ToC.pdf

T.O. 1-1H-39

TABLE OF CONTENTS

Chapter Page Chapter Page

INTRODUCTION........................................................v

SAFETY SUMMARY................................................ix

1 DAMAGE ASSESSMENT ......................................1-1

1.1 General........................................................1-1

1.2 USAF ABDR Philosophy...........................1-1

1.3 Technician Qualifications:..........................1-1

1.4 Assessor Qualifications ..............................1-1

1.5 Responsibilities ...........................................1-2

1.6 Procedures...................................................1-2

1.7 Fire/Heat Damage to Metallic

Parts........................................................1-6

1.8 Reinspection/Reevaluation .........................1-8

1.9 Structural Categories ..................................1-8

1.10 Systems Serviceability Criteria ................1-10

1.11 Damage Assessment Markings ................1-11

1.12 Documentation..........................................1-11

2 STRUCTURAL REPAIR .........................................2-1

2.1 General........................................................2-1

2.2 Publications.................................................2-1

2.3 General Structural Repair Infor-

mation.....................................................2-1

2.4 Personal Protective Equipment ..................2-1

2.5 Metallic Structures......................................2-2

2.6 Metallic Structure Repair Proce-

dures .......................................................2-4

2.7 Types of Metallic Structure Re-

pairs ........................................................2-4

2.8 External Metallic Skin Repairs ..................2-4

2.9 Internal Metallic Repairs............................2-4

2.10 Combination External/Internal

Metallic Repairs.....................................2-5

2.11 Composite Structure Repairs......................2-5

2.12 Types of Composite Structure

Repairs ...................................................2-6

2.13 Bolted Metallic Doubler Repair.................2-6

2.14 Bonded/bolted Metallic Doubler

Repair .....................................................2-6

2.15 Two Part Resin Mixing..............................2-8

2.16 Composite Ply Lay-up................................2-8

2.17 Scarfed Wet Lay-up Repair .......................2-8

2.18 Low Observable Structural Re-

pairs ........................................................2-9

2.19 Conductive Paint Coating Repair

(LO)........................................................2-9

2.20 Magnetic Radar Absorbing Mate-

rial Repair (MagRAM)........................2-10

2.21 External Metallic Doubler Repair

(LO)......................................................2-11

2.22 Flush Metallic Repairs (LO) ....................2-11

2.23 Air Inlet Duct Repairs ..............................2-12

2.24 Pressurized Area Repairs .........................2-12

2.25 Bonded Honeycomb Repair .....................2-12

2.26 Radomes....................................................2-12

2.27 Canopies/Windshields/Windows ..............2-12

2.28 Filler Material ...........................................2-12

2.29 (Reference T.O. 1-1A-9) Aero-space Metals General Data and Usage Factors................................2-12

2.29.1 Steel...........................................................2-12

2.29.2 Titanium Alloys........................................2-13

2.29.3 Aluminum Alloys .....................................2-14

2.29.4 Magnesium Alloys....................................2-16

2.29.5 Magnesium Designations .........................2-16

3 ELECTRICAL AND AVIONICS SYS-

TEMS REPAIR....................................................3-1

3.1 General........................................................3-1

3.2 Publications.................................................3-1

3.3 Electrical/Avionics Repairs ........................3-1

3.4 Wiring Identification ..................................3-2

3.5 Isolation of Nonessential Systems .............3-3

3.6 Damage to Electrical Wiring .....................3-8

3.7 Types of Repairs.........................................3-8

3.8 Common Splice Repair (In Line

Splice) ....................................................3-8

3.9 Terminal Lug Splicing (See

Figure 3-3) .............................................3-8

3.10 Splicing with Solder (See

Figure 3-4) .............................................3-9

3.11 Alternate Small Diameter Wire

Repair Methods......................................3-9

3.12 Splicing Large (#10/or larger)

Wires with Terminal Lugs (See Figure 3-6)...................................3-10

3.13 Alternate Splicing Methods for

Large Wires..........................................3-10

3.14 Damaged Wire Insulation and

Convoluted Tubing Conduit ................3-10

3.15 Shielded Cable Repair (not In-

cluding Coaxial or Triaxial Cable) Using Grounding Sheath Connector.................................3-10

3.16 Alternate Shielded Cable Repairs

(not Including Coaxial or Tri-axial Cable) ..........................................3-11

3.17 Coaxial and Triaxial Cable Re-

pair .......................................................3-12 i

3.18 Multiple Damages Within The

Same Wire Bundle...............................3-14

3.19 Cable Clamps............................................3-14

3.20 Connector Repairs ....................................3-14

3.21 Potted Connector Repair ..........................3-14

3.22 Damaged Connector Replacement ...........3-15

3.23 Associated Electrical Equipment .............3-15

4 MECHANICAL SYSTEMS REPAIR .....................4-1

4.1 General........................................................4-1

4.2 Publications.................................................4-1

4.3 Push-Pull Control rod Repairs ...................4-1

4.4 Control Cable Specifications......................4-1

4.5 Cable Repairs..............................................4-2

4.6 Cable Pulley Repair....................................4-3

4.7 Levers and Bellcranks ................................4-3

5 PNEUDRAULIC SYSTEMS REPAIR....................5-1

5.1 General........................................................5-1

5.2 Publications.................................................5-1

5.3 Damage Investigation and Evalu-

ation........................................................5-1

5.4 Tubing and Hose Repair Tech-

niques .....................................................5-2

5.5 Metal Tubing Identification

Application, and Limitations .................5-2

5.6 Tubing Manufacturing................................5-2

5.7 Flared Fitting Installation ...........................5-3

5.8 Flareless Fitting Assembly and

Installation..............................................5-4

5.9 Flareless Fitting Seal ..................................5-7

5.10 Cleaning and Sealing Tubing and

Hoses ......................................................5-7

5.11 Tubing and Hose Supports.........................5-8

5.12 High/Medium, and Low Pressure

Tubing Insertion Repairs .......................5-8

5.13 Manufacturing High Pressure

Hose Assemblies....................................5-8

5.14 Hose Installation .......................................5-10

5.15 Repairing Low Pressure Tubing

and Hoses.............................................5-10

5.16 Tubing Repairs Using H-Fitting ..............5-11

5.17 Permaswage Tubing Repair .....................5-12

5.18 Bleed Air Duct - Repairs .........................5-14

6 FUEL SYSTEM REPAIR ........................................6-1

6.1 General........................................................6-1

6.2 Publications.................................................6-1

6.3 Integral Fuel Tanks.....................................6-1

6.4 Bladder Fuel Cell Repair ...........................6-2

6.5 External Fuel Tanks ...................................6-2

6.6 Fuel System-Seals.......................................6-2

6.7 Fuel Line Repair.........................................6-2

6.8 Fuel Line Patch Repair Procedure .............6-2

6.9 Bend Damage .............................................6-3

7 ENGINE REPAIRS ..................................................7-1

7.1 General........................................................7-1

8 ARMAMENT SYSTEM REPAIR...........................8-1

8.1 General........................................................8-1

9 LANDING GEAR SYSTEM REPAIR....................9-1

9.1 General........................................................9-1

10 EGRESS SYSTEM REPAIR .................................10-1

10.1 General......................................................10-1

11 TOOL AND MATERIEL CORE KIT

LISTING.............................................................11-1

11.1 General......................................................11-1

11.2 Shelf Life Items........................................11-1

12 BALLISTIC DAMAGE SIMULATOR.................12-1

12.1 General......................................................12-1

12.2 Terms Used...............................................12-1

12.3 Improvement Reports ...............................12-1

12.4 Safety ........................................................12-1

12.5 BDS Kit Fabrication.................................12-2

12.6 Attachment Preparation ............................12-3

12.7 Operation...................................................12-4

12.8 Post Detonation.........................................12-6

A SUPPLEMENTAL DATA ......................................A-1

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1 Effects of Repairing Combat Damage ........... viii 1-1 AFTO Form 97, Aerospace Vehicle

Battle Damage Incident Debrief/As-sessment/Repair Record ........................... 1-17

1-2 AFTO Form 97A, Aerospace Vehicle Battle Damage Assessment/Repair Record....................................................... 1-19

2-1 Aircraft Construction .................................... 2-17 ii

2-2 Blind Rivet Information................................ 2-19 2-3 Jo-bolt Information ....................................... 2-23 2-4 Composi-Lok Information ............................ 2-27 2-5 Typical External Patch Layout Tech-niques........................................................ 2-30 2-6 Extruded Angle Repairs................................ 2-34 2-7 Typical Former Repair.................................. 2-42 2-8 Typical Combination Repair ........................ 2-43 2-9 Composite Structural Repair ........................ 2-44 2-10 Low Observable Structural Repair ............... 2-52 2-11 Typical Repair of Honeycomb Core

Structure ................................................... 2-59 2-12 Canopy/Windshield/Window Temporary

Repair ....................................................... 2-66 3-1 Circuit Identification..................................... 3-17 3-2 Common Splice Repair................................. 3-18 3-3 Splicing with Terminal Lug Barrel .............. 3-18 3-4 Repairing Broken Wire by Soldering .......... 3-19 3-5 Alternate Twisted Wire Repair Method....... 3-19 3-6 Terminal Lug Splice ..................................... 3-19 3-7 Split Strand Repair........................................ 3-20 3-8 Clamp Splice................................................. 3-20 3-9 Insulation Repair ........................................... 3-21 3-10 Shielded Cable Repair .................................. 3-22 3-11 Alternate Shielded Cable Repair .................. 3-23 3-12 Pigtail Splice for Shielded Cable ................. 3-24 3-13 Typical Coaxial Cable Repair ...................... 3-25 3-14 Triaxial Cable Repair Using ST5M1344

Connector ................................................. 3-29 3-15 Alternate Coaxial Cable Repair.................... 3-33 3-16 Multiple Damage Repair .............................. 3-34 3-17 Connector with Spare Wires ........................ 3-35 3-18 By-pass Damaged Connectors, Terminal

Boards or Junction Boxes........................ 3-36 3-19 Damaged Connector Replacement ............... 3-37 4-1 Suggested Repairs for Control Rods or

Tubes .......................................................... 4-4 4-2 Manufacturing Control Rods (Male to

Male Fittings) ............................................. 4-5 4-3 Manufacturing Control Rods (Male to

Female Fittings) ......................................... 4-6 4-4 Insertion Repair for Damaged Control

Rods............................................................ 4-7 4-5 Cable Cross Section........................................ 4-8 4-6 Broken Wires in Cable ................................... 4-8 4-7 Clamp Splice and Cable Swaging Re-pairs ............................................................ 4-9 4-8 Replacement Pulley Manufacturing ............. 4-11

5-1 Hose Cut-Off Factors (In Inches) for Teflon Hose.............................................. 5-15

5-2 Proper Use of Tube Cutter ........................... 5-16 5-3 Properly Deburred Tube ............................... 5-16 5-4 Tube Bending................................................ 5-17 5-5 Tube Flaring.................................................. 5-19 5-6 Repair of Flare Union................................... 5-20 5-7 Correct and Incorrect Method of Install-ing Flared Fittings.................................... 5-21 5-8 Flareless Fitting Inspection Criteria ............. 5-22 5-9 Flareless Fitting Seal .................................... 5-23 5-10 Acceptable Tubing and Hose Clamping

Procedures ................................................ 5-24 5-11 High, Medium, and Low Pressure Tub-ing Repair (Tubing to Union Meth-od)............................................................. 5-25

5-12 High Pressure Rubber Hose Assembly ........ 5-26 5-13 Tubing Repair (Low Pressure) ..................... 5-27 5-14 Low Pressure Hose Repair ........................... 5-29 5-15 Hi-Fitting Installation Procedures ................ 5-30 5-16 Repair Bleed Air Pipelines ........................... 5-32 5-17 High Pressure Teflon Hose Assembly ......... 5-33 6-1 Integral Fuel Tank Repair .............................. 6-4 6-2 Clamp Fuel Tubing Repair ............................. 6-5 6-3 Fuel Line Patch Repair Procedures................ 6-6 6-4 Fuel Tubing Elbow Repair ............................. 6-7 12-1 Ballistic Damage Simulator (BDS) Kit........ 12-7 12-2 Launcher........................................................ 12-8 12-3 C-4 Cutter...................................................... 12-9 12-4 Roller and Tray........................................... 12-10 12-5 Attachment Strips........................................ 12-11 12-6 Fragment Package....................................... 12-12 12-7 Hose Clamp................................................. 12-13 12-8 Mounting Attachment Strips to Training

Aircraft ................................................... 12-14 12-9 Attachment Strips Installed ........................ 12-15 12-10 Rolling Out C-4 .......................................... 12-16 12-11 Cutting C-4.................................................. 12-17 12-12 C-4 Wafer.................................................... 12-18 12-13 Fragment Package Being Installed into

Launcher ................................................. 12-19 12-14 Loaded Launcher Being Mounted to

Training Aircraft .................................... 12-20 12-15 Launcher Mounted to Aircraft Before

Attachment Strips Are Folded Down ... 12-21 12-16 BDS Launcher (Loaded and Installed) ...... 12-22 12-17 Flak Blanket Over Launcher ...................... 12-23

LIST OF TABLES

Number Title Page Number Title Page

1-1 Approximate Colors of Heat Damaged Primer/Lacquer/Urethane Finishes (all temperatures in degrees Fahrenheit) ............ 1-7

1-2 AFTO Form 97 Documentation ..................... 1-12

3-1 Function and Designation Letters..................... 3-3 5-1 Torque for Fitting Nuts on Various Sizes of Tubing ...................................................... 5-5 iii

5-2 Number of Turns for Presetting Opera-tion ................................................................ 5-6

5-3 High Pressure Rubber Hose Cut-Off Fac-tors ................................................................ 5-9

5-4 Permaswage Repair with D10000 Series Tooling - Tube Material and Maxi-mum Operating Pressure Limitations

(PSI)............................................................ 5-13

11-1 Assessor Kit .................................................... 11-1 11-2 Composite PMEL Kit/Assessor Kit................ 11-2 11-3 Material List .................................................... 11-3 11-4 Tool List ........................................................ 11-15 11-5 Shelf Life Items For Reference Only........... 11-30 11-6 Composite List .............................................. 11-31 A-1 Decimal Equivalents ........................................ A-1 A-2 Bolt/Screw Hole Size Fits ............................... A-4

A-3 Recommended Torque Values (Inch- Pounds) ........................................................ A-5

A-4 Drill Bit and Extractor Sizes ........................... A-6 A-5 Gauges of Aluminum Alloy ............................ A-6 A-6 Standard Sizes for Aluminum Alloy/Cor-rosion-Resistant Steel Tubing ..................... A-7 A-7 Dimensions for Single and Double Flare

Tubing Joints ............................................... A-8 A-8 Flexible Cable Construction and Physical

Properties ..................................................... A-9 A-9 Degradation of Material Properties ............... A-10 A-10 Minimum Recommended PPE for ABDR

Operations (NBC Training Scenarios)...... A-12 A-11 Substitute Materials for Structural Repair .... A-13 A-12 Abbreviations and Acronyms ........................ A-18 iv

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