPACE GROUND EQUIPMENT

AF41 (608)-34477

This manual supersedes TO 35D6-1-106, dated 18 October 2013.

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government Agencies and their contractors (Administrative or Operational Use) (1 October 2003). Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to AFLCMC/WNZEA.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published Under Authority of the Secretary of the Air Force

11 SEPTEMBER 2014

CHAPTER 1

INTRODUCTION

1 INTRODUCTION.

This publication is intended to outline general instructions for periodic inspection and maintenance of all aircraft and engine slings and restraining devices not covered by specific Air Force Technical Orders. In addition to this manual, in-spection work cards and AFI91-203 may provide inspection and maintenance instructions. In cases where discrepancies exist between any of these manuals, the most stringent re-quirement takes precedence. This publication does not apply to slings, harnesses, or other lifting devices used to lift or secure personnel.

2 GENERAL.

These instructions are intended to prevent the failure of component parts of sling and restraining assemblies which could result in serious injury to operating personnel and/or extensive damage to Air Force equipment. These instructions are necessarily general in nature, due to the many configura-tions and designs of aircraft and engine slings and restrain-ing devices, but they can be applied to specific equipment as applicable. The equipment referred to herein is designated as Aerospace Ground Equipment (AGE).

3 PRE-USE INSPECTION INSTRUCTIONS.

Visual inspection shall be performed before each use of sling and restraining device in accordance with Table 1.

Table 1. Pre-Use Inspections

Component Part Instructions Cable Assemblies Inspect for broken wires, excessive rust or corrosion.

Spreaders, Beams, Links and Plates Check for distortion, strain and cracks.

Note especially areas around bolt holes.

Shackles, Safe-Line/U-bolt Clamps and Hardware Inspect for security of attachment and evidence of strain.

Welds Check for cracking or separation.

Cloth Webbing and Straps Inspect for mildew, dry-rot and broken stitching.

Chain and Chain Assemblies Check for bent, twisted, worn and poorly welded links.

4 MONTHLY LUBRICATION.

a. Perform monthly lubrication in accordance with Table 2.

b. The time period specified for lubrication is intended for equipment in frequent use. If equipment is used only occasionally (less than once a month), perform lubrication procedures prior to each use.

c. In dusty, dry climates reduce the amount of lubrication applied to exposed surfaces to a minimum. In damp or salt air climates increase lubrication to prevent rust and corrosion. Corrosion Preventive Compounds (CPC) should be applied per TO 1-1-691 prior to storage and reapplied at an interval set to match the life expec-tancy of the CPC.

d. Complete lubrication, when applicable, must be ac-complished whenever equipment has been cleaned or exposed to inclement weather.

5 ANNUAL INSPECTION.

All field sling and restraining devices shall be visually in-spected for general condition annually. The slings and re-straining devices will be cleaned and lubricated in accor-dance with the instructions contained in this Technical Order prior to re-storage.

5.1 Wire Rope, Chain and Metal Bar Type Slings and

Restraining Devices.

Perform all solvent cleaning operations in an ap-proved cleaning cabinet or in a well ventilated area. Avoid prolonged breathing of vapors. Avoid eye and repeated skin contact. Keep solvents away from sparks and flames.

a. Remove all dirt and foreign matter by cleaning with solvent, Specification MIL-PRF-680, Type II or Type III. Remove stubborn accumulations with a wire brush and dry thoroughly with compressed air.

b. Inspect bolts, collars, hooks, pins, shackles, welds and/or any other area as identified by specific blue print or technical order using the inspection method identi-fied in the specific document. If no specific document is available, visually inspect all parts with the aid of a 3x magnifier. Inspect questionable or repaired areas using the magnetic particle method (MT) for ferrous parts and the liquid penetrant method (PT) for non-ferrous parts (see TO 33B-1-2). Parts that require the MT or PT inspection methods must be disassembled and have any coatings removed that may interfere with the inspection. In circumstances where alternative tech-niques are required the local NDI supervisor shall fol-low guidance in TO 33B-1-1 Section III Reporting New or Improved NDI Techniques.

NOTE

Slings equipped with rubber-coated attaching fit-tings, such as aircraft canopy slings, are exempt from magnetic particle, dye-penetrant and radio-graphic inspection cited in Step b. Slings in this category will be proof-load tested in accordance with Paragraph 7.

c. Inspect all bolts, pins and miscellaneous hardware for evidence of wear, strain and distortion.

d. Inspect all bolt holes subject to strain for elongation and/or stripped threads.

e. Inspect cable assemblies for security of fittings and presence of broken wires in strands. The presence of more than six broken wires in any one-inch length of 7- by 19-inch wire rope, or three broken wires in any one-inch length of 7- by 7-inch wire rope, shall be cause for replacement. If excessive corrosion or rust is present, cables will be replaced, regardless of the num-ber of broken wires. Wire ropes will also be taken out of service when the wires in the crown of the strand are worn to less than 60 percent of their original diam-eter.

f. Inspect adjusting screws for crossed threads, burrs, rust, corrosion and alignment.

g. Inspect rollers on trolley assemblies for evidence of gouging or grooving.

h. Inspect chain and chain assemblies for security and serviceability. Chains having bent, twisted, worn and/or poorly welded links will be removed and replaced.

Table 2. Lubrication Instructions

Component Part Lube Instructions Beams, Rails and Links Grease, Specification MIL-

PRF-23827C

Clean and butter-lubricate all mating areas subject to wear.

Screw Assemblies Fully extend, clean and butter-lubricate.

Rollers Clean and butter-lubricate.

Cables Oil, Specification MIL-C-

16173E, Grade 4 Clean and oil lightly.

Pin Joints and Bushings Clean and oil lightly.

Chain and Chain Assemblies Oil, Specification MIL-C-

16173E, Grade 4 Clean and oil; wipe off excess but allow oil to re-main between links.

5.2 Fabric Webbing-Type Slings.

Perform all solvent cleaning operations in an ap-proved cleaning cabinet or in a well ventilated area. Avoid prolonged breathing of vapors. Avoid eye and repeated skin contact. Keep solvents away from sparks and flames.

a. Spot clean with solvent, Specification MIL-PRF-680, Type II, to remove dirt and grease; dry thoroughly with compressed air.

b. Inspect all straps for frayed webbing and parting of stitching at all seams.

6 REPLACEMENT OF COMPONENTS.

Replacement of components consists of changing parts that do not require welding, swaging, fabrication or machining.

Replacement components are limited to commercial off the shelf parts, stock listed parts and parts sourced from a quali-fied manufacturer.

a. All component parts found defective during pre-use and/or annual inspection will be repaired or replaced.

When a component is replaced, use an exact duplicate.

b. Replacement consisting only of the substitution of components such as hooks, chains or shackles supplied with a proof test certification do not require a new load test.

7 SLING REPAIRS.

NOTE

Although welding is not recommended unless oth-erwise specified in the applicable Technical Order for a specific sling, it is included herein so repairs may be accomplished in case of emergency.

a. When welding, use standard equipment and welding rods for the material involved. For all load bearing structural members such as beams, channels, etc., after weld repair, the material must be returned to the tem-per specified on the manufacturer’s drawing.

b. After heat treat, check for hardness.

c. Component parts manufactured by any activity will be manufactured in accordance with the manufacturer’s drawing for that part. Sling and restraining device drawings can be obtained from the ALC having prime responsibility for the sling or restraining device.

d. Repaired slings or restraining devices will be proof tested prior to use in accordance with Paragraph 8.2.

8 TESTING SLINGS.

Before subjecting the sling to any weight, make sure the sling is not damaged or defective; the loads are properly attached and secured; and no personnel will be standing or walking under sus-pended loads. Failure to observe this warning may result in serious damage to equipment and death or serious injury to personnel.

8.1 Load Testing of Slings Used to Lift Either a Critical

or Non-Critical Load.

NOTE

When required by component replacement, slings and restraining devices shall be subject to a load test. A load test is defined as a load no less than 100%, and no greater than 125% of the rated ca-pacity, or the load applied under actual working conditions. Records of inspection, lubrication and load testing shall be strictly maintained by the unit.

a. All slings in regular service (used weekly, monthly, bi-monthly, etc.) shall be annually inspected, lubricated and load tested to no less than 100% and no greater than 125% of rated capacity. A sling in storage, that will not be used, is not required to be load tested an-nually, but shall be inspected and lubricated annually.

b. Slings coming out of storage to be put into service shall be inspected and lubricated prior to use. If no load test was accomplished within the prior year, the sling shall also be load tested prior to use.

8.2 Proof Testing.

a. When repair other than component replacement is re-quired, slings, spreader bars, lifting beams and other specialized lifting attachments shall be subject to a proof test as outlined in AFI 91-203. Rated-loads ap-pear on many slings and restraining device drawings, but when drawings are not available, the object can be weighed and/or engine thrust researched through ap-plicable aircraft/engine Technical Orders and the weight calculated to determine the load required for the proof test. Component parts, such as legs, chain and cable assemblies that have been manufactured and/or repaired, may be load tested individually. When main structural members, such as beams, channels, etc., are manufactured or repaired, the entire sling as-sembly/restraining device must be proof-load tested.

b. Complete slings and restraining devices may be sus-pended from an overhead hoist or lifting crane for test-ing. Install a crane-type dial indicating scale between lift hook and sling/restraining device lift attachment.

Attach weights to sling/restraining device lift members or attach members to a stationary point. With the sling/ restraining device suspended in its intended use con-figuration, gradually and continuously apply lifting force until the full proof test is attached.

c. The proof test shall remain on the sling/restraining de-vice for not less than 3 minutes. Inspect sling restrain-ing device for evidence of slipping, loosening of fit-tings, fraying of cable or webbing, permanent bending or set on beams, or any other signs of failure. Evi-dence of the above shall be cause for rejection of the sling/restraining device.

d. Detachable components from very large capacity sling and restraining devices may be tested separately in the above manner or by attaching the component to a sta-tionary point and applying testing force to the free end, with the sling and restraining device in a horizontal position.

e. Slings and restraining devices which withstand proof test testing shall be considered serviceable. Slings and restraining devices which fail proof-load testing shall be repaired or replaced.

NOTE

After proof testing, inspect by Non-Destructive Inspection (NDI) in accordance with Paragraph 5.1, Step b, as applicable.

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Table 3. Suggested Testing Equipment

Nomenclature Capacity Part Number NSN Scale, Crane Type 0-1,000 lbs 64EL 6670-00-078-0502 Scale, Crane Type 0-4,000 lbs HC2-12 6670-00-557-5594 Scale, Crane Type 0-10,000 lbs HC5-24 6670-00-816-6705 Tensiometer, Dial 0-20,000 lbs TD5-20000 6635-00-065-7096 Calibration Kit, with Load Cell 0-100,000 lbs M170-5A1TC100K or CR40004/2A 6670-00-795-3253

THE END

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