Attachment_0003_-_MO_Plan_Guidance.xlsx
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ATT 0003 M & O PLAN GUIDANCE
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OPSHEET
| Rev: REV 3 | |||
| 21 June 2010(Current Rev and Rev date) | Company Name | ||
| Full address, CAGE code, and plan number. | OPERATION SHOP TRAVELER |
WORK ORDER NO:
Date: ACFT: AH-64, OH-58, ETC SUBMITTED BY
Incoming Part Number: Outgoing Part Numbers:
AUTHORIZATION:
Date:
Approved by:
| Outgoing NSN: | |
| S/N - |
| REFERENCES: 1. All references that are not referenced in the Depot Maintenance Work Requirements (DMWR, Usually Appendix A) will be annotated on the cover page, this includes Maintenance Engineering Orders (MEO's). MEO's will also be annotated in the affected step. 2. The current DMWR with date and changes will also be referenced on the cover page . | |
| REMARKS: |
CRITICAL SAFETY ITEM: 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.
| STEPS# | PROCEDURES/OPERATIONS | REFERENCE | ACTION TAKEN | MECH PID | TI STAMP |
| 1 | RECEIPT AND INITIAL INSPECTION |
QC: A. Record and/or verify serial number on tags are the same as on the component it is attached to.
B. Verify that all forms, records, tags, and other documents accompanying the Forward Longitudinal Bellcrank Assembly follow procedures prescribed by DA PAM 738-751.
| CC (CSI). Perform external inspection of Part for obvious damage. | LOCAL SHOP PRACTICES | ||||||
| 2 | Pre-Shop analysis, this will be conducted per chapter 3 in the DMWR. All 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. | Paragraph's 3-1 thru 3-7.1 pages 3-1 and 3-2 | Sign off for mechanic when applicable | Sign off for QA when applicable | |||
| REMOVAL OF Major Assemblies | |||||||
| 3 | Control of parts, and inspect for damage. | Para. 3-8 through 3-10.1, page 3-5 | |||||
| 4 | Removal of Linkage Assembly, figure 3-2 item 1. Remove Linkage assembly. NOTE: Do not remove Name plate (28) unless required. (notes in DMWR will be adhered to) | Para. 3-11.1 a., thru k. pages 3-5 through 3-13 | |||||
| 5 | Removal of Rod end Assembly, figure 3-7 item 1. Caution: To prevent damage to glands, pistons must be positioned at mid-stroke. | Para. 3-11.2 a. thru d. page 3-13 | |||||
| 6 | Removal of Piston. Figure 3-7 item 15. | Para. 3-11.3, a - j, pages 3-13 and 3-14. | |||||
| 7 | If there is a tolerance, shim measurement or anything that should be singled out that will require use later in the M&O that should be written as a write up of it's own. | ||||||
| 8 | Removal of Actuator assembly, Figure 3-2 item 29. | Para. 3-11.4, a. thru n. page 3-14 | |||||
| 9 | Pressure switch removal, figure 3-2 item 26. | Para. 3-11.5, a thru d. page 3-14 | |||||
| 10 | Screen removal, figure 3-2 item 42. | Para 3-11.6, a. thru c. page 3-14 | |||||
| 11 | Self cleaning Coupling, Figure 3-2 item 43. | Para 3-11.7, a. and b. page 3-14 | |||||
| 12 | Bypass Lap Assembly removal, figure 3-2 item 49. | Para 3-11.7, a thru i. page 3-14 and 3-15 | |||||
| 13 | Input Crank Assembly removal, figure 3-2 item 68. | Para 3-11.9, a. thru k. page 3-15 | |||||
| 14 | Relief Valve Assembly, figure 3-2 item 73. | Para 3-11.10, a. thru f. page 3-15 | |||||
| 15 | Jam Simulation Button, figure 3-2 item 78 | Para 3-11.11, a. thru e. page 3-15 an 3-16 | |||||
| DISASSAMBLEY GENERAL | |||||||
| 16 | Control of parts. | Para. 3-13, page 3-17 | |||||
| 17 | Inspect for damage. | Para. 3-14.1, page 3-17 | |||||
| DISSAMBLEY PROCSDURES | |||||||
| 18 | Servo Assembly procedures: Notes and Cautions WILL BE ADHEARDED to through this procedure. | Para 3-15.1, a. thru f. page 3-17 | |||||
| 19 | NOTE: Lap assembly (8) consisting of lap assembly (9), lap assembly (12) and manifold (15) is a matched set. Do not exchange similar parts with other sets. ● Do not disassemble manifold (15) unless required. (This must be a separate write up to ensure these parts are kept together) | Note page 3-17 | |||||
| 20 | Servo Assembly procedures continued: Notes and Cautions WILL BE ADHEARDED to through this procedure. | Para. 3-15 g. and h. page 3-17 | |||||
| 21 | Actuator Assembly. Install actuator assembly (Figure 3-7) in actuator assembly holding fixture (274040AT1) (Figure 3-8) using four 1/4-20 X 2-1/2 inch SCHS with four washers and four nuts. | Para. 3-15.2 page3-21 | |||||
| 22 | Feedback Link Assembly Disassembly. | Para. 3-15.3.1 Page 3-21 | |||||
| 23 | Feedback Lever Assembly and Summing lever assembly, Disassembly. | Para. 3-15.3.2, a thru l. page 3-21 | |||||
| 24 | Bracket disassembly. | Para. 3-15.3.3, page 3-24 | |||||
| 25 | Clevis Disassembly. | Para. 3-15.3.4, page 3-24 | |||||
| 26 | 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. | Para 3-15.3.5, a. and b. page 3-24 | |||||
| 27 | Relief Valve Assembly, disassembly. | Para. 3-15.4 a. thru c. page 3-31 | |||||
| CLEANING | |||||||
| 28 | General Cleaning. All cleaning will be completed I/A/W DMWR. (Note, if specific cleaning of parts is mentioned, these parts should have separate entries) | Para 3-16, page 3-31 | |||||
| In-Process Inspections | |||||||
| 29 | In process inspection will be completed I/A/W DMWR, all notes and warnings will be complied with through out these inspections. | Para. 3-17 thru 3-17.5 pages 3-32 and 3-33 | |||||
| Overhaul Inspection Procedures (OIPs), All OIPs must be written individually. | |||||||
| OIP 1, Linkage Assembly, PN 274060-103 or 107 | |||||||
| 30 | Serviceability, Visual inspection | Page 3-34, NO 1 | Inspection results here | Mech. Sign | QA as needed | ||
| 31 | Boost assembly condition (2 places), Visual, no cracks allowed. | Page 3-34, NO 2A | |||||
| 32 | Bearing Condition, (2 places), Manual, bearing should turn smoothly | Page 3-34, NO 3B | |||||
| 33 | Clevis threads (2 places), Visual, No stripped, crossed, flattened or missing threads allowed. | Page 3-34, NO 4C | |||||
| OIP 2, Rod Assembly, PN 274086-1 | |||||||
| 34 | Serviceability, Visual, Examine for corrosion, burrs or gouges. | Page 3-35, No. 1 | Inspection results here | Mech. Sign | QA as needed | ||
| 35 | Thread condition (Left hand thread), Visual, No stripped, crossed, flattened or missing threads allowed. | Page 3-35, No. 2A | |||||
| 36 | Thread Condition, Visual, No stripped, crossed, flattened or missing threads allowed. | Page 3-35, No. 3B | |||||
| 37 | Fractures and cracks, Visual inspect per Para 3-17.2. When cracks are suspected Fluorescent Penetrant per Para. 3-17.5 | Page 3-35, No. 4 | Visual, pass___ or Fail_____ If failed, FPI will be completed, see appendix (?) for results | ||||
| 38 | 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. | |||||||
| 39 | ******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. | Page 3-60 | Results will be here | Mechanic signature | QA are required for CC's | ||
| 40 | ***Warning, Fluorescent Penetrant inspection is a CC*** | Page 3-60 | Pass_____ Fail ______ Technique sheets are found in appendix (?) | Mechanic signature | QA are required for CC's | ||
| 41 | 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 | |||||||
| 42 | General Assembly, ALL warning and note will be adhered to through out the assembly | Para. 3-20.1 page 3-99 | |||||
| 43 | Assemble Relief Valve | Para 3-21.1a. thru d. page 3-99 - 3-100 | results here (completed) | Mech sig. | QA if needed | ||
| 44 | Linkage Assembly | Para. 3-21.2, a and b. page 3-100 | results here (completed) | Mech sig. | QA if needed | ||
| 45 | Linkage Assembly, continued | Para. 3-21.2, c. thru e. page 3-101 | |||||
| Warning CSI, Verification of swagging of pin (28) and collar (27) is a critical characteristic. | |||||||
| 46 | Install new collar (figure 3-11, 27) on pin (28). | Para 3-21.2 c, page 3-101 | results here (completed) | Mech sig. | QA for CC | ||
| 47 | Install bracket (23) on other feedback lever assembly (12). Orient bracket similar to opposite bracket. | Para 3-21.2 d, page 3-101 | results here (completed) | Mech sig. | QA for CC | ||
| 48 | Install new pin (25) through bracket (23) and feedback lever assembly (12). | Para 3-21.2 e, page 3-101 | results here (completed) | Mech sig. | QA for CC | ||
| Warning CSI, Verification of proper swaging of pins (25 and |
31) and collars (24 and 30) is a critical characteristic.
| 49 | Linkage Assembly, continued | Para. 3-21.2, f. thru k., page 3-101 | ||
| 50 | Install new collar (Figure 3-11, 24) on pin (25). | |||
| NOTE: Pin head must face out toward summing lever. | Para. 3-21.2 f, page 3-101 | |||
| 51 | Install one clevis (29) on summing lever assembly (15) with one new pin (31) and new collar (30). | Para. 3-21.2 g, page 3-101 | ||
| 52 | Install second clevis (29) on other summing lever assembly (15) with new pin (31) and new collar (30). | Para. 3-21.2 h, page 3-101 | ||
| 53 | Install bushing (36) into summing lever assembly (15) as shown in Figure 3-11. | Para. 3-21.2 I, page 3-101 | ||
| 54 | Install new pin (33) through feedback lever assembly (12), washer (35), and through bushing (36). | Para. 3-21.2 j, page 3-101 | ||
| 55 | Install washer (35) on pin (33). | Para. 3-21.2 k, page 3-101 | ||
| 56 | Warning CSI, Verification of proper swaging of pins (33) and |
(32) is a critical characteristic.
| 57 | NOTE: See Figure 3-17 and 3-18 for proper installation and verification procedures. Use pin/collar gage, (HG77-14A) for swage verification. | |
| 58 | Install one new collar (Figure 3-11, 32) on pin (33). | Para. 3-21.2 l, page 3-102 |
| 59 | Install second new pin (33) through second feedback lever assembly (12) and through second summing lever assembly (15). | Para. 3-21.2 m, page 3-102 |
| 60 | Install bushing (34) over pin (33) and into summing lever assembly (15). | Para. 3-21.2 n, page 3-102 |
| Warning CSI, |
Verification of proper swaging of pin (33) collar (32) is a 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.
| 61 | Install new collar (Figure 3-11, 32) on pin (33). | Para. 3-21.2 o, page 3-102 |
| WARNING If hydraulic fluid is decomposed by heat, toxic gases are released. Prolonged contact with liquid or mist can cause dermatitis and irritation. If there is any prolonged contact with skin, wash contacted area with soap and water. If liquid contacts eyes, flush eyes with water immediately for 15 minutes. Remove saturated clothing. If fluid is swallowed, do not induce vomiting. |
Get immediate medical attention. When handling liquid, wear rubber gloves. Inhalation of vapors should be avoided.
| 62 | Linkage Assembly, continued | Para 3-21.2, p. thru t. page 3-105 |
| 63 | Warning CSI, Verification of Installation of input linkage spacer is a CC | |
| 64 | Linkage Assembly, continued | |
| 65 | Install one input linkage spacer (18) on outer |
stop bolt (22) next to summing lever assembly
| (15). | Para 3-21.2 u. Page 3-105 | |||
| 66 | Install input link assembly (19) on outer stop | |||
| bolt (22) next to input linkage spacer (18). | Para 3-21.2 v. Page 3-105 | |||
| 67 | Warning CSI, Verification of Installation of input linkage spacer is a CC | |||
| 68 | Install second input linkage spacer (18) and second summing lever assembly (15) on outer stop bolt (22). | Para 3-21.2 w, page 3-105 | ||
| 69 | Install nut (11) on outer stop bolt (22). | Para 3-21.2 x, page 3-105 | ||
| 70 | Torque nut using linkage assembly tool (274060AT2) (Figure 3-12) to 70-80 inch pounds. Actual Torque____________ Serial number__________________ Calibration DUE date __________ This is required even though this is not a CC. | Para 3-21.2 y, page 3-105 | ||
| 71 | Linkage Assembly, continued | Para. 3-21.2 z thru an. pages 3-105 thru 3-107 | ||
| 72 | Install nut (3) on linkage retaining bolt. Torque nut to 20-25 inch-pounds. Actual Torque_______________ Serial number__________________ Calibration DUE date ______________ | Para 3-21.2 ao., page 3-107 | ||
| 73 | Linkage Assembly, continued | Para 3-21.2, ap thru aq page 108 | ||
| 74 | Warning CSI, Verification of proper swaging of pin (2) and collar (1) is a CC. | |||
| 75 | NOTE: |
● See Figure 3-17 and 3-18 for proper installation and verification procedures. Use pin/collar gage (HG77-13A) for swage verification.
● Swage pin head must be on same side as bolt heads.
| 76 | Install new collar (Figure 3-11, 1) on swage pin (2). | Para 3-21.2, ar. page 108 | ||
| 77 | Linkage Assembly, continued | Para 3-21.2, as and at. page 108 | ||
| 78 | Testing procedures (if applicable) should closely follow the assembly procedures. All testing producers must be incorporated, if a table for recording parameters is in the DMWR, that table's information must be incorporated in the plan. Testing equipment must also have the Serial number and calibration due date. | |||
| 79 | Final Testing and Assembly | |||
| 80 | Make sure all parts are clean and that corrosion preventive materials have been removed. | Para 4-1.1 a, page 4-1 | ||
| 81 | Replace all parts listed in App. B, Table B-3. | Para 4-1.1 b, page 4-1 | ||
| 82 | NOTE: | |||
| Torque values given are in addition to rundown torque. Torques must be within specified limits. If part is to be safety tied, tighten to lowest recommended torque, then advance to line up for safety tying. Never go above highest recommended torque. Unless specified, do not drill a second cotter pin or lockwire hole in any part previously drilled. Replace part if holes cannot be lined up. | Para 4-1.1 c, page 4-1 | |||
| 83 | Install cotter pins and lockwire per NASM33540. | Para 4-1.1d, page 4-1 | ||
| Final Assembly | ||||
| 90 | General Assembly | Para. 4-2.1 | ||
| 84 | General Assembly continued | Para. 4-2.1, a, (1) - (6) | ||
| 85 | Shipping will be I/A/W the DMWR and follow the guideline above. | |||
| 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. | ||||
| 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. | ||||
| 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.” | ||||
| 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. | ||||
| 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. |
01-242-1495 Repair Procedure I Removal and Installation Of Damaged or Worn Basic (production) Bushing/Bearing &"Arial,Bold"&12(PVA) WON_________ Critical Safety Item QE-ST-2 does apply
Rev. 3 dated 21 June 2010 Critical Safety Item QE-STD-2 does apply
&"Arial,Bold"&12PVA Page &P &"Arial,Bold"&12PVA
&"Arial,Bold"&12 Page &P &"Arial,Bold"&12
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