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*TM 1-1500-204-23-1

TECHNICAL MANUAL

AVIATION UNIT MAINTENANCE (AVUM) AND AVIATION INTERMEDIATE MAINTENANCE (AVIM) MANUAL

FOR

GENERAL AIRCRAFT MAINTENANCE

(GENERAL MAINTENANCE AND PRACTICES)

VOLUME 1

*This manual together with TM 1-1500-204-23-2 through TM 1-1500-204-23-10, dated 31 July 1992, supersedes TM 55-1500-204-25/1, dated 6 April 1970, including all changes.

DlSTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY 31 JULY 1992

STATEMENT A : Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY 31
TM 1-1500-204-23-1 An operating or maintenance procedure, practice, condition, statement, etc.,

TM

1-1500-204-23-1

An

operating

or

maintenance

procedure,

practice,

condition,

statement,

etc.,

which

if

not

strictly

observed,

could

result

in

injury

to

or

death

of

personnel.

 
 
 

An

operating

or

maintenance

procedure,

practice,

condition,

statement,

etc.,

which,

if

not

strictly

observed,

could

result

in

damage

to,

or

destruction

of,

equipment

or

loss

of

mission

effectiveness

or

long

term

health

hazards

to

personnel.

 

NOTE

An

essential

operating

or

maintenance

procedure,

condition,

or

statement,

which

must

be

high-

lighted.

or statement, which must be high- lighted. PRECAUTIONARY DATA information in Personnel performing

PRECAUTIONARY

DATA

information

in

Personnel

performing

manual

cause

instructions

shall

involving

the

operations,

following

or

an

aborted

procedures,

and

practices

of

these

which

are

this

technical

can

observe

injury,

instructions.Disregard

mission.

warnings

serious

death,

instructions.Disregard mission. warnings serious death, ELECTRICAL TESTS included and precautionary implied or

ELECTRICAL

TESTS

included

and

precautionary

implied

or

Electrical

power

up

to

volts 500

is

used

in

testing

the

equipment.Exercise

extreme

caution

during

these

tests.

Ensure

the

equipment

is

grounded

and

operated

in

accordance

with

the

operator’s

manual.

Never

operate

electrical

equipment

during

rain

or

while

standing

in

water

or

wet

areas.

Use

rubber

mats

to

stand

on.

 
   
 

ELECTRICAL

EQUIPMENT

 

All

switches

and

electrical

equipment

shall

be

of

the

enclosed

explosion-proof

type.All

metal

apparatus

shall

be

grounded

to

avoid

the

danger

of

igniting

test

fluid

fumes

or

creating

electrical

shock.

 
   
 

USING

SOLVENTS/PAINTS

 

Standard

precautions

such

as

fire

prevention

and

adequate

ventilation

shall

be

exercised

when

using

solvents

or

applying

primer

and

coating.

 

Wear

gloves

or

gauntlets

when

handling

solvents

as

solvents

may

cause

skin

disorders.

Cements

and

solvents

used

to

repair

life

rafts

are

flammable

and

shall

be

treated

as

such.

Never

smoke

or

permit

any

type

of

open

flame

near

when

using

cements

or

solvents.

 

Deleted.

Change

8a

any type of open flame near when using cements or solvents.   Deleted. Change 8a

TM

1-1500-204-23-1

Wear

gloves

to

protect

hands

while

TM 1-1500-204-23-1 Wear gloves to protect hands while handling HANDLING PLASTICS hot plastic.Boiling water shall not

handling

HANDLING

PLASTICS

hot

plastic.Boiling

water

shall

not

be

used

for

heating

acrylate

base

plastics.

Provide

adequate

ventilation

when

working

with

Furane

Plastics,

Epocast

H-991-A,

Furane

hardener

941,

or

equiv-

alents

as

these

materials

are

toxic.

941, or equiv- alents as these materials are toxic. LUBRICATINGOIL Lubricating oil MIL-L-7808 or

LUBRICATINGOIL

Lubricating

oil

MIL-L-7808

or

MIL-L-23699,

contains

an

additive

which

is

poisonous

and

absorbed

readily

through

the

skin.

Do

not

allow

oil

to

remain

on

skin.

Wash

with

soap

and

water.

to remain on skin. Wash with soap and water. FUEL When servicing aircraft or support

FUEL

When

servicing

aircraft

or

support

equipment,

clean

up

spilled

fuel

with

cotton

mops

or

cotton

rags.Wash

off

any

fuel

on

hands,

body,

or

clothing.

off any fuel on hands, body, or clothing. HANDLINGACID Wear protective clothing when mixing

HANDLINGACID

Wear

protective

clothing

when

mixing

acid

with

water.

Always

pour

acid

into

water,

never

water

into

acid.

pour acid into water, never water into acid. HANDLING PYROTECHNIC FLARES Handle pyrotechnic

HANDLING

PYROTECHNIC

FLARES

Handle

pyrotechnic

flares

with

the

same

care

as

high

explosives.

flares with the same care as high explosives. MAGNESIUM ALLOY FIRE Do not use water or

MAGNESIUM

ALLOY

FIRE

Do

not

use

water

or

any

standard

liquid

or

foam-type

fire

extinguishers

on

a

magnesium

alloy

fire,

as

they

may

cause

an

explosion.

Use

dry

sand

or

talcum

powder,

Federal

Specification

U-T-30.

or talcum powder, Federal Specification U-T-30.   AIRCRAFT ENGINE VALVES Severe personal
 

AIRCRAFT

ENGINE

VALVES

Severe

personal

injury

may

result

when

sodium-filled

valves

are

mutilated.

The

metallic

sodium

used

in

these

valves,

when

brought

into

contact

with

the

skin

(contacts

moisture),

gives

off

highly

flammable

hydrogen

gas.

 
 
   
 

REMOVING

CORROSION

 

Take

precautions,

such

as

wetting

the

area

or

exhausting

debris,

to

prevent

possible

dust

explosions

when

removing

corrosion

from

steel

alloys.

Use

goggles

or

face

shield

when

removing

paint

or

corrosion

with

a

wire

brush

or

by

the

grinding

method.

 

bChange

5

 
TIRES AND WHEELS Tires Ensure Do Use If it is necessary extreme not the use

TIRES

AND

WHEELS

Tires

Ensure

Do

Use

If

it

is

necessary

extreme

not

the

use

shall

valve

air

be

caution

to

approach

removed

booster

prying

a

when

outside

is

or

a

wheel

out

with

a

hot

designed

material

brake,

do

so

either

bolts

in

from

tire

tread.

directly

in

foreign

not

imbedded

for

tire

bottles

core

inflated

pumps

inflation.

or

restraining

before

removing

device

wheel

only

to

screws.

a

pressure

sufficient

front

or

to

force

TM

1-1500-204-23-1

directly

the

tire

behind

the

bead

onto

aircraft.

the

rim

ledge

and

create

an

airtight

seal

with

the

tire

and

bead.

Use

no

more

than

15

pounds

pressure

outside

the

restraining

device.

If

seal

is

not

formed,

check

tire

rim

and

bead

and

repeat

procedure.

Use

soap

type

liquid

on

rim

for

ease

of

movement.

Do

not

allow

petroleum

base

for ease of movement. Do not allow petroleum base OXYGENSYSTEM products to come in contact with

OXYGENSYSTEM

products

to

come

in

contact

with

oxygen

system

components,

as

an

explosion

or

fire

may

result.

Do

not

use

masking

tape

to

seal

openings

in

oxygen

regulators.

Masking

tape

constitutes

a

safety

hazard

when

use

on

either

serviceable

or

repairable

oxygen

equipment.

 

DELETED

 
 
   
 
 

GROUND

SUPPORT

EQUIPMENT

 

Always

operate

all

equipment

in

accordance

with

the

operator’s

manual.

 

Do

not

attempt

to

lift

any

load

when

the

hydraulic

axle

jack

is

tilted.

To

prevent

accidental

falls,

appropriate

maintenance

platforms/safety

stands

illustrated

in

appropriate

workstand

manuals

or

any

other

approved

locally

procured/manufactured

safety

stands/restraint

equipment

will

be

used

when

safety stands/restraint equipment will be used when working (above 10 feet) on aircraft in a

working

(above

10

feet)

on

aircraft

in

a

non-tactical

environment.

 

Install

safety

lock

when

an

adjustable-height

maintenance

platform

is

in

use.

Ensure

the

air

hose

used

with

compressed

air

is

safe

for

the

pressure

being

handled.

Release

air

pressure

in

air

compressor

tank

before

performing

maintenance

on

air

compressors.

Disconnect

power

before

changing

belts

on

electrically-driven

compressors.

 

Disconnect

electrical

power

before

opening

or

disassembling

any

part

of

electrical

equipment.

disassembling any part of electrical equipment. RADIOGRAPHIC EQUIPMENT Exercise extreme caution when

RADIOGRAPHIC

EQUIPMENT

Exercise

extreme

caution

when

performing

radiographic

inspections

to

prevent

personnel

from

coming

in

contact

with

radiation.

Radiation

from

X-ray

units

and

radioisotope

sources

is

extremely

destructive

to

living

tissue.

 
 

Change

5c

TM

1-1500-204-23-1

TM 1-1500-204-23-1 FIRE EXTINGUISHERS Halon type fire extinguishers, Monobromotrifluoromethane (CF3BR) are

FIRE

EXTINGUISHERS

Halon

type

fire

extinguishers,

Monobromotrifluoromethane

(CF3BR)

are

odorless

gasses.When

used

in

confined

areas,

available

oxygen

for

breathing

may

be

depleted.Use

supplied

breathing

air

when

using

these

gasses

in

enclosed

spaces.

when using these gasses in enclosed spaces. HYDRAULICFLUID opened To avoid contamination, do and

HYDRAULICFLUID

opened

To

avoid

contamination,

do

and

used.When

not

use

previously

can,

clean

opened

top

and

cans

use

a

opening

of

hydraulic

clean,

sharp,

fluid.A

new,

sealed

unplated

instrument

can

of

fluid

to

prevent

contami-

be

must

nation.

Acrylic

monomer

and

polymer

base

adhesive,

MIL-A-8576,

contains

a

volatile

liquid

which

may

prove

toxic

when

vapors

are

inhaled

over

extended

periods.

Use

only

with

adequate

ventilation.

 

Observe

fire

precautions

when

using

aliphatic

naphtha,

Federal

Specification

when using aliphatic naphtha, Federal Specification TT-N-95. COMPRESSEDAIR Compressed air shall not be

TT-N-95.

COMPRESSEDAIR

Compressed

air

shall

not

be

used

for

cleaning

purposes

except

if

reduced

to

less

than

30

psi

and

then

only

with

effective

chip-guarding

and

personal

protective

equipment.

chip-guarding and personal protective equipment. NOISEHAZARD Noise levels reached during ground

NOISEHAZARD

Noise

levels

reached

during

ground

runup

of

Army

aircraft

are

of

a

level

that

may

cause

permanent

hearing

loss.

Maintenance

personnel

shall

wear

adequate

hearing

protection

when

working

on

aircraft

with

engines

in

operation.

working on aircraft with engines in operation. and To avoid used. contamination, do When opening not

and

To

avoid

used.

contamination,

do

When

opening

not

can,

TURBINE

ENGINE

OIL

clean

use

previously

top

and

opened

use

a

cans

of

engine

oil,

clean,

sharp

un-plated

and opened use a cans of engine oil, clean, sharp un-plated instrument new sealed can to

instrument

new

sealed

can

to

prevent

of

fluid

must

be

opened

contamination.

MERCURY

that

tenance

A

very

are

of

small

amount

of

mercury

may

produce

for

hazardous

safety

vapors.

Electrical/Electronic

to

clean

up

spillage.

Equipment,

precautions

used

mercury

to clean up spillage. Equipment, precautions used mercury Refer to to use when TM 385-4, Safety

Refer

to

to

use

when

TM

385-4,

Safety

Precautions

and

for

handling

mercury

for

methods

Main-

sonal

whenever

tridges

Electrically

activated

removed

cargo

fire

hook

from

and

injury.

extinguisher

thruster

shall

cartridges,

cartridges

the

aircraft

installation

CARTRIDGES

external

stores

release

wrapped

cartridges,

in

external

load

foil

or

activation

cable

cutter

per-

shunted

car-

be

protectively

to

preclude

aluminum

voltage

electrically

and

"stray"

electrical

resulting

dChange

8

 

TM

1-1500-204-23-1

 
 
 

PROPER

USE

OF

PLATED

TOOLS

Use

only

chrome

plated

steel

or

unplated

steel

tools

for

disassembly

or

reassembly

procedures

described

in

this

manual.

Use

of

cadmium

or

zinc

plated

tools

is

not

permitted

since

these

platings

are

prone

to

chipping

and

aking.

Should

these

chips

or

akes

become

embedded

in

aircraft

parts,

galvanic

corrosion

will

result.Should

these

chips

or

akes

enter

fuel

or

oil

wetted

components,

they

may

eventually

clog

the

lter

or

produce

intergranular

attack

of

nickel

or

titanium

base

alloys

at

elevated

temperature.

All

tools

regardless

of

type

plating

should

be

serviceable

and

free

of

chipping.

should be serviceable and free of chipping. SPECIAL INSTRUCTIONS Guidance Safety (SOPs) unavailable, All

SPECIAL

INSTRUCTIONS

Guidance

Safety

(SOPs)

unavailable,

All

equipment

will

for

Ofce

must

be

operated

for

the

and

use

in

accordance

and

care

will

be

to

for

found

provide

all

shop

in

with

be

the

manufacturer’s

operating

supporting

Procedures

instructions.If

instructions

be

prepared

industrial

will

use

their

developed.Standard

(refer

to

AR

Federal

Operating

used

operations

assistance.

the

Code

of

385-95).The

Code

expertise

can

hazards

Regulations,

of

Federal

Regulations

29

CFR

1910.

 
   
 
 

DEGREASING

SOLVENTS

 

Degreasing

Solvent,

MIL-PRF-680,

is

combustible

and

toxic

to

eyes,

skin,

and

respiratory

tract.

Wear

protective

gloves

and

goggles/face

shield.

Avoid

repeated

or

prolonged

contact.

Use

only

in

well

ventilated

areas

(or

use

approved

respirator

as

determined

by

local

safety/industrial

hygiene

personnel).

Keep

away

from

open

ames,

sparks,

or

other

personnel). Keep away from open ames, sparks, or other sources of ignition. ALIPHATIC NAPHTHA personnel). well

sources

of

ignition.

ALIPHATIC

NAPHTHA

personnel).

well

Wear

Aliphatic

Naphtha,

Keep

TT-N-95,

and

is

extremely

ames,

ammable

shield.

Avoid

respirator

sparks,

and

toxic

to

eyes,

skin,

and

respiratory

Use

hygiene

in

tract.

protective

ventilated

gloves

areas

(or

away

goggles/face

open

approved

repeated

or

by

prolonged

local

of

contact.

only

from

use

as

or

determined

other

safety/industrial

sources

ignition.

as or determined other safety/industrial sources ignition. CLEANING SOLVENT Cleaning Solvent, HFE-71DE, is

CLEANING

SOLVENT

Cleaning

Solvent,

HFE-71DE,

is

toxic

to

eyes,

skin,

and

respiratory

tract,

and

decomposes

into

other

hazardous

products

when

exposed

to

extreme

heat.Wear

chemical

protective

gloves

and

goggles/face

shield.Avoid

repeated

or

prolonged

contact.Use

only

in

well

ventilated

areas.If

ventilation

is

not

adequate,

use

approved

respirator

as

determined

by

local

safety/industrial

hygiene

personnel.

Keep

away

from

open

ames,

welding,

or

other

sources

of

extreme

heat.

welding, or other sources of extreme heat. Type CLEANING irritate COMPOUND and Cleaning Compound,

Type

CLEANING

irritate

COMPOUND

and

Cleaning

Compound,

MIL-PRF-87937,

repeated

or

II,

can

eyes

goggles.Avoid

prolonged

contact.

and

skin.Wear

protective

gloves

Change

5e

TM

1-1500-204-23-1

TM 1-1500-204-23-1 CLEANING COMPOUND Cleaning Compound, MIL-PRF-85570, Type II, can irritate eyes,

CLEANING

COMPOUND

Cleaning

Compound,

MIL-PRF-85570,

Type

II,

can

irritate

eyes,

skin,

and

respiratory

tract.Wear

protective

gloves

and

goggles.

Avoid

repeated

or

prolonged

contact.

Use

in

well

ventilated

areas.

 
 
 

ISOPROPYL

ALCOHOL

Isopropyl

Alcohol,

TT-I735,

is

ammable

and

toxic

to

eyes,

skin,

and

respiratory

tract.

Wear

protec-

tive

gloves

and

goggles/face

shield.

Avoid

repeated

or

prolonged

contact.

Use

only

in

well

ventilated

areas

(or

use

approved

respirator

as

determined

by

local

safety/industrial

hygiene

personnel).

Keep

away

from

open

ames,

sparks,

or

other

sources

of

ignition.

 

fChange

5

CHANGE

NO.

8

TM

1-1500-204-23-1

C8

ROUTINE

2012

THE

HEADQUARTERS

ARMY

DEPARTMENT

DC.,

28

OF

WASHINGTON,

December

AVIATION

AND

UNIT

MAINTENANCE

(AVUM)

AVIATION

INTERMEDIATE

MAINTENANCE

(AVIM)

FOR

MANUAL

GENERAL

AIRCRAFT

MAINTENANCE

(GENERAL

MAINTENANCE

AND

VOLUME1

PRACTICES)

1301). (Halon Agent Extinguisher Fire (CF3BR); Bromotrifluoromethane EXCEPT possible where materials hazardous
1301).
(Halon
Agent
Extinguisher
Fire
(CF3BR);
Bromotrifluoromethane
EXCEPT
possible
where
materials
hazardous
less
or
non-hazardous
with
tution
substi-
by
document
this
from
removed
been
have
Substances
Toxic
and
Chemicals
Hazardous
to
references
all
2010,
December
22
dated
07,
change
through
document
base
of
As
Division.
Environmental
(Logistics)
G-4
AMCOM
the
by
lists
313
and
302
EPCRA
the
by
defined
as
SUBSTANCES
TOXIC
AND
CHEMICALS
HAZARDOUS
of
presence
the
for
reviewed
been
has
document
This
INFORMATION
MATERIAL
HAZARDOUS

TM

DISTRIBUTION

STATEMENT

A

:Approved

for

1-1500-204-2-1,

Dated

31

July

1992,

is

changes

as

public

release;

follows:

distribution

is

unlimited.

1.

Remove

and

insert

pages

as

indicated

below.

New

or

changed

text

material

is

indicated

by

a

vertical

bar

in

the

margin.

An

illustration

change

is

indicated

by

a

miniature

pointing

hand.

 
 

Remove

PagesInsert

Pages

 

a

through

da

through

d

A

and

BA

through

C/(D

blank)

 

i

and

and iii

ii

 

2-5

through

2-82-5

through

2-8

3-5

and

3-63-5

and

3-6

9-41

and

9-429-41

and

9-42

11-3

and

11-411-3

and

11-4

11-7

and

11-811-7

and

11-8

11-13

and

11-1411-13

and

11-14

11-17

and

11-1811-17

and

11-18

11-29

and

11-3011-29

and

11-30

 

A-1

and

A-2A-1

and

A-2

2.Retain

this

sheet

in

front

of

manual

for

references

purposes.

By Order of the Secretary of the Army:

Official:

purposes. By Order of the Secretary of the Army: Official: JOYCE E. MORROW Administrative Assistant to

JOYCE E. MORROW Administrative Assistant to the Secretary of the Army

1232801

RAYMOND T. ODIERNO General, United States Army Chief of Staff

Distribution:

To be distributed in accordance with the initial distribution number (IDN) 313302,

requirements for TM 1-1500-204-23-1.

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