GENERAL SHOP PRACTICES

Where applicable, prior to performing maintenance, ensure batteries are disconnected. Failure to observe this warning could result in severe injury or death.

a. Wear protective overalls, and keep items of loose clothing clear of all hot and moving parts. Use protective barrier cream when necessary.

b. Whenever possible, clean components and surrounding area before removing or disassembling. Take care to exclude all dirt and debris from equipment while it is being serviced.

c. Some parts are cemented with gasket compound with others being dry. Before assembly, remove all traces of old gasket and compound. Take extreme care to exclude dirt from all gasket surfaces and gasket compound from all tapped holes unless otherwise specified.

d. It is recommended that all oil seals be replaced once they have been removed from their original position. Seals must be installed square in the housing and all lip seals must be installed with lip facing towards lubricant to be retained. A service tool should be used to install all oil seals and care must be taken to prevent damaging new seal when passed over shafts.

e. Replace all nuts, bolts, capscrews, and studs with damaged threads. Do not use a tap or die to repair damaged threads which may impair the strength and closeness of the threads and is not recommended.

f. Do not allow grease or oil to enter a blind threaded hole as hydraulic pressure created when bolt or stud is screwed in could split or stress housing.

g. To check or re-torque a bolt or nut, slackened a quarter of a turn and then tightened to specified value.

 

h. A steel ISO metric bolt, capscrew, or nut can be identified by the letter M either on head or that hexagon. The strength grade will also be marked on top or flat.

i. On nuts with identification marks on one face the frictional area of that surface will be reduced, therefore nut should be installed with unmarked face towards component.

j. Service tools are designed to aid disassembly and assembly procedures and their use will prevent possible unnecessary damage to components. It is recommended that service tools always be used, as some operations cannot be safely carried out without aid of a relevant tool.

1.3 REPAIR. Component repair consists of performing any repair or part replacement necessary to restore the component to a serviceable condition. Perform only those procedures necessary to make the required repair or part replacement.

a. Clean all disassembled components, except electrical parts and prelubricated bearings, with solvent, Federal Specification P-D-680 Type III. Use a stiff-bristle, non-metallic brush to ensure that all orifices, packing grooves, and ports are clean.

b. Dry all cleaned parts using compressed air at less than 30 PSIG, or a clean, lint-free cloth.

c. After cleaning, inspect all parts for wear and defects, such as nick, burrs, scoring, cracks, corrosion, or similar defects. Inspect all threaded areas for stripped, crossed, or broken threads. Inspect mounting holes for elongation which would effect component performance.

Do not use abrasive cloth, Federal Specification P-C-458, on aluminum or magnesium alloy parts, as it contains an iron oxide which causes rapid oxidation of these metals.

 

d. Polish out minor defects from noncritically dimensioned surfaces, using abrasive cloth, Federal Specification A-A-1206, for ferrous alloy parts and abrasive cloth, Federal Specification A-A-1200, for aluminum and magnesium alloy parts. Ensure that precision fits, and seating or sealing surfaces are not destroyed. Reclean any repaired parts.

e. Replace all preformed packaging, backup rings, gaskets, and seals, regardless of condition, each time a component is replaced.

f. During reassembly of hydraulic components, assemble parts dripping wet, dipping them in hydraulic fluid, Military Specification MIL-H-5606/MIL-H-83282.

g. Perform hydraulic component tests using a clean source of hydraulic fluid, Military Specification MIL-H-5606/MIL-H-83282 filtered to 10 Micron, or better.

SAFETY SUMMARY

Highlights an operating or maintenance procedure, practice, condition, statement, etc. which if not strictly observed, could result in injury, death, or long term health hazards to personnel.

Highlights 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.

1.1.7 DIESEL FUEL. Diesel fuel is flammable and toxic to skin, eyes, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact. Good general ventilation is normally adequate.