Aviation Mechanic Handbook

by Crane, Dale

• ISBN13: 9781560274124
• ISBN10: 1560274123
• Format: Paperback
• Copyright: 2000-06-01
• Publisher: Aviation Supplies & Academics

Table of Contents

Introduction	iii
General Information	1	(28)
Fraction, Decimal, and Metric Equivalents	3	(1)
Conversions	4	(9)
Aircraft Nomenclature	13	(3)
Axes of an Airplane	13	(1)
Forces Acting on an Aircraft in Flight	13	(1)
Types of Aircraft Structure	14	(1)
Truss	14	(1)
Monocoque	14	(1)
Semimonocoque	15	(1)
ATA-100 System Of Identification	16	(5)
Aircraft Nationality Identification	21	(3)
Title 14 of the Code of Federal Regulations	24	(4)
Standard Taxi Signals	28	(1)
Physical and Chemical	29	(16)
Temperature Conversion	31	(6)
Absolute Temperature	36	(1)
ICAO Standard Atmosphere	37	(1)
Distribution of Electrons in the Chemical Elements	38	(3)
Density of Various Solids and Liquids	41	(1)
Density of Various Gases	41	(1)
Hydraulic Relationships	42	(2)
Quantity of Liquid in a Drum	44	(1)
Estimating Quantity of Liquid in a Standard 55-Gallon Drum	44	(1)
Mathematics	45	(28)
Measurement Systems	47	(3)
The International System of Units (SI)	47	(1)
The Metric System	48	(1)
U.S. - Metric Conversion	48	(1)
Length	48	(1)
Weight	48	(1)
Volume	49	(1)
Mathematical Constants	50	(1)
Mathematical Symbols	51	(1)
Squares, Square Roots, Cubes, Cube Roots of Numbers	52	(3)
Diameter, Circumference and Area of a Circle	55	(3)
Geometric Formulas	58	(3)
Triangle	58	(1)
Square	58	(1)
Rectangle	58	(1)
Parallelogram	58	(1)
Trapezoid	58	(1)
Regular Pentagon	59	(1)
Regular Hexagon	59	(1)
Regular Octagon	59	(1)
Circle	59	(1)
Ellipse	59	(1)
Sphere	60	(1)
Cube	60	(1)
Rectangular Solid	60	(1)
Cone	60	(1)
Cylinder	60	(1)
Trigonometric Functions	61	(4)
Powers of Ten	65	(3)
Number Systems	68	(5)
Binary Equivalent of Decimal	68	(1)
Octal Equivalent of Decimal	68	(1)
Binary Equivalent of Octal	68	(1)
Hexadecimal Number System	68	(1)
Binary Coded Decimal Equivalent of Decimal	69	(1)
The Gray Code	69	(1)
American Standard Code for Information Interchange (ASCII)	69	(2)
Special Control Functions Used in ASCII:	71	(2)
Aircraft Drawings	73	(8)
Types of Aircraft Drawings	75	(2)
Sketches	75	(1)
Detail Drawings	75	(1)
Assembly Drawings	75	(1)
Installation Drawings	75	(1)
Sectional Drawings	75	(1)
Cutaway Drawing	75	(1)
Exploded-View Drawing	75	(1)
Schematic Diagram	76	(1)
Block Diagram	76	(1)
Repair Drawings	76	(1)
Wiring Diagrams	76	(1)
Pictorial Diagrams	76	(1)
Orthographic Projections	76	(1)
Meaning of Lines	77	(1)
Material Symbols	78	(1)
Location Identification	79	(2)
Fuselage Stations	79	(1)
Water Lines	79	(1)
But Lines	79	(1)
Wing and Horizontal Stabilizer Stations	79	(2)
Aircraft Electrical Systems	81	(38)
Electrical Symbols	83	(8)
Alternating Current Terms and Values	91	(1)
Ohm's Law Relationships	92	(2)
Electrical Formulas	94	(7)
Formulas Involving Resistance	94	(1)
Formulas Involving Capacitance	95	(2)
Formulas Involving Inductance	97	(3)
Formulas Involving Both Capacitance and Inductance	100	(1)
Resonant Frequency	100	(1)
Total Reactance	100	(1)
Impedance	100	(1)
Electrical System Installation	101	(18)
Selection of Wire Size	101	(5)
Notes on Wire Installation	106	(2)
Switch Derating Factors	108	(1)
Wire and Circuit Protectors	109	(1)
MS Electrical Connectors	110	(4)
Resistor Color Code	114	(2)
Aircraft Storage Batteries	116	(1)
Lead-Acid Batteries	116	(1)
Nickel-Cadmium Batteries	117	(2)
Aircraft Materials	119	(14)
Composition of Wrought Aluminum Alloys	121	(1)
Four-Digit Designation System for Wrought Aluminum Alloys	122	(1)
Mechanical Properties of Aluminum Alloys	123	(1)
Temper Designations for Aluminum Alloys	124	(1)
Heat-Treatable Alloys	124	(1)
Non-Heat-Treatable Alloys	124	(1)
Temperatures for Heat Treatment of Aluminum Alloys	125	(1)
Bearing Strength (in pounds) of Aluminum Alloy Sheet	126	(1)
Shear Strength of Aluminum Alloy Rivets	127	(1)
Single-Shear Strength (in pounds) of Aluminum-Alloy Rivets	127	(1)
Double-Shear Strength (in pounds) of Aluminum-Alloy Rivets	127	(1)
SAE Classification of Steel	128	(1)
Strength of Steel Related to its Hardness	129	(1)
Color of Steel for Various Temperatures	130	(1)
Color of Oxides on Steel at Various Tempering Temperatures	131	(2)
Tools for Aircraft Maintenance	133	(42)
Measuring and Layout Tools	135	(6)
Steel Rule	135	(1)
Hook Rule	135	(1)
Combination Set	135	(1)
Vernier Calipers	136	(1)
Dividers	136	(1)
Outside Calipers	136	(1)
Inside Calipers	136	(1)
Hermaphrodite Calipers	136	(1)
Scriber	136	(1)
How to Read the Vernier Scale	137	(1)
Micrometer Caliper	138	(2)
Dial Indicator	140	(1)
Feeler Gages	140	(1)
Small-Hole Gages	140	(1)
Telescoping Gages	140	(1)
Holding Tools	141	(2)
Vises	141	(1)
Bench Vise	141	(1)
Drill Press Vise	141	(1)
Pliers	141	(1)
Combination/Slip Joint Pliers	141	(1)
Water Pump Pliers	142	(1)
Vise-Grip® Pliers	142	(1)
Needle-Nose Pliers	142	(1)
Safety Wiring Tools	143	(1)
Diagonal Cutting Pliers	143	(1)
Duckbill Pliers	143	(1)
Safety Wire Twisting Tool	143	(1)
Bending and Forming Tools	144	(1)
Tools for Making Straight Bends and Curves	144	(1)
Cornice Brake	144	(1)
Box Brake	144	(1)
Press Brake	144	(1)
Slip Roll Former	145	(1)
Forming Compound Curves in Sheet Metal	145	(1)
English Wheel	145	(1)
Cutting Tools	145	(6)
Shears	145	(1)
Throatless Shears	145	(1)
Squaring Shears	146	(1)
Scroll Shears	146	(1)
Hand Shears	146	(1)
Tin Snips	146	(1)
Compound Shears	147	(1)
Saws	147	(1)
Band Saw	147	(1)
Hacksaw	148	(1)
Wood Saws	148	(1)
Crosscut Saw	148	(1)
Ripsaw	148	(1)
Compass, or Keyhole Saw	148	(1)
Backsaw	149	(1)
Chisels	149	(1)
Flat Chisel	149	(1)
Cape Chisel	149	(1)
Diamond Point Chisel	149	(1)
Round Nose Chisel	149	(1)
Files	150	(1)
Hole Cutting Tools	151	(8)
Twist Drills	151	(1)
Twist Drill Sizes	151	(3)
Drill Gage	154	(1)
Twist Drill Sharpening	154	(1)
Drill Point Gage	155	(1)
Large Hole Cutters	156	(1)
Hole Saws	156	(1)
Fly Cutter	156	(1)
Countersink	156	(1)
Reamers	157	(1)
Drills for Wood and Composite Materials	157	(1)
Auger Bits	157	(1)
Forstner Bits	158	(1)
Flat Wood-Boring Bits	158	(1)
Brad-Point Drills	158	(1)
Spade Drill	158	(1)
Threads and Threading Tools	159	(3)
Unified and American Standard Thread Form	159	(1)
Thread-Cutting Tools	159	(1)
Body and Tap Drill Sizes	160	(1)
Taps	160	(1)
Screw Pitch Gage	161	(1)
Torque and Torque Wrenches	162	(4)
Click-Type Torque Wrench	162	(1)
Deflecting-Beam Torque Wrench	162	(2)
Torque Conversions	164	(1)
Recommended Torque Values	164	(2)
Pounding Tools	166	(1)
Carpenter's Claw Hammer	166	(1)
Ball Peen Hammers	166	(1)
Metalworking Hammers	166	(1)
Straight Peen and Cross Peen Hammers	166	(1)
Body, or Planishing Hammer	166	(1)
Mallets and Soft-Face Hammers	167	(1)
Sledge Hammers	167	(1)
Punches	167	(2)
Prick Punch	167	(1)
Center Punch	167	(1)
Drift, or Starting Punch	167	(1)
Pin Punch	168	(1)
Transfer Punch	168	(1)
Automatic Center Punch	168	(1)
Wrenches	169	(4)
Open End Wrench	169	(1)
Adjustable Open End Wrench	169	(1)
Ratcheting Open End Wrench	169	(1)
Box End Wrench	170	(1)
Ratcheting Box Wrench	170	(1)
Combination Wrench	170	(1)
Flare Nut Wrench	170	(1)
Socket Wrenches	171	(1)
Socket Wrench Handles	171	(1)
Hand Impact Tool	171	(1)
Typical Socket Wrenches	172	(1)
Extension and Adapters	172	(1)
Allen Wrenches	172	(1)
Screwdrivers	173	(2)
Slot Screwdrivers	173	(1)
Offset Screwdriver	173	(1)
Recessed-Head Screwdrivers	173	(1)
Screw Heads for Special Structural Screws	174	(1)
Aircraft Hardware	175	(30)
Standards	177	(1)
Threaded Fasteners	177	(16)
Bolts	177	(1)
Hex-Head Bolts	178	(1)
Flush-Head Bolts	179	(1)
Drilled-Head Bolts	179	(1)
Twelve-Point, Washer-Head Bolts	179	(1)
Internal Wrenching Bolts	179	(1)
Clevis Bolts	180	(1)
Eye Bolts	180	(1)
Bolt Installation	180	(1)
Bolt Fits	181	(1)
Screws	181	(1)
Aircraft Screw Heads	182	(1)
Set Screws	183	(1)
Self-Tapping Sheet-Metal Screws	183	(1)
Nuts	184	(1)
Nonlocking Nuts	184	(1)
Self-Locking Nuts	185	(1)
Low-temperature locking nuts	185	(1)
High-temperature locking nuts	186	(1)
Wing Nuts	186	(1)
Anchor Nuts	186	(1)
Channel Nuts	187	(1)
Pressed-Steel Nuts	187	(1)
Instrument Nuts	188	(1)
Rivnuts	188	(1)
Threaded Fastener Safetying	189	(1)
Locking Washers	189	(1)
Cotter Pins	189	(1)
Safety Wire and Safety Wire Twisting	190	(3)
Washers	193	(2)
Special Rivets	195	(7)
Blind Rivets	195	(1)
Friction-Lock Rivets	196	(1)
Mechanical-Lock Rivets	197	(1)
CherryMax Rivets, Olympic-Lok Rivets, Huck Rivets	198	(1)
High-Strength Pin Rivets	198	(1)
Hi-Shear Rivet	198	(2)
Hi-Lok Fasteners	200	(1)
Hi-Tigue Fasteners	201	(1)
Cowling Fasteners	202	(1)
Thread Repair Hardware	203	(2)
Helicoil Insert	203	(1)
Acres Sleeves	204	(1)
Metal Aircraft Fabrication	205	(22)
Sheet Metal Layout and Forming	207	(4)
Definitions	207	(1)
Layout Procedure	208	(1)
Example	208	(2)
Forming	210	(1)
Minimum Bend Radii for 90° Bends in Aluminum Alloys	211	(1)
Setback	212	(3)
Setback (K) Chart	212	(3)
Bend Allowance Chart	215	(3)
Rivets and Riveting	218	(9)
Alternatives to Riveting	218	(1)
Aircraft Solid Rivets	218	(1)
Rivet Material	219	(1)
Rivet Diameter	219	(4)
Examples of Rivet Selection	223	(1)
Rivet Length	223	(1)
Riveting Tools	224	(1)
Rivet Sets	224	(1)
Bucking Bars	224	(1)
Installing Flush Rivets	225	(1)
Blind Rivet Code	225	(2)
Aircraft Fabric Covering	227	(6)
Rib Stitch Spacing	229	(1)
Rib Stitch Knots	230	(3)
Corrosion Detection and Control	233	(12)
Types of Corrosion	235	(2)
Oxidation	237	(1)
Surface and Pitting Corrosion	238	(1)
Intergranular Corrosion	239	(1)
Exfoliation Corrosion	239	(1)
Stress Corrosion	240	(1)
Galvanic Corrosion	240	(1)
Concentration Cell Corrosion	241	(1)
Fretting Corrosion	242	(1)
Filiform Corrosion	242	(1)
Corrosion Control	243	(2)
Nondestructive Inspection	245	(12)
Visual Inspection	247	(1)
NDI	247	(1)
Visual Inspection	247	(1)
Surface Visual Inspection	247	(1)
Internal Visual Inspection	247	(1)
Tap Test	248	(1)
Penetrant Inspection	249	(1)
Magnetic Particle Inspection	250	(1)
Eddy Current Inspection	251	(2)
How it works	251	(1)
What it is suited for	252	(1)
Method	252	(1)
Detection of corrosion	252	(1)
Ultrasonic Inspection	253	(1)
Radiography	253	(4)
X-Rays	253	(1)
Gamma Rays	254	(1)
Inspection---Steps	254	(1)
Considerations	255	(1)
Safety	255	(2)
Aircraft Control Systems	257	(10)
Types of Control Systems	259	(1)
Torque Tubes	259	(1)
Push-Pull Rods	259	(1)
Control Cables	260	(1)
Control Cable Terminals	261	(1)
Turnbuckles	262	(2)
Turnbuckle Safetying	262	(1)
Clip-Locking Turnbuckles	263	(1)
Control Cable Tension	264	(3)
Aircraft Fluid Lines	267	(10)
Rigid Fluid Lines	269	(2)
Materials recommended for rigid fluid lines	269	(2)
Flexible Fluid Lines	271	(2)
Types of Flexible Fluid Lines	271	(2)
Installation of Flexible Hose	273	(1)
Fluid Line Identification	274	(3)
Oxygen System Servicing	277	(4)
Oxygen System Servicing	279	(2)
Filling Pressure for 1,850 PSI Oxygen Cylinders	279	(2)
Aircraft Weight and Balance	281	(10)
Locating the Center of Gravity	283	(1)
Datum Forward of the Airplane---Nose Wheel Landing Gear	284	(1)
Datum Aft of the Main Wheels---Nose Wheel Landing Gear	285	(1)
Datum Forward of the Main Wheels---Tail Wheel Landing Gear	286	(1)
Datum Aft of the Main Wheels---Tail Wheel Landing Gear	287	(1)
Location of CG with Respect to the Mean Aerodynamic Chord	288	(3)
Index	291