Attachment_4_-_35E8-2-5-3 _Sec_5._pg_109-142.pdf

CHAPTER 5

INSPECTION, REPAIR, AND REPLACEMENT

5.1 SCOPE.

This chapter contains special procedures for inspecting dis-assembled components and repair and replacement data for Aircraft Arresting Barrier Model BAK-12/E32A after perfor-mance of procedures described in Chapter 3. AU disas-sembled components are to be cleaned and cheeked for gen-eral condition, corrosion, wear, and proper fit. After inspection, all parts shall be repainted, if necessary. In addi-tion, refer to Appendix C for process specifications and spe-cial finishes. Replace all seals and gaskets. General, com-monly known procedures are not included. Only those procedures which are unique are covered.

5.2 TERMS.

The following is a list of terms which pertain to bearing failures and are the basis for bearing rejection:

a. Spelling: Failure of bearing surface widened by metal particles breaking away from the surface. Usually preceded by minute surface cracks.

b. Smearing: Minute particles of one surface tear away and reveal themselves to the same surface or to the mating sur-face.

c. Corrosion: Pitting, discoloration, and rusting of surfaces.

d. Cracks: May be in balls, rollers, cone, cup, inner case, outer case, cage, or separators.

e. Scoring: Usually outer or inner surface con-tacting housing or shaft. Indicative of problem in mating parts.

f. Discolor-ation:

Usually a sign of excessive heat.

This is not to include a little tar-nish, stain or corrosion on the out-side surfaces of the inner race, outer race, cone, or cup which is not detrimental to the operation of the bearing and need not be re-moved. Overheated areas are gen-erally darkened to a brownish blue or blue-black color.

g. Brinelling: Indentations in the raceways where balls or rollers have impressed their pattern into the surfaces.

h. Abrasion: Evidenced by surface condition and gross wear of parts.

5.3 HYDRAULIC CONTROL VALVE.

Replace old models with new hydraulic control valve. If valve is current model, disassemble and replace all seals.

5.4 RELIEF VALVE.

Proceed as follows:

a. Visually inspect all parts for any signs of dirt, grit, physical damage, or wear. Small scratches on the pis-ton will not be cause for replacement unless on the seating surface. The same applies to the body seat. O-ring grooves must be smooth and undamaged and the bore in the body for the piston must be smooth and free of corrosion or scratches. The spring must be clean and not corroded or nicked in any way. The adjusting nut threads must be in good condition with no signs of upsetting or galling and should turn easily in the body threads.

b. Replace O-rings and seals.

5.5 REWIND GEAR REDUCER.

Proceed as follows:

a. Bearings

(1) Inspect for physical damage to seals, cup, cone, rollers, or cage.

(2) Inspect for corrosive attack to seals, cup, cone, rollers, or cage.

(3) Inspect by slow rotation for roughness, sudden stopping or catching, sticking. Reclean and re-check if any of these conditions exist.

b. Gearset

(1) Check gear for score marks, wiping of metal, pit-ting or other signs of undue wear.

(2) Check wormshaft for score marks, wiping of metal, pitting or other signs of undue wear.

(3) Check shafts for eccentricity.

(4) Cheek gearset for corrosion.

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Attachment 4 FA5215-16-Q-9003

(5) The tolerance limits for worm end-position, gear side-position, and center distance are ± 0.001 inch. Opposed mounted single row tapered roller bearings are properly set for the following end-play:

Worm bearings = 0.004 in.

Gear bearings = 0.000 in.

5.6 SELECTOR VALVE.

Proceed as follows:

a. Visually check stem and seals for wear, scratches, or corrosion. This particularly applies to the seal faces and the stem surface rotating against the seal faces.

These surfaces must be highly polished and free of scratches.

b. Examine thrust washers and the thrust bearing for cor-rosion or signs of physical damage.

c. Check seal springs and detent spring for corrosion or signs of failure.

d. Check the body for damaged threads, security and condition of the stop pin, and for corrosion.

5.7 BARCO UNIT.

At overhaul, this unit is replaced with a Deublin rotary joint.

5.8 DEUBUN ROTARY JOINT.

Proceed as follows:

a. Inspect all parts for corrosion or physical damage.

b. Check seal faces to see they are smooth, polished, and unscratched.

c. Check bearings for wear.

d. Wipe faces of inner seals with clean soft tissue.

e. Wipe faces of bronze bearing (which acts as seal faces) with clean soft tissue.

5.9 HAND PUMP.

Proceed as follows:

a. Inspect body bore for any possible corrosion or physi-cal damage. Bore should be highly finished with no scratches.

b. Check all O-ring surfaces to see that there is no corro-sion or physical damage.

c. Check piston in wiper area to determine if wear or scratching has occurred.

d. Check condition of all threads and the O-ring seating surfaces where used.

e. Check condition of seating surfaces for the poppet subassemblies.

5.10 ACTUATOR.

Proceed as follows (if actuator is not latest model, replace):

a. Inspect rubber boot for flexibility, for weathering cracks, or other signs of deterioration. Discard if de-fective.

b. Check piston for corrosion or signs of physical dam-age. Small scratches or discoloration of the surface is permissible. O-ring groove finish must be free of scratches and corrosion. Install a new O-ring and backup ring.

c. Inspect intake ball check and the seat in the valve block. If the ball shows any sign of wear or corrosion, discard and replace. Check the seat for signs of corro-sion or damage. If necessary, dress the seat in the valve body with lapping compound.

d. Inspect valve body parts to be certain of cleanliness, and check O-ring groove to ascertain it is free of scratches or corrosion.

e. Check links and pins for wear. Replace pins if grooved or worn 0.010 out of round. Links worn 1/64 out of round in holes should be replaced.

f. Check barrel for wear, scratches or corrosion. Some discoloration is permissible but no pitting or major scratches are allowed. Inside surface should be smooth with a 20-33 micro-inch finish. If local surface imper-fections exist, hone after removing stop ring. Maxi-mum metal removal is 0.005 to 0.001 on diameter.

5.11 RESERVOIR.

Proceed as follows:

a. Replace sight glass, if defective.

b. If the fluid return fitting is at a height greater than near the bottom of the sight glass (less than approximately 10 inches from top of reservoir), replace reservoir or relocate fluid return fitting.

c. Examine inside of reservoir for signs of corrosion, re-sidual deposits, or foreign matter. Replace or reclaim if any of these conditions exist.

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d. Replace magnetic plug, O-ring, and breather vent.

e. Perform a hydrostatic test at 25 PSI for 10 minutes.

f. Repaint, if necessary

5.12 ACCUMULATOR.

Proceed as follows:

a. Disassemble and thoroughly flush and clean accumula-tor. No foreign matter, residue or corrosion shall re-main.

b. Upon completion of reassembly, block off all openings and perform a hydrostatic pressure test at 500 PSI for 30 minutes.

5.13 REEL TACHOMETER.

Proceed as follows:

a. There is no disassembly for the indicating head which is basically a sealed unit and does not require routine maintenance.

b. Service of the indicating head is impracticable, so unit replacement is anticipated.

5.14 NEEDLE VALVE.

Proceed as follows:

a. Inspect O-ring groove in bonnet for damage, scratches or corrosion.

b. Check threads in bonnet where stem threads engage, for damage.

c. Check threads on bonnet where they engage the body, for damage, evidence of galling, or corrosion.

d. Inspect stem for evidence of damage scoring, or gall-ing.

e. Inspect body threads for damage, evidence of galling or corrosion.

f. Inspect seat for damage.

g. Replace seals.

5.15 FLUID COUPLING (TWIN DISC).

All couplings are replaced with fluid couplings having an expansion chamber.

5.16 RIGHT ANGLE DRIVE.

Proceed as follows:

All drives must be filled with oil before operation, except RIGHT 90’s which are prelubricated for an ambient temperature range of 15 °F to 60 °F.

a. Remove top plate from housing. Check the condition of the gears by visual inspection and by turning the shaft to obtain backlash and contact feel. Turn several complete revolutions and determine there are no high spots or local resistance indicative of a bent shaft or damaged gears. Turn slowly to determine bearing con-dition and end play in bearings. Unless there is an in-dication of difficulty the disassembly should be limited to seal replacement.

b. With end caps removed, the shafts at the seal positions should be smooth and free of scratches or corrosion.

Surface roughness should be 15 to 25 micro-inches.

Shaft diameter should be plus or minus 0.003 inch.

5.17 CHAIN TENSIONERS.

Proceed as follows:

a. Inspect tensioner shaft for wear. If area of contact with needle bearing has worn more than 0.002 from the nominal shaft diameter, the tensioner shaft should be replaced.

b. Inspect needle bearing for signs of wear, corrosion, flatting, or other damage. Bearing may stay in sprocket for this inspection. If rollers fall out of bearing, the bearing must be replaced.

c. Inspect the sprocket for wear. As these are idler sprock-ets, they are not subject to the severe wear from driv-

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5-3 ing; and, thus, are normally serviceable. However, wear of teeth or corrosion of teeth, if pronounced, is basis for replacement.

5.18 BRAKE ASSEMBLIES.

Refer to List of Related Manuals for data pertaining to Ben-dix brakes. For Bliss type brakes, proceed as follows:

5.18.1 General.

a. Inspect all metal parts for cracks or damage.

b. Inspect threads for damage.

c. Inspect cap screws for wear or damage.

d. Inspect lock washers for locking station.

NOTE

The brake repair kit as described per CAGE 98752 print 9873442 (i.e., the BAK-12 rotors, stators, backing plate, pressure plate) shall not be inter-mixed between manufacturers during the overhaul/ installation or replacement process. As an example:

a BAK-12 system (i.e., two BAK-12 units), re-quires four brake kits during overhaul. The over-haul facility shall replace the four expended or time expired brake kits with four new brake kits from the same manufacturer. Currently, CAGE 21439 and CAGE 87679 are approved manufac-turers of the brake repair kit. Therefore, a BAK-12 system, sent to the field for service, shall be deliv-ered with either all CAGE 21439 brake kits or CAGE 87679 brake kits; however, under no cir-cumstance shall a BAK-12 system contain brake kits from two different manufacturers.

5.18.2 Brake Wear. All frictional brake components shall

either be 100% replaced or overhauled per criteria within this section. Overhaul of rotating discs, backing plate assem-bly, stator assembly, and pressure plate assembly shall only occur once. If brakes that have been overhauled require re-placement, all frictional components shall be 100% replaced.

If there is any question as to whether components have al-ready been overhauled, 100% replace.

5.18.3 Carrier Assemblies.

a. Examine for possible stuck or sluggish pistons.

b. Lubricate pistons with hydraulic fluid.

5.18.4 Rotating Discs.

a. Replace rotor assemblies when worn to a thickness of

0.370 inch or less. Measurements should be made at various points on the rubbing surface.

b. Friction material may be pitted up to 25 percent in any segment. However, it should not be concentrated and should be less than 50 percent in any area.

c. Check rotors for distortion and cracks, and replace if cracked.

(1) Discs that have been distorted enough to cause excessive brake drag should be replaced.

(2) Disk in excess of 0.040 inch should be consid-ered reason for replacement.

d. Individual rotor wear should be uniform between ro-tors. If a rotor is excessively worn compared to others, or one side is unusually worn, it should be replaced.

5.18.5 Backing Plate Assembly.

a. Check for damage or cracks.

b. Check wear pad attaching rivets for tightness.

c. Check backing plate wear pads, and when any wear pads have worn to a thickness of 0.090 inch or less, all pads should be replaced. This means a measurement of the backing plate and wear pads will be 1.085 inches, or less.

d. Cold straighten the backing plate base after the wear pads have been removed, if required.

e. Using the proper rivets, install the pads and rivets with the rivet head flush or below the wear pad.

f. Surface grind the backing plate assembly to a wear pad thickness of 0.120 inch minimum. Surface to be flat within ± 0.010 after grinding.

5.18.6 Stator Assembly.

a. Check for damage or cracks.

b. Check wear pad rivets for tightness.

c. Check stator plate wear pads and when any wear pads have been worn to 0.090 inch or less, all pads must be replaced. This means a measurement of total thickness will be 0.390 inch, or less.

d. Cold straighten the stator plate after the wear pads have been removed, if required.

e. Using the proper rivets, install the new wear pads and rivets with the rivet head flush or below the surface of the pads.

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f. Surface grind the assembly to a wear pad thickness of

0.120 inch minimum. Surface to be flat within ± 0.010 after grinding.

5.18.7 Pressure Plate Assembly.

a. Check for damage or cracks.

b. Check wear pad attaching rivets for tightness.

c. Check pressure plate wear pads, and when any wear pads have worn to a thickness of 0.090 inch or less, all pads should be replaced. This means a measurement of the backplate and pads of 0.405 inch or less.

d. Cold straighten the pressure plate after the wear pads have been removed.

e. Using the proper rivet, install the pads and rivet with the rivet head flush or below the surface of the pad.

f. Surface grind the subassembly to a wear pad thickness of 0.120 minimum and the surface must be flat within ± 0.010 after grinding.

5.18.8 Brake Adjusting Pins. Check for damaged threads

or distortion.

5.18.9 Return Spring Cup. Check for damage or distor-

tion.

5.18.10 Torque Tube.

a. Inspect for damage to key slots.

b. Inspect for cracks.

5.18.11 Heat Shields. Check arid if damaged or cracked, replace.

5.18.12 Pistons.

a. Check for damage or scratches and, if present, polish with fine sand paper (100 - 180 grit).

b. Verify the integrity of the O-ring groove, i.e. no dam-age or corrosion.

5.18.13 Piston Seals (O-Rings). Replace at each over-

haul. If rinse is necessary inspect for cuts, damage, or distor-tion.

5.18.14 Piston Backup Rings. Check for damage or dis-

tortion.

5.18.15 Piston Wiper.

a. Check for damage or distortion.

b. Check fit of piston to assume wiping action.

c. Replace if defective.

5.18.16 Carrier.

a. Check for damage or cracks.

b. Check plugs for leakage.

c. Check piston cavity bores for damage or scratches.

d. Piston walls may have minute nicks or scratches, ap-proximately 0.0015 inch deep and 0.075 inch long.

Scratches and/or nicks will be limited to 10 percent of the areas in any one 90° quadrant of the bore.

e. Nicks or scratches that exceed the above criteria may be repaired by smoothing out blemishes. Finished bore to be 1.378 inches maximum diameter with a mini-mum surface finish of 16 micro-inches.

f. Light corrosion may be polished with crocus cloth and hydraulic fluid.

g. Severe corrosion or deep scratches that cannot be cor-rected by the above will require either carrier replace-ment or sleeving of the damaged piston bore by a ma-chine shop. Typical procedures for sleeving carrier piston bores include the following:

(1) The carrier is placed on mill table and the face is dialed in using a dial indicator.

(2) The carrier is shimmed and clamped so that it is square with the boring head.

(3) The boring tool is dialed in with an indicator to find the center of the piston bore.

(4) The piston bore is then bored to a depth of 1.250” and an I.D. of 1.5015” with a square shoulder to accommodate a liner sleeve. The sleeve has a Rockwell hardness of between 60 and 65 °C and has an interference fit of 0.001” to 0.0015”. It has been honed to an inside diameter of 1.375”.

(5) Clean bored hole of all oil and metal shavings.

Inspect bored hole for smoothness and consis-tency to ensure a clean tight fit between sleeve and bored carrier.

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(6) The sleeve is then frozen in liquid nitrogen and placed in the hole that has been buttered with loctite “609” retaining compound.

(7) After the sleeve has warmed to room temp the I.D. is checked to be sure it is 1.375”. Hone if necessary.

(8) Clean all carrier passage ways and piston bores after machine work and pressure test brake car-rier per TO 35E8-2-5-3, A-23 number 1, Carrier Assembly.

h. Replace carrier.

i. Replace bearings.

5.19 REWIND TAPE SHEAVE ASSEMBLY.

Proceed as follows:

a. Replace sheave seals and check for corrosion. Then clean and inspect sheave bearings for corrosion.

b. Cracking may occur on any flange surface, edge, radii, bolt hole and support areas (see Figure 5-1 and Figure 5-2).

c. Primary NDI procedure-eddy current:

(1) NDI Equipment:

(a) Eddy current inspection unit: Staveley Nortec 2000D.

(b) Probe, 90° angle surface, shielded, 1/8-inch diameter, frequency range to include 200 kHz, differential with a 4 pin fischer connec-tor.

(c) Probe, bolt hole, appropriate diameter, shielded, frequency range to include 500 KHz (rotary) differential/reflection with a 4 pin fischer connector.

(2) Follow locally established safety instructions.

(3) No special access required.

(4) The sheave shall be removed from the assembly prior to inspection.

(5) Clean part as necessary to permit suitable contact between the part and probe.

NOTE

Penetrant inspection is impractical on porous ma-terials, various types of anodized aluminum sur-faces, or other protective coatings on other metals.

Penetrant rapidly enters the pores of the material and becomes trapped. This can result in back-ground that reduces contrast or can mask any po-tential discontinuity indications. In addition re-moval of the penetrant may not be possible after the inspection.

(6) See General Eddy Current supplement, Surface Scan Aluminum for Equipment Settings/Calibra-tion.

NOTE

In order to protect the probe from wear and dam-age, it is recommended that teflon tape be applied to the contact surface of the probes - PN 3M5480, maximum thickness 0.005”’. This practice also helps to reduce noise.

(7) Perform inspection on sheave roller flanges, edges, radii and support areas (see Figure 5-1 and Figure 5-2).

NOTE

If inspection surfaces of the aluminum casting is porous to the extent of being unable to perform the required eddy current inspections (displays too much noise), as an alternate method, a visual in-spection with flashlight and a 10x magnifying glass may be used to accomplish the inspection.

(8) Inspect all accessible bolt holes and any other holes using a flashlight and 10x magnifying glass.

NOTE

The rotary bolt hole scanners shall be used where access is possible. It is recommended that the Staveley Nortec Spitfire or MiniMite rotary scan-ner is used in this application.

(9) Redundant inspection is recommended where ac-cess is possible.

(10) Acceptance criteria is, no cracks are permitted. If cracks are found, mark with approved marking material and report to 642 CBSS/GBZO - ENI engineering.

(11) Clean inspection materials from inspected areas.

If required, have protective finishes restored and components reinstalled in accordance with the applicable TO.

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Figure 5-1. Sheave Assembly Inspection - Top View

Figure 5-2. Sheave Assembly Inspection - Side View

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5-7

5.20 REEL ASSEMBLY - TAPE REEL SHAFT.

Circumferential and longitudinal cracking may occur on any surface, especially the keyway, threaded, or spline areas.

5.20.1 Primary NDI Procedure Magnetic Particle.

a. NDI Equipment:

(1) Portable Magnetic Particle inspection unit: DA 200 DC/AC Articulate Contour Probe or equiva-lent.

(2) Fluorescent Particle Prepared Bath (aerosol).

(3) Ultraviolet Black Light.

b. Safety Precautions: TO 33B-1-1 Section VIII MAG- NETIC PARTICLE INSPECTION SAFETY and ad-here to all locally established safety instructions.

c. No special access required.

d. The Tape Reel Shaft shall be removed from the assem-bly prior to inspection.

e. Insure surfaces are free of all conditions and substances detrimental to satisfactory inspection such as burrs, dirt, excessive bonding compound, sealant, or other foreign materials.

f. Set DA 200 DC/AC Articulate Contour Probe (or equivalent) to A/C max.

NOTE

Ensure process control requirements of TO 33B- 1-1, Chapter 6 are met.

g. Inspection:

NOTE

• Prior to installation, position the Tape Reel Shaft (see Figure 5-3, Sheet 1) in an appropri-ate holding device prior to inspection.

• The effective flux width area is approximately 3 inches (see Figure 5-3, Sheet 2).

h. After inspection, thoroughly demagnetize the Tape Reel Shaft and remove all inspection material residue. Verify demagnetization using a magnetic field indicator.

i. Acceptance/Rejection Criteria: No crack shall be per-mitted. If cracks are found, mark with approved mark-ing material and report to 642 CBSS/GBZO - ENI en-gineering.

j. Clean inspection material from inspection areas. If re-quired, have finishes restored. Remove components re-installed in accordance with applicable TO.

5.20.1.1 Keyway Area and Area A.

5.20.1.1.1 Circumferential Cracking.

a. Adjust the inside width of the articulating legs of the probe to approximately 6 inches prior to inspection.

b. Center the probe over the keyway longitudinally with the feet positioned on Area A and Area B (see Figure 5-3, Sheet 2, View A).

c. Inspection of Area A shall include both adjacent tran-sition areas from Area A to Area B (see Figure 5-3, Sheet 2, View A).

d. After each probe shot, move the probe approximately 6 inches horizontally (see Figure 5-3, Sheet 2). Con-tinue this process until the entire keyway areas are in-spected.

e. Inspect the entire length of each keyway for circumfer-ential cracks originating from the upper and lower keyway corners (see Figure 5-3, Sheet 1, Area A).

f. After each keyway area inspections are complete, ro-tate the shaft approximately 3 inches (see Figure 5-3, Sheet 2). Continue this inspection process until 100% of the surface area of Area A and both transition areas are inspected.

g. Perform the Wet Continuous method of inspection in accordance with TO 33B-1-1, Chapter 2.

5.20.1.1.2 Longitudinal Cracking.

a. Adjust the inside width of the articulating legs of the probe to approximately 6 inches prior to inspection.

b. Place probe feet in the transition area, centered trans-versely over keyway area (see Figure 5-3, Sheet 2, View A).

c. Inspection of Area A shall include each adjacent tran-sition area from Area A to Area B (see Figure 5-3, sheet 2, View A).

d. After each probe shot, move the probe approximately 3 inches horizontally (see Figure 5-3, Sheet 2). Con-tinue this process until the entire keyway areas are in-spected.

e. Inspect the entire length of the keyway for longitudinal cracks originating from the upper and lower keyway

TO 35E8-2-5-3

5-8 corners Additional attention is required for the inspec-tion of the lower corners of the keyway and the two horizontal radii along the entire length of the keyway (see Figure 5-3, Sheet 1, Area A).

f. After each keyway area inspections are complete, ro-tate the shaft approximately 6 inches (see Figure 5-3, Sheet 2). Continue this process until 100% of the sur-face area of Area A and both transition areas are in-spected.

g. Perform the Wet Continuous method of inspection in accordance with TO 33B-1-1, Chapter 2.

5.20.1.2 Threaded Keyway Area and Area B.

5.20.1.2.1 Circumferential Cracking.

a. Adjust the inside width of the articulating legs of the probe to approximately 4 inches prior to inspection.

b. Center the probe over threaded keyway areas longitu-dinally with the feet positioned on Area C and Area B (see Figure 5-3, Sheet 3, View B).

c. Inspection of Area B shall include each adjacent tran-sition area from Area B to Area C (see Figure 5-3, Sheet 3, View B).

d. After each probe shot, move the probe approximately 4 inches horizontally to allow sufficient shot overlap (see Figure 5-3, Sheet 3, View B). Continue this pro-cedure until the entire keyway has been inspected.

e. Inspect the entire length of the threaded keyway areas for circumferential cracks originating from the upper and lower keyway corners (see Figure 5-3, Sheet 1, View A and View B), as well as the threaded area (see Figure 5-3, Sheet 3, Area B).

f. After each keyway area inspections are complete, ro-tate the shaft approximately 3 inches (see Figure 5-3, Sheet 3). Continue this process until 100% of the sur-face area of Area B and both transition areas are in-spected.

g. Perform the Wet Continuous method of inspection in accordance with TO 33B-1-1 Section II.

5.20.1.2.2 Longitudinal Cracking.

a. Adjust the inside width of the articulating legs of the probe approximately 4 inches prior to inspection.

b. Place probe feet on the transition area and centered transversely over the keyway threaded areas (see Fig-ure 5-3, Sheet 3, View B).

c. Inspection of Area B shall include each adjacent tran-sition areas from Area B to Area C (see Figure 5-3, Sheet 3, View B).

d. After each probe shot, move the probe approximately 3 inches horizontally (see Figure 5-3, Sheet 3). Con-tinue this process until the entire keyway has been in-spected.

e. Inspect the entire length of the threaded keyway areas for longitudinal cracks originating from the upper and lower keyway corners. Additional attention is required for the inspection of the lower corners and the two horizontal radii along the entire length of the keyways as well as in the threaded areas (see Figure 5-3, Sheet 1, Area A and B).

f. After each keyway area inspections are complete, ro-tate the shaft approximately 4 inches (see Figure 5-3, Sheet 3). Continue this process until 100% of the sur-face area of Area B and both transition areas are in-spected.

g. Perform the Wet Continuous method of inspection in accordance with TO 33B-1-1, Chapter 2.

5.20.1.3 Area C.

5.20.1.3.1 Circumferential Cracking.

a. Adjust the inside width of the articulating legs of the probe to approximately 3 inches prior to inspection.

b. Position the probe longitudinally with the feet posi-tioned on Area C and Area D and Area C and Area E (see Figure 5-3, Sheet 4, View C).

c. Inspection of Area C shall include both adjacent tran-sition areas from Area C to Area D and Area C to Area E (see Figure 5-3, Sheet 4, View C).

d. After each probe shot, rotate the shaft approximately 3 inches horizontally (see Figure 5-3, Sheet 4). Continue this process until 100% of the surface area of Area C and each transitions area are inspected.

e. Inspect the entire length of the Area C for circumfer-ential cracks (see Figure 5-3, Sheet 4, View C).

f. After each area inspections are complete, rotate the shaft approximately 3 inches. Continue this process until 100% of the surface area of Area C and both transition areas are inspected (see Figure 5-3, Sheet 4).

g. Perform the Wet Continuous method of inspection in accordance with TO 33B1-1, Chapter 2.

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5.20.1.3.2 Longitudinal Cracking.

a. Adjust the inside width of the articulating legs of the probe to approximately 3 inches prior to inspection.

b. Place the probe feet transverse in the transition area (seeFigure 5-3, Sheet 4, View C).

c. Inspection of Area C shall include both adjacent tran-sition areas Area D and Area E (see Figure 5-3, Sheet 4, View C).

d. After each probe shot, move the probe horizontally (see Figure 5-3, Sheet 4). Continue this process until Area C has been inspected.

e. Inspect the entire length of the Area C for longitudinal cracks (see Figure 5-3, Sheet 4, View C).

f. After each area inspections are complete, rotate the shaft approximately 3 inches (see Figure 5-3, sheet 4).

Continue this process until 100% of the surface area of Area C and both transition areas are inspected (see Figure 5-3, Sheet 4, View C).

g. Perform the Wet Continuous method of inspection in accordance with TO 33B-1-1, Chapter 2.

5.20.1.4 Keyway Area and Area D.

5.20.1.4.1 Circumferential Cracking.

a. Adjust the inside width of the articulating legs of the probe approximately 3 inches prior to inspection.

b. Center the probe over the keyway longitudinally with the feet positioned on Area D to Area C and Area D to Area E (see Figure 5-3, Sheet 5, View D).

c. Inspection of Area D shall include the keyway on the left end of shaft (see Figure 5-3, Sheet 1, Area A and Figure 5-3, Sheet 5, View D).

d. After each probe shot, rotate the shaft 180° (see Figure 5-3, Sheet 5). Continue this process until 100% of the keyway and surface areas of the Area D and Area E are inspected.

e. Inspect the entire length of the keyway area for cir-cumferential cracks originating from the upper and lower keyway corners (see Figure 5-3, Sheet 1, Area A and Area B).

f. Perform the Wet Continuous method of inspection in accordance with TO 33B1-1.

5.20.1.4.2 Longitudinal Cracking.

a. Adjust the inside width of the articulating legs of the probe to shaft diameter prior to inspection.

b. Place the probe feet transversely (see Figure 5-3, Sheet 5, View D).

c. Inspection of Area D shall include the keyway area on the left end of shaft (see Figure 5-3, Sheet 5).

d. After each probe shot, rotate the shaft 45° (see Figure 5-3, Sheet 5). Continue this process until 100% of the surface of Area D is inspected.

e. Inspect the entire length of the keyway area for longi-tudinal cracks originating from the upper and lower keyway corners. Additional attention is required for the inspection of the lower corners and the two horizontal radii along the entire length of the keyway (see Figure 5-3, Sheet 1, Area A).

f. Perform the Wet Continuous method of inspection in accordance with TO 33B1-1.

5.20.1.5 Area E. (Spline).

5.20.1.5.1 Circumferential Cracking.

a. Adjust the inside width of the articulating legs of the probe approximately 5 inches prior to the inspection.

b. Position the probe longitudinally with the feet posi-tioned on Area E and Area D (see Figure 5-3, Sheet 5, View E).

c. Inspection of Area E shall include the adjacent transi-tion Area E to Area D (see Figure 5-3, Sheet 5, View E).

d. After each probe shot, rotate the shaft approximately 45°. Continue this process until 100% of the surface of Area D is inspected.

e. Inspect the entire length of Area E as well as the adja-cent transition area for circumferential cracks (see Fig-ure 5-3, Sheet 5, View E).

f. Perform the Wet Continuous method of inspection in accordance with TO 33B-1-1.

5.20.1.5.2 Longitudinal Cracking.

a. Adjust the inside width of the articulating legs of the probe to shaft diameter prior to performing the inspec-tion.

b. Center probe transversely (see Figure 5-3, Sheet 5, View E).

TO 35E8-2-5-3

5-10

c. Inspection of Area E shall include the adjacent transi-tion Area E to Area D (see Figure 5-3, Sheet 5, View E).

d. After each probe shot move the probe approximately 3 inches. Continue this process until the 100% of the surface area of Area E is inspected.

e. Inspect the entire length of Area E for longitudinal cracks (see Figure 5-3, Sheet 5, View E).

f. Rotate the shaft approximately 45° (see Figure 5-3, Sheet 5, View E) and continue this process until 100% of the surface area of Area E is inspected.

g. Perform the wet continuous method of inspection in accordance with TO 33B-1-1.

TO 35E8-2-5-3

5-11

Figure 5-3. Tape Reel Shaft, PN 52-D-341, showing Key Way Areas and reference Areas; A through E (Sheet 1 of 5)

TO 35E8-2-5-3

5-12

Figure 5-3. Tape Reel Shaft, PN 52-D-341, showing Key Way Areas and reference Areas; A through E (Sheet 2)

TO 35E8-2-5-3

5-13

Figure 5-3. Tape Reel Shaft, PN 52-D-341, showing Key Way Areas and reference Areas; A through E (Sheet 3)

5-14

Figure 5-3. Tape Reel Shaft, PN 52-D-341, showing Key Way Areas and reference Areas; A through E (Sheet 4)

5-15

Figure 5-3. Tape Reel Shaft, PN 52-D-341, showing Key Way Areas and reference Areas; A through E (Sheet 5)

5-16

5.21 BASE.

Proceed as follows:

a. Sandblast if paint is chipped, or base is corroded.

b. Prime and repaint.

5.22 REEL ASSEMBLY.

Proceed as follows:

a. If 66-inch sideplates, inspect. If corroded, or worn, discard.

b. Inspect sprocket. If worn, replace. If good, replace re-wind bushing, and reuse.

c. If 66-inch reels, strip off phenolics from restraining rings; then clean, paint and install new phenolic wear strips.

5.23 REEL ASSEMBLY - TAPE DRUM RING.

Cracking may occur on any surface area with particular at-tention to areas around threaded bolt hole surfaces: (see Fig-ure 5-4.)

5.23.1 Primary NDI Procedure - Eddy Current:.

a. NDI Equipment:

(1) Eddy current inspection unit: Staveley Nortec 2000D.

(2) Probe, 90° angle surface, shielded, 1/8-inch di-ameter, frequency range to include 200kHz, dif-ferential with a 4 pin fischer connector.

b. Follow locally established safety instructions.

c. No special access required.

d. Tape Drum Ring shall be removed from the assembly before inspection.

e. Clean part as necessary to permit suitable contact be-tween part and probe.

NOTE

Penetrant inspection is impractical on porous ma-terials, various types of anodized aluminum sur-faces, or other protective coatings on other metals.

Penetrant rapidly enters the pores of the material and becomes trapped. This can result in back-ground that reduces contrast or can mask any po-tential discontinuity indications. In addition re-moval of the penetrant may not be possible after the inspection.

f. See General Eddy Current supplement, Surface Scan Aluminum.

g. Aluminum surface inspection.

NOTE

In order to protect the probe from wear and dam-age, it is recommended that teflon tape be applied to the contact surface of the probes - PN 3M 5480, maximum thickness 0.005”. This practice also helps to reduce noise.

(1) Surface Scan Inspection.

(2) Perform inspection around the circumference of each threaded bolt hole both inner and outer sur-face areas of the tape drum ring (see Figure 5-6.

NOTE

If the inspection surface of the aluminum casting is porous to the extent of being unable to perform the required eddy current inspections a flashlight and magnifying glass may be used to accomplish the inspection.

h. Backup inspection: Not required.

i. Acceptance/Rejection: No cracks are permitted. If cracks are found, mark with approved marking mate-rial and report to 642 CBSS/GBZO - ENI engineering.

j. Clean inspection materials from inspected areas. If re-quired, have protective finishes restored and compo-nents reinstalled in accordance with applicable TO.

TO 35E8-2-5-3

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5.24 REEL ASSEMBLY - BRAKE DRUM.

Cracking may occur on any of the surface areas as well as around bolt hole surfaces and inside the bolt hole bore: (see Figure 5-5 and Figure 5-6).

NOTE

Defective anchor rods shall be immediately re-paired per Paragraph 5.25.

5.24.1 Primary NDI Procedure - Eddy Current:.

a. NDI Equipment:

(1) Eddy current inspection unit. Staveley Nortec 2000D.

(2) Probe, 90° angle surface, shielded, 1/8 inch diam-eter, frequency range to include 200kHZ, differ-ential with a 4 pin fischer connector.

(3) Probe, bolt hole, appropriate diameter, shielded, frequency range to include 500KHz (rotary), dif-ferential/reflection with a 4 pin fischer.

b. Follow locally established safety instructions.

c. No special access required.

d. Preparation of Reel Assembly: The Brake drum shall be removed from the assembly prior to inspection.

e. Tape Drum Preparation: Clean part as necessary to permit suitable contact between the part and probe.

NOTE

Penetrant inspection is impractical on porous ma-terials, various types of anodized aluminum sur-faces, and other protective coatings on other met-als. Penetrant rapidly enters the pores of the material and becomes trapped. This can result in background that reduces contrast or mask any po-tential discontinuity indications. In addition re-moval of the penetrant may not be possible after the inspection.

f. Equipment Settings/Calibration: See General Eddy Current supplement, Surface Scan Aluminum.

Figure 5-4. Tape Drum Ring

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5-18 Change 1

g. Inspection: Aluminum surface and bolt hole inspec-tion.

NOTE

Teflon tape: It is recommended that teflon tape be applied to the contact surface of the probes to pro-tect the probe tip from excessive wear and damage and to reduce probe noise. PN 3M 5480 or equiva-lent, maximum thickness 0.005”.

(1) Surface Scan Inspection: Perform inspection around the circumference of each bolt hole both inner and outer surface areas of the brake drum (see Figure 5-5).

NOTE

The rotary bolt hole scanners shall be used where access is possible. It is recommended that the Staveley Nortec Spitfire or MiniMite rotary scan-ner is used in this application.

(2) Bolt Hole Inspection: Inspect all accessible holes.

NOTE

If the inspection surface of the aluminum casting is porous to the extent of being unable to perform the required eddy current inspections (displays too much noise), as an alternate method, a visual in-spection with flashlight and a 10x magnifying glass may be used to accomplish the inspection.

h. Backup inspection: It is recommended to perform a redundant inspection.

i. Acceptance/Rejection Criteria: No cracks are permit-ted. If cracks are found, mark with approved marking material and report to WR-ALC/SEVSG/GBZO-ENI engineering.

j. System Securing: Clean inspection materials from all areas. If required, have protective finishes restored and components reinstalled in accordance with applicable

TO.

k. Inspect drum ring for cracks or severe corrosion. Use dye penetrant test for cracks.

l. Remove all brake keys. Then inspect. Replate, if re-used.

m. Reanodize brake drums.

Figure 5-5. Brake Drum - Outside View

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5.25 REEL ASSY - TAPE REEL BOLT, MAGNETIC

PARTICLE INSPECTION (MPI) FOR DEFECTS.

Tape Reel Bolt, PN 52-B-1070-1, defect acceptance criteria:

no cracks allowed.

NOTE

Personnel performing this inspection must be qualified/certified in accordance with NAS-410.

5.25.1 Part Description. Tape Reel Bolt, PN 52-B-

1070-1, material CF 4340 steel, see Figure 5-7.

5.25.2 Defect or Condition Description. Fatigue cracks

orientated circumferentially and/or longitudinally along the entire length of the bolt to include the threaded area, see Figure 5-7.

5.25.3 Primary NDI Procedure - Fluorescent Magnetic

Particle Inspection. Perform Fluorescent Magnetic Particle inspection of the Tape Reel Bolt, PN 52-B-1070-1, see Fig-ure 5-7, Figure 5-8, and Figure 5-9.

a. NDI equipment to be used with this inspection.

b. Magnetic Particle inspection unit, Stationary.

c. Demagnetizing equipment, AC open coil.

d. Magnetic Particle field indicator.

e. Magnetic particles, fluorescent, wet method, oil vehicle or aerosol can, meeting the requirements of AMS 3045 or 3046.

f. Black light, ultraviolet.

g. Marker: use locally approved temporary marking ma-terials.

5.25.4 Access. Have Tape Reel Assembly disassembled

and Tape Reel Bolts removed in accordance with applicable TO’s.

5.25.5 Preparation of Part.

Solvent is flammable and toxic to eyes, skin and respiratory tract. Avoid repeated/prolonged con-tact. Use only in well ventilated areas. Keep away from open flames or other sources of ignition.

Figure 5-6. Brake Drum - Inside View

TO 35E8-2-5-3

5-20

a. Clean the Tape Reel Bolt, in accordance with TO 33B- 1-1 Chapter 3, Section 4, Surface Preparation for the Wet Suspension Method. Ensure the surfaces of part are free of all conditions and substances detrimental to satisfactory inspection.

NOTE

Prior to performing the Magnetic Particle Inspec-tion, when coating removal is required, the pre-ferred finish removal method is chemical. It is not recommended to use mechanical coating removal due to possible thread damage.

b. Most parts will require coating removal. Paint or chrome plating thicker than 0.003 inch SHALL be re-moved. Ferromagnetic coatings such as electroplated nickel greater than 0.001 inch SHALL be removed. All sealant shall be removed. If coatings are nonconduc-tive, they SHALL be removed where electrical contact is made. A surface coating that is uneven, broken, or marred SHALL be removed. Generally, light even coat-ings of primer do not require removal. All dirt, oil, or grease SHALL be removed. Refer to the applicable Technical Order and the Structural Maintenance or Corrosion Control Shop for coating removal proce-dures. Use cleaning methods that are approved by lo-cal procedures.

NOTE

• All relevant safety equipment and procedures directed by Chapter 3, Section 8 of TO 33B- 1-1 and AFOSH Standard 91-501 SHALL be adhered to.

• Ensure that the equipment meets the require-ments of TO 33B-1-1, Chapter 3, Section 6 Process Controls for Magnetic Particle Inspec-tion.

5.25.6 Stationary Equipment NDI Equipment Settings/

Standardization/Setup. Direct Contact Technique, use 200- 220 amperes (AMPS) direct current (DC), see Figure 5-8.

5.25.7 Inspection - Circular Magnetism Utilizing Equip-

ment Stationary. This inspection will detect longitudinal discontinuities throughout the length of the bolt, see Figure 5-7 and Figure 5-8.

a. Set unit to CONTACT, DC 200-220 AMPS and MAG.

Controls of different brands of equipment may vary.

Clean contact pads with a wire brush. Wet the contact pads with the suspension vehicle prior to current application to help prevent overheating of the part. Ensure surfaces of the part are clean and free of paint or similar coatings and have adequate pressure applied to achieve good mechanical and electrical contact over a sufficient area of the part’s surface.

b. Place the bolt between the HEAD STOCKS (contacts).

See Figure 5-8.

c. Perform a wet continuous inspection method in accor-dance with TO 33B-1-1, Chapter 3, Magnetic Particle Inspection Method, Section 4, Circular Magnetism.

Spray or flow the suspension over the test part, then divert suspension simultaneously or slightly before en-ergizing the magnetic circuit.

d. Initiate 2 shots in quick succession.

e. Examine the test part under black light illumination.

This technique is most sensitive to longitudinal discon-tinuities.

f. Rotate 180° and repeat the inspection to ensure 100% bolt coverage. (Rotate to gain access to the bottom of the bolt for inspection.)

g. Mark defects, using locally approved temporary mark-ing materials. Report in accordance with local proce-dures.

5.25.8 Stationary Equipment NDI Equipment Settings/

Standardization/Setup. Longitudinal Technique, use 320- 350 amperes (AMPS) direct current (DC) coil shot (five turns), see Figure 5-9.

5.25.9 Inspection - Longitudinal Magnetism Utilizing

Stationary Equipment. This inspection will detect circum-ferential discontinuities throughout the length of the bolt, see Figure 5-7 and Figure 5-9.

a. Set unit to COIL, DC 320-350 AMPS and MAG. Con-trols of different brands of equipment may vary.

b. Place the bolt in the bottom of the COIL, see Figure 5-9.

c. Perform a wet continuous inspection method in accor-dance with TO 33B-1-1, Chapter 3, Magnetic Particle Inspection Method, Section 4, Longitudinal Magne-tism. Spray or flow the suspension over the test part, then divert the suspension simultaneously or slightly before energizing the magnetic circuit.

d. Initiate two shots in quick succession.

e. Examine the test part under black light illumination.

This technique is most sensitive to circumferential dis-continuities.

TO 35E8-2-5-3

5-21

f. Rotate the bolt 180° and repeat the inspection to en-sure 100% bolt coverage. (Rotate to gain access to the bottom of the bolt for inspection.)

g. Mark defects, use locally approved temporary marking materials. Report in accordance with local procedures.

5.25.10 Demagnetize the part: AC Demagnetization

Using Stationary Equipment.

a. Set unit to AC, COIL and DEMAG.

b. Turn the current control clockwise to 3/4 of scale or 10% greater than the magnetizing current used on the test part.

c. Initiate DEMAG. During the AC Demag cycle the cur-rent is ramped down to zero in approximately 10 sec-onds.

d. Using a field indicator/gauss meter measure the ends of the test part. Residual field SHALL be less than two increments indication on a field indicator or three gauss on a gauss meter.

5.25.11 Clean Residual Inspection Materials from Reel

Bolt. Use cleaning methods that are approved by local pro-cedures.

5.26 BACKUP NDI PROCEDURE - FLUORESCENT

PENETRANT INSPECTION.

NOTE

• This fluorescent penetrant inspection procedure may ONLY be used to verify questionable indi-cations found by the Primary NDI Procedure.

• Prior to performing the fluorescent penetrant inspection, when coating removal is required, the preferred finish removal method is chemi-cal. It is not recommended to use mechanical coating removal due to possible thread damage.

5.26.1 NDI Materials and Equipment.

a. Fluorescent penetrant materials, Type I, Method C, level 3, Form d, meeting the requirements of and listed in SAE-AMS- 2644.

b. Black Light, ultraviolet.

c. Temporary Marking Materials: use locally approved temporary marking materials.

5.26.2 Preparation of Part.

Solvent is flammable and toxic to eyes, skin and respiratory tract. Avoid repeated/prolonged con-tact. Use only in well ventilated areas. Keep away from open flames or other sources of ignition.

Clean areas to be inspected. The area of the possible defect to be verified must be cleaned to the maximum extent pos-sible of soils coatings and lubricants that would interfere with the inspection. Use solvent and hand brushing to re-move the surface contaminants. If the surface contaminants produce excessive fluorescent background, continue cleaning until the background is at an acceptable level, see TO 33B- 1-1, Chapter 2, Liquid Penetrant Inspection Method, Section 2.

5.26.3 NDI Equipment Settings/Standardization/

Setup. Not applicable.

5.26.4 Inspection.

NOTE

• All relevant safety equipment and procedures directed by Chapter 2, Section 8 of TO 33B- 1-1 and AFOSH Standard 91-501 SHALL be adhered too.

• Ensure that the equipment meets the require-ments of TO 33B-1-1, Chapter 2, Section 6, Process Controls for Liquid Penetrant.

a. Perform fluorescent penetrant inspection of areas to be inspected in accordance with TO 33B-1-1, Chapter 2, Liquid Penetrant Inspection Method.

b. Apply penetrant by spraying, dipping or swabbing.

c. Allow the penetrant to dwell; assuring the item is kept wet during the dwell time.

d. Penetrant dwell time:

Temperature 40° - 60° F Minimum - Service Damage/ Fatigue Cracks 60 minutes dwell time.

Temperature 60° - 125° F Minimum - Service Damage/ Fatigue Cracks 30 minutes dwell time.

e. Penetrant removal. The solvent cleaner SHALL NOT be applied directly onto the inspection area to remove excess penetrant. Only solvents appearing on QPL SAE AMS 2644 or technical grade isopropyl alcohol (TT-I- 735, Grade A) SHALL be used for Method C, removal

TO 35E8-2-5-3

5-22 of excess penetrant. The use of high sensitivity, fluo-rescent penetrant with the solvent removal method will produce indications from small, tight flaws; however, improper application procedures will seriously degrade the indications. The use of excess solvent will remove or dilute entrapped penetrant resulting in a failure to produce a visible indication.

f. Following the penetrant dwell period, the surface SHALL be wiped with a clean, dry lint-free rag or paper towel to remove the major portion of surface penetrant. The proper procedure, which SHALL be followed, is to make only a single pass and then fold the rag or towel over to provide a fresh surface for each succeeding wipe.

g. When the surface penetrant has been reduced to a minimum, remove any remaining residual penetrant with a fresh lint-free rag or towel moistened with sol-vent. The amount of solvent applied to the rag or towel is critical. The cloth or towel SHALL only be lightly moistened with the application of a fine spray of sol-vent to the cloth. The cloth SHALL NOT be saturated either by pouring, immersion or excessive spraying.

h. A black light SHALL be used to examine the part sur-face during the intermediate and final wiping stages.

The surface of the rag SHALL also be examined with the black light after the final solvent wipe. If the rag shows more than a trace of penetrant, it SHALL be folded to expose a clean surface, remoistened with sol-vent, and again wiped across the part.

i. This procedure SHALL be repeated until the rag shows little or no trace of penetrant.

The presence of any moisture will interfere with the developer action, and small flaws may be missed. Solvent developers SHALL NOT be ap-plied to a part until the surface and any disconti-nuities are thoroughly free of moisture. Since these developers are self-contained in a pressurized spray can, the only preparation required is shaking the can in order to thoroughly mix the developer, carrier solvent, and propellant.

j. Finally the part SHALL be wiped with a clean, dry rag to remove any residual solvent on the surface.

k. Developer Application. (Formed) - Nonaqueous Devel-opers - aerosol spray.

NOTE

Excessive thickness of developer SHALL NOT occur. Parts that have received excessive devel-oper SHALL be completely reprocessed. Liquid flow on the part surface SHALL be avoided. Non-aqueous-wet developers are always applied by spraying. Proper spraying produces a thin, uniform layer very sensitive in producing indications.

l. Developer dwell time:

Temperature 40° - 60° F Min. - Max. - Service Damage/ Fatigue Cracks 20-60 minutes dwell time.

Temperature 60° - 125° F Min. - Max. - Service Dam-age/Fatigue Cracks 10-30 minutes dwell time.

m. Mark defects, using locally approved temporary mark-ing materials. Report in accordance with local proce-dures.

TO 35E8-2-5-3

5-23

5.27 SYSTEM SECURING.

a. Clean residual inspection materials from the part. Use cleaning methods that are approved by local proce-dures.

b. Have protective coatings restored, if necessary, in ac-cordance with Applicable TO’s.

Figure 5-7. Tape Reel Bolt

Figure 5-8. Tape Reel Direct Contact Technique (Circular Magnetism)

TO 35E8-2-5-3

5-24

5.28 HYDRAULIC STAND.

After weldment has been stripped as described in Section III, it is cleaned, primed, and repainted (if necessary).

5.29 REPAIR AND REPLACEMENT.

Defective parts are replaced using the assembly procedures in Chapter 6.

5.30 BAK-12 FAIRLEAD BEAM ANCHOR BOLT

INSPECTIONS.

5.31 DESCRIPTION.

NOTE

Personnel performing this inspection must be qualified/certified in accordance with NAS-410, Level 2 or Active Duty CFETP 5 Level or higher.

The Y and Z-bolts…