Atch_0003_-_M O_Plan_Guidance.pdf

Rev. 3 dated 21 June 2010 Critical Safety Item QE-STD-2 does apply

STEPS# REFERENCE MECH PID TI STAMP

1 LOCAL SHOP

PRACTICES

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

Para. 3-8 through 3-10.1, page 3-5

4 Para. 3-11.1 a., thru k.

pages 3-5 through 3-13

5 Para. 3-11.2 a. thru d.

page 3-13

Para. 3-11.3, a - j, pages 3-

13 and 3-14.

Para. 3-11.4, a. thru n.

page 3-14

Para. 3-11.5, a thru d.

page 3-14

10 Para 3-11.6, a. thru c.

page 3-14

Para 3-11.7, a. and b.

page 3-14

12 Para 3-11.7, a thru i.

page 3-14 and 3-15

ACTION TAKEN

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.

Control of parts, and inspect for damage.

Removal of Piston. Figure 3-7 item 15.

Pre-Shop analysis, this will be conducted per chapter 3 in the DMWR. All form 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.

Self cleaning Coupling, Figure 3-2 item 43.

REMOVAL OF Major Assemblies

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)

Screen removal, figure 3-2 item 42.

OPERATION SHOP TRAVELER

PROCEDURES/OPERATIONS

Removal of Actuator assembly, Figure 3-2 item 29.

Removal of Rod end Assembly, figure 3-7 item 1. Caution:

To prevent damage to glands, pistons must be positioned at mid-stroke.

Rev: REV 3 21 June 2010(Current Rev and Rev date)

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 .

SUBMITTED BY

Company Name Full address, CAGE code, and plan number.

UH-60 Rotary Head Servo Assembly

WORK ORDER NO:

Date:

ACFT: AH-64,

OH-58, ETC Incoming Part Number: Outgoing Part Numbers:

AUTHORIZATION:

Date:

Approved by:

Outgoing NSN:

REMARKS:

CRITICAL SAFETY ITEM: This must be on the cover page and the following statement: “All CCs are 100% inspected, the part is repaired and overhauled in accordance with QE-STD-2.” This statement must also be on subsequent pages of plan.

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.

S/N -

Bypass Lap Assembly removal, figure 3-2 item 49.

Pressure switch removal, figure 3-2 item 26.

STEPS# REFERENCE MECH PID TI STAMPACTION TAKENPROCEDURES/OPERATIONS

13 Para 3-11.9, a. thru k.

page 3-15

14 Para 3-11.10, a. thru f.

page 3-15

15 Para 3-11.11, a. thru e.

page 3-15 an 3-16

16 Para. 3-13, page 3-17 17 Para. 3-14.1, page 3-17

18 Para 3-15.1, a. thru f. page 3-17

19 Note page 3-17

20 Para. 3-15 g. and h. page 3-

21 Para. 3-15.2 page3-21

22 Para. 3-15.3.1 Page 3-21

23 Para. 3-15.3.2, a thru l.

page 3-21

24 Para. 3-15.3.3, page 3-24

25 Para. 3-15.3.4, page 3-24

26 Para 3-15.3.5, a. and b.

page 3-24

27 Para. 3-15.4 a. thru c.

page 3-31

28 Para 3-16, page 3-31

29 Para. 3-17 thru 3-17.5 pages 3-32 and 3-33

DISASSAMBLEY GENERAL

DISSAMBLEY PROCSDURES

Relief Valve Assembly, figure 3-2 item 73.

Servo Assembly procedures continued: Notes and Cautions WILL BE ADHEARDED to through this procedure.

In process inspection will be completed I/A/W DMWR, all notes and warnings will be complied with through out these inspections.

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)

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.

Feedback Link Assembly Disassembly.

CLEANING

Bracket disassembly.

Relief Valve Assembly, disassembly.

Clevis Disassembly.

Feedback Lever Assembly and Summing Lever Assembly, Disassembly.

Feedback lever assembly (Figure 3-11, 12) consists of lever (14) and bearing (13).

Summing lever assembly (15) consists of lever (17) and bearing (16). Do not remove bearings unless necessary.

In-Process Inspections

Feedback Lever Assembly and Summing lever assembly, Disassembly.

Servo Assembly procedures: Notes and Cautions WILL BE ADHEARDED to through this procedure.

Control of parts.

Jam Simulation Button, figure 3-2 item 78

Inspect for damage.

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)

Input Crank Assembly removal, figure 3-2 item 68.

STEPS# REFERENCE MECH PID TI STAMPACTION TAKENPROCEDURES/OPERATIONS

30 Page 3-34, NO 1 Mech. Sign QA as needed

31 Page 3-34, NO 2A

32 Page 3-34, NO 3B

33 Page 3-34, NO 4C

34 Page 3-35, No. 1 Mech. Sign QA as needed

35 Page 3-35, No. 2A

36 Page 3-35, No. 3B

37 Page 3-35, No. 4

39 Page 3-60 Mechanic signature

QA are required for CC's

40 Page 3-60 Mechanic signature

QA are required for CC's

42 Para. 3-20.1 page 3-99

43 Para 3-21.1a. thru d.

page 3-99 - 3-100 Mech sig. QA if needed

44 Para. 3-21.2, a and b.

page 3-100 Mech sig. QA if needed

45 Para. 3-21.2, c. thru e.

page 3-101

46 Para 3-21.2 c, page 3-101 Mech sig. QA for CC

47 Para 3-21.2 d, page 3-101 Mech sig. QA for CC

48 Para 3-21.2 e, page 3-101 Mech sig. QA for CC

49 Para. 3-21.2, f. thru k., page 3-101

50 Para. 3-21.2 f, page 3-101

Inspection results here

Install new pin (25) through bracket (23) and feedback lever assembly (12).

General Assembly, ALL warning and note will be adhered to through out the assembly

Warning CSI, Verification of swagging of pin (28) and collar (27) is a critical characteristic.

Warning CSI, Verification of proper swaging of pins (25 and

31) and collars (24 and 30) is a critical characteristic.

Visual, pass___ or Fail_____ If failed, FPI will be completed, see appendix (?) for results results here (completed)

Pass_____ Fail ______ Technique sheets are found in appendix (?)

results here (completed) results here (completed)

Results will be here

Linkage Assembly, continued

Inspection results here

Install bracket (23) on other feedback lever assembly (12). Orient bracket similar to opposite bracket.

Clevis threads (2 places), Visual, No stripped, crossed, flattened or missing threads allowed.

Serviceability, Visual, Examine for corrosion, burrs or gouges.

Thread Condition, Visual, No stripped, crossed, flattened or missing threads allowed.

Serviceability, Visual inspection

Overhaul Inspection Procedures (OIPs), All OIPs must be written individually.

OIP 1, Linkage Assembly, PN 274060-103 or 107

Boost assembly condition (2 places), Visual, no cracks allowed.

Fractures and cracks, Visual inspect per Para 3-17.2. When cracks are suspected Fluorescent Penetrant per Para. 3-17.5

Install new collar (figure 3-11, 27) on pin (28).

***Warning, Fluorescent Penetrant inspection is a CC***

Linkage Assembly, continued

******WARNING, Spring measurement is a CC.****** Measure 0.745 - 0.780.

The following information MUST be provided. Serial Number___________ Calibration Due____________________ Actual measurement _______________ The Serial Number, Calibration Due date, and the actual measurement must be in the step being completed. CC's must stand out and be noticeable to ensure this is completed.

Bearing Condition, (2 places), Manual, bearing should turn smoothly

Thread condition (Left hand thread), Visual, No stripped, crossed, flattened or missing threads allowed.

OIP 2, Rod Assembly, PN 274086-1

All OIPs should follow the examples as above, they can vary, but must contain the information.

Below are example's of OIP's with different Critical Characteristic (CC). These examples may or may not pertain to this particular DMWR.

Repair procedure will be I/A/W DMWR, the page and paragraph of the repair can be put in the task and should have a pass or fail block. Repairs do not need to be as detailed as OIP's, however, if TMDE is involved , the serial number, Calibration due date, and actual measurement will be in that step.

Assembly procedures

Assemble Relief Valve results here (completed) results here (completed)

Install new collar (Figure 3-11, 24) on pin (25).

NOTE: Pin head must face out toward summing lever.

Linkage Assembly

STEPS# REFERENCE MECH PID TI STAMPACTION TAKENPROCEDURES/OPERATIONS

51 Para. 3-21.2 g, page 3-101

52 Para. 3-21.2 h, page 3-101

53 Para. 3-21.2 I, page 3-101

54 Para. 3-21.2 j, page 3-101

55 Para. 3-21.2 k, page 3-101

58 Para. 3-21.2 l, page 3-102

59 Para. 3-21.2 m, page 3-102

60 Para. 3-21.2 n, page 3-102

61 Para. 3-21.2 o, page 3-102

62 Para 3-21.2, p. thru t.

page 3-105

Para 3-21.2 u. Page 3-105

66 Para 3-21.2 v. Page 3-105

68 Para 3-21.2 w, page 3-105

69 Para 3-21.2 x, page 3-105

70 Para 3-21.2 y, page 3-105

Para. 3-21.2 z thru an.

pages 3-105 thru 3-107

Install nut (11) on outer stop bolt (22).

Warning CSI, Verification of proper swaging of pins (33) and

(32) is a critical characteristic.

Warning CSI, Verification of Installation of input linkage spacer is a CC

Warning CSI, Verification of Installation of input linkage spacer is a CC

Install input link assembly (19) on outer stop bolt (22) next to input linkage spacer (18).

Install washer (35) on pin (33).

NOTE: See Figure 3-17 and 3-18 for proper installation and verification procedures. Use pin/collar gage, (HG77-14A) for swage verification.

Install one new collar (Figure 3-11, 32) on pin (33).

Install new pin (33) through feedback lever assembly (12), washer (35), and through bushing (36).

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.

Linkage Assembly, continued

Install one clevis (29) on summing lever assembly (15) with one new pin (31) and new collar (30).

Warning CSI, Verification of proper swaging of pin (33) collar (32) is a critical characteristic.

NOTE

See Figure 3-17 and 3-18 for proper installation and verification procedures. Use pin/collar gage (HG77-14A) for swage verification.

Install new collar (Figure 3-11, 32) on pin (33).

Install second new pin (33) through second feedback lever assembly (12) and through second summing lever assembly (15).

Torque nut using linkage assembly tool (274060AT2) (Figure 3-12) to 70-80 inch pounds. Actual Torque____________ Serial number__________________ Calibration DUE date __________ This is required even though this is not a CC.

Install bushing (34) over pin (33) and into summing lever assembly (15).

Install bushing (36) into summing lever assembly (15) as shown in Figure 3-11.

Install second clevis (29) on other summing lever assembly (15) with new pin (31) and new collar (30).

Linkage Assembly, continued

Install one input linkage spacer (18) on outer stop bolt (22) next to summing lever assembly (15)

Linkage Assembly, continued

Install second input linkage spacer (18) and second summing lever assembly (15) on outer stop bolt (22).

STEPS# REFERENCE MECH PID TI STAMPACTION TAKENPROCEDURES/OPERATIONS

72 Para 3-21.2 ao., page 3-107

Para 3-21.2, ap thru aq

76 Para 3-21.2, ar. page 108

Para 3-21.2, as and at.

80 Para 4-1.1 a, page 4-1

81 Para 4-1.1 b, page 4-1

82 Para 4-1.1 c, page 4-1

83 Para 4-1.1d, page 4-1

90 Para. 4-2.1

84 Para. 4-2.1, a, (1) - (6)

Linkage Assembly, continued

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.

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.

Warning CSI, Verification of proper swaging of pin (2) and collar (1) is a CC.

Linkage Assembly, continued

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.

Install new collar (Figure 3-11, 1) on swage pin (2).

Install nut (3) on linkage retaining bolt. Torque nut to 20-25 inch-pounds.

Actual Torque_______________ Serial number__________________ Calibration DUE date ______________

Tooling Certification: A written statement certifying possession of, or access to any required special tooling and inspection equipment, and/or special test equipment current to latest DMWR revision must be provided. If “equivalent” tooling will be utilized instead of the tooling specified in the DMWR, a complete technical description of the tooling is required, and must be sufficient to determine equivalency. Specify availability of in house test equipment, whether it has to be purchased, or built. If no special tooling or inspection equipment is required, state this fact.

If shotpeen is to be preformed, a shotpeen plan must accompany the plan. The shotpeen company can submit their plan directly to the Aviation Engineering Directorate if the shotpeen company does not want to release their plan directly to the company.

This is just a template to show what the AED is looking for in a Maintenance & Overhaul plan. How you format a plan is up to the company, but must contain the above content. This is just for an M&O plan, all other documents that are required on the CMO web page must also received.

All, OIP's must be incorporated.

Serial Number, Calibration DUE date, and actual torque/tolerance must be in that step requiring Test, Measurement, and Diagnostic Equipment (TMDE). TMDE is defined as, anything that is calibrated, torque wrench, I.D. and O.D. micrometers, electrical test equipment, gauges (electric or pneumatic), to name a few.

Magnetic Particle Inspection and Fluorescent Penetrant Inspection: These inspection must have technique sheets and process sheets that accompany the plan, this is for ALL parts, not just parts that have the CC.

When a part is out outsourced, there MUST be a receiving inspection to ensure the part was completed and no damage to the part occurred while at the outsourced company. The outsourced companies name, address, and CAGE code must also be in that step.

Final Testing and Assembly

Final Assembly

Shipping will be I/A/W the DMWR and follow the guideline above.

General Assembly continued

Install cotter pins and lockwire per NASM33540.

Further instructions: The plan must follow a logical order, initial receiving, Pre-shop analysis/component data form, disassembly, cleaning, OIP's, repair, assembly, testing, and shipping.

The plan should be written to the flow of your shop, if you do all your visual inspection first, the plan can be written like this, but a paragraph explaining this should be added.

Revision and revision date must be on every page. QE-STD-2 statement must be on every page “All CCs are 100% inspected, the part is repaired and overhauled in accordance with QE-STD-2.”

General Assembly

Make sure all parts are clean and that corrosion preventive materials have been removed.

Replace all parts listed in App. B, Table B-3.

OPSHEET