LIBRARY OF THE UNIVERSITY OF ILLINOIS AT URBANA-CHAMPAICN 629.13 146a no.ll-2U The person charging this material is re- sponsible for its return to the library from which it was withdrawn on or before the Latest Date stamped below. Theft, mutilation, and underlining of books are reasons for disciplinary action and may result in dismissal from the University. UNIVERSITY OF ILLINOIS LIBRARY AT URBANA-CHAMPAIGN AUG 3 1975 JVL 1 2 1975 FEB 16 JAN 2 7 0EC30 MAR' ? zifeo BOOING Vi'£ OltL* VU . ; 2 jg JUN may: 161934 6 199** ^3*96 FEB m AUG « 9 2008 dec i o w FEB 2 7 mo 7 1996 2O0J L161 — O-1096 :£3 \i.Kt of .u.no.s bulletin AIRPORT SHOP OPERATIONS UNIVERSITY OF ILLINOIS INSTITUTE OF'AVIATION Leslie A. Bryan, Ph.D., LL.B., Director James M. Hancock, A.B., Editor UNIVERSITY OF ILLINOIS BULLETIN Volume 52, Number 50; March, 1955. Published seven times each month by the University of Illinois. Entered as second-class matter December 11, 1912, at the post office at Urbana, Illinois, under the Act of August 24, 1912. Office of Publication, 207 Administration Building, Urbana, Illinois. by LESLIE A. BRYAN Director, Institute of Aviation University of Illinois AIRPORT SHOP OPERATIONS PUBLISHED BY THE UNIVERSITY OF ILLINOIS, URBANA THE WS&RY OF THr »»nl7 ::5J UNIVERSITY OF ILLINOIS Foreword The University of Illinois has been actively interested in aviation for a long period of time dating at least from World War I. During World War II that interest increased and culminated in the establishment of the Institute of Aviation in 1945 which, among its various activities, con- ducts aeronautical research, flight training, and subprofessional technical aviation courses for students of the University. The Link Foundation, recognizing the pioneering experience of the Institute of Aviation, provided a grant to the University of Illinois Foun- dation for use by the Institute in order to prepare and publish informa- tion about its program believing that the compilation of this information might be valuable to other institutions and to other segments of the aviation industry considering the establishment of similar activities. This bulletin, the fourth of five such publications, attempts to give the basic information necessary to organize and operate an aircraft repair and maintenance unit. Other bulletins published under The Link Foun- dation grant cover the organization of a college-level aircraft and engine maintenance curriculum, the operation of a university airport, including essential facts and figures about repair and maintenance services, the or- ganization of an aviation ground school, and the organization of a flight training curriculum. While the aim has been to provide sources of general information, there is frequent reference to the operations of the aviation program of the University of Illinois for illustrative purposes. In the preparation of the material for this bulletin, Mr. Forrest L. Lancaster, Aircraft Maintenance Engineer and Mr. N. C. Grimm, Super- vising Engineer of the Institute of Aviation staff, have been most helpful. In this monograph, as in all publications of the Institute, the author has had complete freedom to express his opinions, with the understanding thai he will assume sole responsibility therefor. LESLIE A. BRYAN, Director /)< < < mber. 1954 '?. Id tU. Table of Contents FOREWORD 2 THE AIRCRAFT MAINTENANCE SHOP 4 ORGANIZATION 4 SHOP APPROVAL 5 THE APPLICATION FILE 6 CERTIFICATE REQUIREMENTS 6 PERSONNEL 7 AIRCRAFT MAINTENANCE ENGINEER 7 AIRCRAFT SHOP FOREMAN 8 MASTER AIRCRAFT AND AIRCRAFT ENGINE MECHANIC 8 MASTER AIRCRAFT INSTRUMENT REPAIRMAN 9 MASTER AIRPORT MECHANIC 10 SENIOR AIRCRAFT MAINTENANCE MECHANIC 10 JUNIOR AIRCRAFT MAINTENANCE MECHANIC 11 AIRCRAFT MAINTENANCE MECHANIC HELPER 11 STOREKEEPER 12 CLERK-STENOGRAPHER 13 APPENDIX A. AN INSPECTION AND PROCEDURE MANUAL 14 B. EQUIPMENT LIST 18 C. FORMS AND THEIR USE 38 THE AIRCRAFT MAINTENANCE SHOP ORGANIZATION An aircraft maintenance shop, like the ground school and the flight activities, is a basic function of a complete university aviation program. Like the other activities it can start on a relatively small basis and cai grow as needed. At the University of Illinois, the Institute of Aviation operates complete aircraft, engine, accessory, instrument, propeller, and radic repair shop. The shop is operated for the purpose of maintaining the University fleet of aircraft and offering repair and maintenance facilities lor other aircraft based on the field and for transients who need emer- gency service. The University maintains the latter service as part of its agreement with the Federal government to operate a public airport ir return lor government aid in the construction of the airport. The air- i nil i maintenance department also operates a Civil Aeronautics Admin- istration (C.A.A.) Approved Parachute Loft for inspection, repair, anc repacking of all types of parachutes. A loft does not become economical until the volume ol repacking exceeds six parachutes a day. The following chart shows the present organization of the aircraft maintenance shop with the numbers indicating the number of employees in each classification: r ; Aircraft Maintenance Engineer and Co-assistant Airport Manager (1) Aircraft Shop Foreman (1) Clerk Stenographer (1) Master Airport Mechanic ( 1 ) Storekeeper ( 1 ) Master Aircraft and Aircraft Engine Mechanic (2) Master Aircraft Instrument Repairman (1) Senior Aircraft Maintenance Mechan wm] Junior Aircraft Maintenance Mechanic (2) Aircraft Maintenance Mechanic Helper ( 1 ) 5H0P APPROVAL It is necessary to have Federal approval of the aircraft maintenance hop if full benefit is desired. The method of securing this approval and pe requirements for the approval are outlined in detail in C.A.M 52 I his manual, entitled "Repair Station Certificates," can be purchased 3m the Superintendent of Documents, Washington 25, D.C., for $1. contains the general rules for certification, including the procedure for pplying for a certificate, and the requirements for the particular ratings -sired. It is wise to go over the provisions of the manual carefully and o consult with the C.A.A. representatives from the nearest local C.A.A ce. When that has been done the applicant then fills out form ACA- 394 which is provided by the C.A.A. district or regional office. The manual gives the location of offices. THE APPLICATION FILE The completed application file, in duplicate, consists of the following documents: the executed form ACA-394, a roster of the supervisory and inspection personnel, a copy of the repair station inspection manual, and a list of maintenance functions contracted to outside agencies. A copy of the Institute of Aviation's inspection manual is contained in Appendix A. CERTIFICATE REQUIREMENTS The C.A.A. will not issue a repair station certificate unless the in- specting agent finds that all the requirements of C.A.M. 52 have been complied with. However, peculiar circumstances may be taken into con- sideration and, if the standards are not lowered, a certificate may be granted with the limitations noted. As far as housing and facilities are concerned, the C.A.A. will want to ascertain that working space, storage facilities, and parts protection are such that the work being accomplished is protected at all times from the elements. They will also check to see that the workers are so pro- tected that they can perform their work adequately without impairment of quality and with proper facilities for the accomplishment of the maintenance operation. Ventilation, lighting, temperature control, and painting space will also be checked. Floor space may range from one hundred to several thousand square feet. Special additional facilities are required for airframe, engine, pro- peller, instrument, accessory, and radio repair stations. These require- ments are listed in Civil Aeronautics Manual (C.A.M.) 52. In general, the C.A.A. wants a responsible operation and will be most helpful in planning the station. At the inception of the operation the minimum requirements for the airframe and engine repair station will be sufficient to get under way. In fact, one licensed mechanic will be adequate to get a flight program going. Normally such a mechanic has his own han tools. So a small investment in supplies, small machines, and test equip ment will suffice until the organization develops. The investment can run from a few hundred dollars to many thousands. In localities where there are specialized facilities, such as a plating company, available to the station, the C.A.A. will often permit a state menl from the owners of the facilities to be substituted for the facilities required by Manual 52. Educational institutions can secure much special ized equipment through government surplus channels. PERSONNEL AIRCRAFT MAINTENANCE ENGINEER The aircraft maintenance engineer, under administrative supervision. is responsible for the management and operation of the aircraft mainte- nance shop. His characteristic duties and responsibilities are to supervise the aircraft maintenance staff, organize aircraft maintenance and repair, maintain a satisfactory stockroom, be responsible for records and reports, 25, 50, 75, and 100 hour inspections are routine heck time cards and other records, supervise in-service trainees, recom- nend appointments to shop staff, and perform related duties as assigned. The minimum acceptable qualifications are administrative and super- isory ability, university graduation, C.A.A. aircraft and engine rating, 1A.A. private or commercial pilot rating, and five years of responsible ,nd technical experience in aircraft and engine repair. The salary range or this position is $5000-8000. The aircraft maintenance engineer at the University of Illinois Air- >ort is in charge of all aircraft maintenance activities and is directly esponsible to the Director of the Institute of Aviation. He is a Civil aeronautics Administration licensed aircraft and engine mechanic with fourteen years of experience in the maintenance, inspection, and overhaul of aircraft, aircraft engines, and accessories. According to the C.A.A. Repair Station Approval No. 3708, the aircraft maintenance engineer is the manager, chief inspector, technical supervisor, and C.A.A. -desig- nated maintenance representative. AIRCRAFT SHOP FOREMAN Under general supervision, the aircraft shop foreman supervises and is immediately responsible for the work of aircraft maintenance mechanics, airport mechanics, instrument repairmen, storekeepers, and other per- sonnel in the aircraft maintenance shop. His characteristic duties and responsibilities are to assign and supervise regular work on aircraft and aircraft engines, conduct inspections, maintain safety practices, plan work flow, maintain time records, calculate costs, correlate stockroom activities, cooperate with teaching programs, and perform related duties as assigned. The minimum acceptable qualifications for a shop foreman are supervisory ability, high-school graduation, a currently valid C.A.A. aircraft and engine mechanic rating, and five years of experience in air- craft and engine maintenance. The salary ranges from $4000-6000 an- nually. At the University of Illinois Airport the aircraft shop foreman is a C.A.A. licensed aircraft and aircraft engine mechanic with fourteen years of experience in the maintenance, inspection, and overhaul of aircraft, aircraft engines, and accessories. In accordance with C.A.A. Repair Sta- tion Approval No. 3708, the aircraft shop foreman is an inspector, tech- nical supervisor, and designated maintenance representative, and is in charge of the shop during the absence of the aircraft maintenance engineer. MASTER AIRCRAFT AND AIRCRAFT ENGINE MECHANIC The master aircraft and aircraft engine mechanic must be qualified to do precision work, under general supervision, requiring a high degree of mechanical skill in the development, building, maintenance, and repair of aircraft, aircraft engines, and component parts. His char- acteristic duties and responsibilities are to develop, design, and build aircraft and aircraft engines from blueprints and specifications, perform skilled mechanical work with fine tolerances, plan, assign, and oversee work of subordinates, be responsible for repairs, overhauls, and inspec- tions of such aircraft and aircraft engines as may be assigned, assist in t( a< ding when required, operate all types of testing devices, as well as all shop mai hinery, install and repair all types of aircraft accessories, and perform related duties as assigned. The minimum acceptable qualifica- tions are knowledge of shop mathematics, precision tools, and special skills as required, supervisory ability, teaching ability, high-school gradu- ation, currently valid C.A.A. aircraft and engine mechanic rating, and five years of experience in aircraft engine and aircraft instrument work. The salary range is $4000-6000 annually. At the University of Illinois master aircraft and aircraft engine me- chanics are C.A.A. licensed aircraft and aircraft engine mechanics with from ten to fourteen years experience in the maintenance, inspection, and overhaul of aircraft, aircraft engines, and accessories. The master me- chanics are required to have had at least seven years of experience, five of which must have been with the University of Illinois Institute of Aviation. They must be C.A.A. licensed mechanics and, in accordance with C.A.A. Repair Station Approval No. 3708, are also technical super- visors in charge of various intershop departments, such as engine over- haul, periodic inspection, fabrication, instruments and accessories, etc. MASTER AIRCRAFT INSTRUMENT REPAIRMAN The qualifications for the master aircraft instrument repairman are to perform duties, under general supervision, requiring a high degree of skill in the installation, maintenance, repair, and calibration of various aircraft instruments, including radio. His characteristic duties and re- sponsibilities are to repair, calibrate, and adjust recording, regulating, and control instruments, such as compasses, altimeters, fuel gauges, tachometers, and similar instruments, install new or additional instru- ments, act as laboratory instructor in instrument uses, develop, design, and build experimental instruments, construct instruments from blue- prints and specifications, perform precision lathe work, and perform related duties as assigned. The minimum acceptable qualifications are knowledge of shop mathematics and precision instruments, skill in the use of tools and equipment, five years of experience in the design, con- struction, repair, and adjustment of precision instruments, and high- school graduation. The salary ranges from $4000-6000 annually. The master aircraft instrument repairman and master airport me- chanic have the same qualifications and responsibilities as the master aircraft and aircraft engine mechanic except that the master airport me- chanic, being principally a machinist and welder, need not be a licensed C.A.A. mechanic. One of the master mechanics is also a master parachute rigger and has the additional responsibility of parachute inspections, maintenance, and repacking. Aircraft maintenance personnel completely rebuild an airplane MASTER AIRPORT MECHANIC The qualifications for the master airport mechanic are to perform, under general supervision, duties requiring the high degree of skill in- volved in servicing, repairing, and altering airport machinery, buildings, and other physical facilities, and in the general maintenance, repair, or construction work at an airport. His characteristic duties and responsi- bilities are to check equipment for defects, repair motors, tractors, snow- removal equipment, trucks and buses, build special tools required lor aircraft repair, build storage cabinets, make carpentry alterations, and perform related duties as assigned. The minimum acceptable qualifica- tions are aptitude in automotive repair, machinist work, carpentry work, or other (rafts, grade-school graduation, and five years of experience in general repair and maintenance work. The salary scale is $4000-6000 annually. SENIOR AIRCRAFT MAINTENANCE MECHANIC The senior aircraft maintenance mechanic is a licensed C.A.A. air- < rafl and aircraft engine mechanic with seven years of experience in the inspection, maintenance, and overhaul of aircraft and aircraft engines. 10 In accordance with the C.A.A. Repair Station Approval No. 3708, he may also act as technical supervisor but with a lesser degree of freedom. The senior mechanic is required to have at least five years of experience as a C.A.A. licensed mechanic. His duties are identical to those of the master mechanic but to a lesser degree of responsibility, since he is not assigned to jobs requiring supervision over extensive major repairs and alterations. The qualifications for this classification are to perform, under general supervision, responsible duties requiring a high degree of skill and experience in the maintenance and repair of aircraft, aircraft engines, and component parts. The characteristic duties and responsibilities arc to supervise subordinates, be responsible for such repairs, overhauls, in- spections, and work as may be assigned on aircraft and engines, operate drills, lathes, and testing devices, install aircraft and engine instruments, assist in teaching when required, flight test aircraft as required, and per- form related duties as assigned. The minimum acceptable qualifications are supervisory ability, high-school graduation, currently valid C.A.A. aircraft and engine mechanic rating, and three years of experience in aircraft maintenance. The salary range is $3500-5000 yearly. JUNIOR AIRCRAFT MAINTENANCE MECHANIC The junior aircraft maintenance mechanic is a C.A.A. licensed me- chanic with one to five years-of experience in the inspection, maintenance, and repair of aircraft and aircraft engines. He has no supervisory respon- sibilities and is required to carry out any and all duties within the scope of his trade and abilities as may be assigned by the shop foreman or any of the mechanics of higher classification to whom he may be assigned. The qualifications for the junior aircraft maintenance mechanic are to perform duties, under general supervision, of considerable responsi- bility in maintaining aircraft and aircraft engines in an airworthy condi- tion. The characteristic duties and responsibilities are to be responsible for the maintenance, overhaul, repair, construction, and inspection of aircraft engines, remove and install instruments, radios and accessories, ; supervise helpers, run inspections, aid in laboratory teaching, and per- form related duties as assigned. The minimum acceptable qualifications are supervisory ability, high-school graduation, and a currently valid C.A.A. mechanic rating. The salary range is $3000-4000 yearly. AIRCRAFT MAINTENANCE MECHANIC HELPER The aircraft maintenance mechanic helpers need not be C.A.A. licensed mechanics. The only qualifications required are an interest in aircraft mechanics and enough mechanical aptitude to assist in the maintenance of aircraft and aircraft engines. Washing, cleaning, and waxing of the aircraft arc the general assigned duties of the mechanic- helper, but he is permitted and encouraged to do more as his ability progresses, and assistance is given to him so that he may eventually obtain the C.A.A. mechanic license. The qualifications for the mechanic helper are, under direct super- vision of authorized mechanics, to assist in performing duties involved in the maintenance of aircraft and aircraft engines. The characteristic duties and responsibilities are to aid in the maintenance, overhaul, repair, and construction of aircraft and aircraft engines, help with the repair and installation of aircraft instruments, assist in servicing aircraft, aid in in- spection and cleaning of aircraft, and to perform related duties as assigned. The minimum acceptable qualifications are mechanical apti- tude, manual dexterity, and high-school graduation. The salary range is $2800-3500 yearly. STOREKEEPER The storekeeper's characteristic duties and responsibilities are to re- ceive, store, and issue equipment, material, merchandise, or tools in a The airport stockroom maintains necessary parts and replacements 12 stockroom or storeroom, check incoming orders against items listed on requisitions, invoices, or other proper forms, prepare preliminary forms for items that show shrinkage or damage and route to proper authority for action, count, grade, or weigh articles, store supplies in bins, on the floor, or on shelves, depending upon the nature of the articles, in a loca- tion and position convenient for removal when needed, assist in develop- ing methods of moving the old stock before the new is issued, mark articles with identifying codes, figures, or letters when required, fill orders from requisitions or issue supplies and stock to students, faculty, and staff upon proper request or authority, make periodic inventory or keep a per- petual inventory of stock on hand, keep records of issuance of expendable or non-expendable items, request or order supplies when needed, make special purchases under authorized regulations, prepare necessary reports, make minor adjustments or repairs to articles carried in stock, mix or compound items carried in stock under the specific direction of an authorized person, assist the faculty or staff in setting up and operating items of equipment for lectures, regular laboratory work, or special dem- onstrations, and perform related duties as assigned. The minimum accept- able qualifications are high-school graduation and one year of experience in the field of storekeeping, accounting, or business administration. The salary ranges from $3000-4000_annually. CLERK-STENOGRAPHER The clerk-stenographer works part time assisting the aircraft main- tenance engineer in taking care of all aircraft records, work orders, pur- chase orders, a small amount of correspondence, and individual personnel records. The qualifications and duties for this position are to be responsible, under general supervision, for the performance of difficult and respon- sible stenographic and clerical work requiring a thorough knowledge of aircraft maintenance procedures, records, problems, and policies. The characteristic duties and responsibilities are to maintain aircraft and aircraft maintenance records, logbooks, and ledgers, purchase order records, keep work order records on work done in the aircraft mainte- nance shop, keep personnel files, prepare payrolls, requisitions for the purchase of equipment and supplies, make insurance reports, compose routine correspondence, compile reports and statistics, answer inquiries, copy reports and manuscripts, and perform related duties as required. The minimum acceptable qualifications are high-school graduation, superior intelligence and clerical aptitude, mastery of typing and short- hand skills, tact and supervisory ability, pleasant but business-like per- sonality, poise, and a minimum age of 21. The annual salary range is $2000-3000. 13 Appendix A — An Inspection and Procedure Manual INSPECTION PERSONNEL The inspection personnel will be thoroughly familiar with all inspec- tion methods, techniques, and equipment used in their specialty necessary to determine quality of airworthiness of the units and components under- going repairs or alterations. The shop foreman will maintain a complete file of aircraft specifica- tions, Airworthiness Directives (A.D. Notes) and service bulletins which will be filed in the aircraft maintenance office and will be available to all authorized shop inspectors in the fulfillment of their inspection duties. A second set of aircraft specifications and engine service bulletins will be maintained by the master aircraft and aircraft engine mechanic in charge of engine overhaul and will be filed in the engine accessory room. The aircraft maintenance engineer and the shop foreman will main- tain a file, in the office, of all technical reference material as well as a library of various types and models of aircraft and aircraft engine maintenance and overhaul manuals, parts manuals, and price lists. These will all be available for use by all authorized inspectors and technical supervisors. Magnaflux and black-light inspections will be performed only by those inspectors or technical supervisors experienced with magnaflux operation. The master mechanic in charge of engine overhaul will be responsible for the maintenance of the magnaflux and for checking out any inspector so designated by the aircraft maintenance engineer on the proper operation of the magnaflux machine and its accessories. At least one qualified person will be employed at all times proficient in the use of magnetic and fluorescent inspection equipment. Magnifying glasses, micrometers, dial indicators, and other inspection aids are available from the stockroom. Malfunctioning of any inspection equipment will be reported to the shop foreman or aircraft maintenance engineer who will in turn see that the equipment is satisfactorily repaired, recalibrated, or replaced by new equipment. All test equipment will be tested and recalibrated as per manufacturers' recommendations and records of these inspections will be maintained by each individual department. The chief inspector and/or alternate inspector will be responsible lor the approval of all major repairs and major alterations, on form ACA-337, and the inspeetion and approval of annual inspections, in- < luding issuance of form ACA-1362, Airworthiness Certificate, on all air- i t;ilt within the limits of this repair station approval. 14 INSPECTION OF INCOMING MATERIAL The storekeeper will be responsible for unpaeking and checking all incoming material as to condition and quantity as indicated by the pack- ing slip and University of Illinois receiving report. Questionable ma- terial will be brought to the attention of the aircraft maintenance engineer. The chief inspector or alternate inspector will ascertain the airworthiness condition of all incoming stock prior to its being put in the bins available for use. All material in the stockroom and reserve storage room will be tagged by manufacturer's part number or binned, in which case the bin will be labeled by part number. Insofar as possible all stock bins are labeled in sequence by manufacturer's number which tends automatically to locate parts in easy-to-find locations and tends to keep all Aeronca parts to- gether as well as Continental engine parts, Cessna parts, Beechcraft parts, and so forth. All parts and stock in the stockroom will be serviceable. Unservice- able stock will be disposed of upon authorization of the shop foreman or aircraft maintenance engineer, and repairable items will be repaired or completely overhauled prior to returning to stockroom for reissue. Obso- lete stock will be surveyed and removed from stock immediately upon notice of obsolescence. PRELIMINARY INSPECTION Preliminary inspections will be made by the aircraft maintenance engineer or the shop foreman and the results listed on the shop work order for item concerned. Master mechanics as well as the shop foreman will continually inspect work being done by other mechanics not desig- nated as inspectors. All work orders, upon completion of work, must be signed by the inspector making the final inspection, and various jobs performed are to be initialed by the mechanic who actually performed the work. INSPECTION FOR HIDDEN DAMAGE Inspection for hidden damage will be performed by the shop fore- man or master aircraft and aircraft engine mechanic or the aircraft maintenance engineer. These inspections will be mandatory on engine and accessory overhaul and on all 100-hour as well as annual inspections. It will also be mandatory when specified by service bulletins or A. D. notes. Inspections for hidden damage in the case of engine and accessory overhaul will be by magnaflux and black-light. Other steel parts remov- 15 able for magnaflux or black-light inspection will be so inspected as required by service bulletins or A. D. notes. Other inspections will be made by the aid of 10-power magnifying glass when applicable, other- wise by close visual inspection. INSPECTION PROCEDURE MANUAL The aircraft maintenance engineer will be responsible for the con- tinued review and correction of the inspection manual to keep it adequate for the functions or services performed by the repair station. When cor- rections or supplements are added to the inspection manual a copy will be furnished to each employee of the repair station and one copy posted on the bulletin board by the stockroom window. All employees will be furnished with a copy of the repair station inspection manual, and new employees will receive a copy upon employ- ment. The aircraft maintenance engineer is the manager of the C.A.A. repair station and is also the chief inspector. The shop foreman is an inspector and will assume the duties of the chief inspector when the chief inspector is absent. The line of authority within the aircraft maintenance department will be as follows: 1. Director of Institute of Aviation 2. Aircraft maintenance engineer 3. Shop foreman 4. Master aircraft and aircraft engine mechanic 5. Senior aircraft maintenance mechanic 6. Junior aircraft maintenance mechanic 7. Aircraft maintenance mechanic helper All work orders will be executed by the inspector or alternate in- spector who will note the work to be performed and time the aircraft is desired for use by the owner. The number of the work order and the pertinent information is entered in the work order ledger and the work order given to the appropriate shop foreman who will assign mechanic or mechanics, as the job calls for, to perform the work designated on the work order. After the aircraft has been moved to the shop, the shop foreman, master or senior mechanic assigned to the work order will make his preliminary inspection, note results on the work order, or con- firm the defects noted by the aircraft maintenance engineer. After com- pletion of work, the work order will be signed by the employee (in- spector) supervising or performing the work. The work order is then turned over to the shop foreman who returns it to the maintenance 16 office where it is processed and filed. All work orders and records will be filed and maintained for a period of at least two years. The chief inspector or alternate inspector will make a final inspec- tion of all major alterations and major repairs prior to approval and release for service. The chief inspector and alternate inspector are re- sponsible for the approval of all annual inspections performed in the shop and are authorized and responsible for the issuance of airworthi- ness certificates, form ACA-1362, for all aircraft within the limits of this repair station approval. Master and senior mechanics are also designated as technical super- visors and may pass inspection on work performed by the junior me- chanics and mechanic helpers assigned to them as assistants. They also are authorized to sign repair station work orders. The Radio and Instrument Laboratory is an integral part of aircraft maintenance operations 17 Appendix B — Equipment List The Institute of Aviation Aircraft Maintenance equipment list now completely fulfills C.A.A. requirements. In the Civil Aeronautics Manual 52 some equipment is marked required, but other equipment is starred, which means that such equipment or service need only be available, e.g., a letter from the Danville Plating Company verifying their ability to do plating work. This may be done for any equipment or service listed in Manual 52, which is followed by an asterisk. In the equipment list it should be noted that the same piece of equipment appears under several of the different classifications, e.g., an air compressor under equipment for steel structural components and for fabric covering. This does not mean two different air compressors and regulators are needed. The same is true of other equipment which may be used in different classifications of maintenance or repair work. It is possible to list only the approximate cost of the equipment since a majority of the larger items were obtained through surplus or obtained new but with an educational discount. The Institute of Aviation mechanics are required to furnish their own hand tools, but the Institute does furnish special tools such as micrometers, dial indicators, electric drills, etc. The amount of stock necessary to obtain approval will be based on the size of operation which is established and the type of aircraft it is necessary to maintain. REPAIR STATION EQUIPMENT LIST R — Required Equipment O — Optional Equipment A — Available Equipment From Outside Source AIRFRAME RATING Figures which appear in boldface type denote equipment which has been listed previously. 1 . Steel Structural Components R O A 1 Ea. - Arc Welder - Deluxe 200 250.00 2 Ea. - Acetylene - Portable 75.00 2 Ea. - Torch and set of tips (Smith) .... 50.00 3 Ea. — Benches with vise 75.00 2 Ea. - Metal saw (Do-all and Delta) ... 1 950.00 1 Ea. - Grinder and buffer (Pedestal, R O A bench, portable) 100.00 Jigs and fixtures (Assortment of). 50.00 Corrosion proofing equipment. . 25.00 Anodizing facilities 500.00 Metal Plating facilities 500.00 Steam Cleaning Equipment. . . . 300.00 2 Ea. - Pressure pots (Paint and dope). . 200.00 2 Ea. — Suction cups and gun heads. . . . 50.00 1 Ea. - Metal lathe (Sebastian 16x6 in.) 1 500.00 1 Ea. - Planer (Delta) 250.00 1 Ea. - Shaper (Stanley) 500.00 1 Ea. — Milling machine (Milwaukee model H) 1700.00 1 Ea. - Surface grinder (Norton) 500.00 2 Ea. — Drill press and assorted drills (Pedestal and bench)..- 200.00 1 Ea. - Nibbler (Savage) 1 25.00 Assorted hand tools (Special wrenches, reamers, taps, dies, etc.) 200.00 2 Ea.-Sand blast units 315.00 4 Ea. — Chemical cleaning tanks 100.00 2 Ea. - Degreasing tanks 100.00 1 Ea. - Heat treat oven 400.00 1 Ea. — Magnaflux machine 1 500.00 2 Ea. — Magnifying glasses 10.00 1 Ea. — Fluorescent inspection unit 1000.00 2 Ea. — Compressor and regulators. . . . 1700.00 1 Ea. - Rockwell test unit 500.00 1 Ea. - Brinell test unit 500.00 Wood Structures Hand saws, planes, and chisels (Assortment of each) 50.00 1 Ea. - Miter saw 40.00 1 Ea. - Table saw (Delta) 11 0.00 1 Ea. - Band saw (Delta) 1 50.00 1 Ea. - Sander (Disc, belt, and vibrator) 150.00 1 Ea. - Thickness planer (Delta) 250.00 2 Ea. - Drill press (Delta) 50.00 1 Set - Brace and bit. . 25.00 19 R 2 Ea. — Riveting equipment (Complete sets) 25.00 1 Ea. — Planer-joiner (Delta). . 1 Ea. — Router (Stanley) 1 Ea. — Carpenter square 5.00 2 Ea. — Trammels (Two sets of points and assortment of bars) 5.00 Cabinet maker clamps (Assort- ment of each type) 15.00 1 Ea. - Sand and shot bags 1 0.00 Paint brushes (Assortment of ) . . . 25.00 3. Alloy skin and structural components 1 Set — Smoothing dollies (Complete set) 50.00 1 Set — Bucking bars (Complete assort- ment) 25.00 1 Ea. - Metal rolls and dies (30" Pexto slip rolls) 75.00 1 Ea. - Nibbler (Savage) 1 25.00 1 Ea. — Metal brake (Box and cornice). . 560.00 1 Ea. — Metal shear (Open and closed throat) 850.00 1 Ea. — Do-all (Completely equipped).. 2 Ea. — Hand drill (Powered) and assorted drills 35.00 2 Ea. - Drill press (Delta) 200.00 2 Ea. — Planishing iron Jigs (As required) 25.00 Fixtures and clamps (Complete assortment) 25.00 2 Ea. — Riveting equipment powered (and also two cherry rivet guns, two squeeze riveters) 150.00 Clecos and similar fastners (As- sortment of each) 1 Ea. - Rivet oven (As required) 150.00 1 Ea. - Cold storage box (As required). 150.00 1 Ea. - Fluorescent inspection unit 4. Fabric covering Assorted needles (Straight and curved) 10.00 20 1 Ea. — Sewing machine (Single and R O A double needle) 365.00 1 Ea. - Fabric table 50.00 2 Ea. - Pinking shears 1 0.00 Clamp and pins (Assortment of each) 10.00 Paint brushes (Assortment of ) . . . 25.00 Dope spraying equipment (Two pressure pots and 2 suction cups and gun heads) 50.00 Spray booth (39' x 32' steel structure, exhaust fan, heated air manifold, four air regula- tors) 500.00 1 Set — Number and letter templates. . . 60.00 Plastic and upholstery repair equipment 5.00 Compressor and regulators (Two compressors and regulators). .1700.00 Engraving equipment 350.00 Control systems 1 Set — Splicing equipment (Clamps and awls) 5.00 1 Set — Swaging equipment (Nicopress set) 25.00 2 Ea. - Tensiometer 1 0.00 Cable stretching and testing equipment 500.00 1 Ea. - Bubble protractor 1 0.00 Contour boards and templates (As required) 10.00 1 Ea. - Bench arbor press 40.00 Control Balancing Jigs (As re- quired) 10.00 Hinge and bushing repair equip- ment 50.00 2 Ea. — Drill press (Reamers and drills) Delta 200.00 1 Ea. - Lathe (South Bend 1 0") 350.00 21 6. Landing gear systems R O A Aircraft jacks and pads (Six large and six small and two DC-3 wing jacks) 500.00 1 Ea. — Heating torch and oven 225.00 1 Ea. - Arbor press 40.00 Bungee jigs and servicing tools. . 10.00 Special tools (Reamers, drills, etc.) 1 00.00 Anodizing and plating equipment 1000.00 2 Ea. - Drill press (Delta) 200.00 1 Ea. — Brake drum turning lathe (Sebas- tian 14") 1500.00 Brake shoe riveting equipment. . 25.00 1 Ea. - Work stands and fixtures 1 50.00 Machine shop equipment (for hy- draulic accessory overhaul) 1 Ea. — Hydraulic pressure test unit. . . . 500.00 Tube fabrication equipment (Bending, flaring, and beading kits) 50.00 Tire tools (Assortment, including hydraulic bead breaker) 50.00 2 Ea. - Voltohmeter 35.00 1 Ea. - Wire striper 5.00 1 Ea. — Stakon equipment (Complete set) 40.00 Soldering equipment (Irons, guns, and torch) 30.00 Electric motor test equipment. . . 50.00 7. Electric wiring 2 Ea. - Voltohmeter 35.00 Soldering equipment 30.00 Electric power supply Local Service Conduit fabrication tools 50.00 8. Assembly operations Racks and cradles (Adequate assortment) 1 00.00 2 Ea. - Plumb bobs 2.00 2 Ea. - Levels 5.00 Profile boards 5.00 Straight edge 1 .00 22 2 Ea. — Combination square and bubble R O A protractor 1 2.00 2 Ea. - Chain hoist and bridle 70.00 Engine stands (Assortment).... 150.00 2 Ea. — Tensiometers 1 0.00 Aircraft jacks and pads (6 large, 6 small, and 2 DC-3 wing jacks, hydraulic operated)... 500.00 Jigs and fixtures as required. . . 100.00 Scales for weighing (Platform and Cox and Stevens elec- tronic) 1000.00 8 Ea. - Work benches 75.00 8 Ea. - Wing stands 1 00.00 8 Ea. - Wing racks _. . . 1 00.00 Fuselage cradles (Assortment).. 100.00 Lubrication equipment (Complete assortment of guns, etc.). . . . 100.00 Auxiliary aircraft power supply (12 and 24 volt) 350.00 1 Ea. — Vacuum cleaner 175.00 Aircraft ground handling gear. . 1000.00 2 Ea. - Steel tape (50 ft. tapes) 5.00 23 POWERPLANT RATING Figures which appear in boldface type denote equipment which has been listed previously. Maintain, repair, and alter powerplants, R O A including replacement of parts Mechanical cleaning 5.00 2 Ea. — Degreasing & chemical cleaning booths 200.00 1 Ea. - Heating torch 75.00 1 Ea. - Oil bath 1 50.00 Chilling — shrinking facilities . . . 150.00 2 Ea. — Abrasive air blast units 31 5.00 Valve guide mandrels 25.00 Valve seat insert mandrels 25.00 1 Ea. - Arbor press 40.00 1 Ea. — Grinder and buffer (Bench & portable) 1 00.00 Metal plating facilities 500.00 Tap and dies (Assortment of ) . . . 100.00 Reamers and broaches (Assortment) . 500.00 Counterbores (Assortment) .... 25.00 1 Ea. — Oven (Temperature control). . . . 150.00 Special engine tools (Continen- tal, Lycoming, Franklin, Wright and Pratt & Whitney) 750.00 Paint spraying equipment (2 pots & 2 guns) 250.00 1 Ea. - Air & Electric drill motors 75.00 Thread chasers (Assortment). . . . 25.00 Assorted drill 50.00 Heliocoil equipment 150.00 2 Sets - Easy outs 25.00 Forming tools (Hand) 50.00 1 Set - Riveting equipment (Hand) 25.00 Engraving equipment 350.00 1 Ea. — Metal stamping set (Letters & figures) 60.00 Plating facilities 500.00 24 Inspection of parts, using appropriate R O A inspection aids 1 Ea. — Magnaflux machine 1 500.00 1 Ea. — Fluorescent inspection unit 100.00 1 Ea. - Dial gauge 25.00 1 Set — Inside & outside micrometer. . . . 75.00 2 Ea. — Magnifying glasses 1 0.00 1 Ea. — Torque wrench 1 5.00 1 Set — Feeler gauge 3.00 1 Set - Height gauges 65.00 1 Ea. - Surface plate 75.00 1 Set-V blocks 10.00 Jigs and fixtures 100.00 Parallel blocks 15.00 1 Set — Telescoping gauges "". . 20.00 1 Set - Radius gauges 1 0.00 Inspection bench & parts rack. . 250.00 1 Ea. — Valve spring compression gauge 55.00 1 Ea. — Combination square 1 2.50 Accomplish routine machine work 1 Ea. — Honing and lapping equipment. 150.00 1 Ea. — Precision grinder 1 50.00 1 Ea. - Lathe (Sheldon 56" bed) 350.00 1 Ea. - Portable grinder 75.00 1 Ea. - Drill press (Delta) 200.00 1 Ea. — Milling machine (Vertical) Milwaukee 1 700.00 Drills, taps, dies, and boring tools (Assortment) 200.00 Reamers and broaches (Assortment) 200.00 Buffing and cleaning wheels. . . 150.00 Valve grinding & lapping equipment 400.00 Valve seat grinding & lapping equipment 700.00 4. Performing assembly operations Valve and ignition timing tools. 50.00 25 1 Ea. — High tension ignition harness R O A tester 60.00 Ignition harness fabrication tools 25.00 Fuel and oil line fabrication and test equipment 25.00 Soldering irons and low pressure torch 30.00 Propeller installation tools 150.00 Engine accessory test equipment (Allen Test Stand) 1021.00 Engine stands (Assortment) 300.00 Hoisting equipment (Three chain hoist) 1 50.00 Test overhauled powerplants in compli- ance with manufacturer's recommenda- tions 2 Ea. -Test stand (Portable) 200.00 2 Ea. - Test clubs 200.00 26 PROPELLER RATING Figures which appear in boldface type denote equipment which has been listed previously. Maintain, repair, and alter propellers, R O A including installation and replacement of parts Metal fabrication tools (Hand) 2 Ea. - Power driven hand drills 35.00 1 Ea. — Sander (Disc, belt, and vibrator type) 1 50.00 -2~£ar- Drift press " (DefTaT. '. • 200.00 1 Ea. - Planer-joiner (Delta) „ 11 5.00 1 Ea. — Milling machine (Vertical) Milwaukee 1700.00 Soldering equipment (Irons, guns & torch) 30.00 1 Ea. - Table saw (Delta) 11 0.00 1 Ea. - Band saw (Delta) 1 50.00 Assorted clamps 100.00 1 Ea. - Grinder & buffer (Portable & bench mounted) 75.00 « Prop tools (Special as recom- mended by manufacturers). . . 125.00 Paint spray equipment (Including compressor & regulators). . . .1800.00 -Chemical cleaning .......... 200.00 1 Ea. —Chain hoist & assortment of propeller bridles 150.00 Metal plating 500.00 Assortment of propeller racks & stands 250.00 1 Ea. - Portable grinder & buffer 75.00 Propeller lubricating equipment. 25.00 1 Ea. — Torque wrench 1 7.50 1 Ea. — Spring scales for checking torque 5.00 2 Sets - Blade turning bars 20.00 27 2. Inspection components, using appropri- R O A ate aids 1 Ea. - Surface table 600.00 Assortment of propeller mandrels 300.00 2 Ea. - Propeller protractor 25.00 1 Ea. - Magnaflux machine (Long Bed). 1000.00 1 Ea. — Fluorescent inspection unit 500.00 2 Ea. — Magnifying glasses 1 0.00 Etching equipment 50.00 Propeller spline, "go" and "no go" gauges 50.00 Assortment of thread & plug gauges 50.00 1 Set - Height gauges 65.00 1 Set — Feeler gauges 3.00 1 Ea. - Dial indicator 25.00 1 Set — Inside & outside micrometers. . . 75.00 1 Ea. — Combination square 1 2.50 Assortment of stencils . 50.00 1 Set - Metal stamps (Letters & numbers) 60.00 3. Repair or replace component parts 2 Ea. - Voltohmeters 35.00 4. Balance propellers 1 Ea. — Balance stand and assortment of mandrels 300.00 5. Test the propeller pitch changing mechanisms 1 Ea. - Hydraulic test bench 500.00 1 Ea. - Electrical test bench 350.00 1 Ea. — Propeller governor test — hydraulic 500.00 1 Ea. — Propeller governor test — electrical 500.00 28 "A™ RAT,NG Bra-iat-'ss^*-*- - — . -.— -,« 1. Diagnose radio malfunctions R O A (See 3 below) 2. Maintain, repair, and alter radios, in- cluding installation and replacement of parts 1 Ea. - Metal lathe - .^ ^ , c ... 350.00 I ta. - Mica undercutter . . -- -^ . 75.00 Assortment of gear and bearing Pullers - cnA t c . , 75.00 I ta. - Arbor press -- -^ , c ~. , 40.00 I ta. - Dial motor test stand Paint & spray equipment (Pres- sure pot and suction cup). . . . 1800 00 I- Spray booth 500 ' ' Ea ;-° Ve " 150.00 l bet -Metal stamping tools (Letters & numbers) 60.00 Engraving equipment 350 0Q Drawing equipment 2500 1 Ea. - Drill press (Delta) 75.00 Hand tools (Complete assortment) 50.00 Work benches & shop furniture. 300.00 Sheet metal tools (Complete metal sh °P> 2500.00 I Inspect and test radios AC power supply LoccH Supply DC power supply 170.00 2 Ea. - Voltmeters 35.00 2 Ea. - Ohmmeters 35 qq 2 Ea. - Ammeters 35.00 1 Ea. - Frequency meter (Miller absorp- tion meter) 65 00 1 Ea. - Multi test set 35.00 1 Ea.- Megger 200.00 1 Ea. - Signal generator (A.M. Hickok 288x ) 320.00 1 Ea. - V.H.F. signal generator (precision E400) 104.00 29 R 1 Ea. - Audio oscillator 30.00 1 Ea. — Output power meter 35.00 1 Ea. - Tube tester (Hickok) 1 55.00 1 Ea. — Vacuum tube voltmeter (EV 1 0A) precision) 75.00 Dummy antenna (Assortment). . . 15.00 Standard test antennas (Assortment) 50.00 Microphone and headset tester. 50.00 1 Ea. — Condenser tester 65.00 Shielded room (10 ft. by 8 ft.). . 500.00 1 Ea. - VOR test set (Omni T-3) 500.00 1 Ea. -Oscilloscope (Precision 500A) . . 135.00 4. Make frequency checks (See above) * 5. Perform such calibrations as necessary for the proper operation of radios (See above) 30 INSTRUMENT RATING Figures which appear in boldface type denote equipment which has been listed previously. Diagnose instrument malfunctions R O A (Use item 3 below) Maintain, repair, and alter instruments, including installation and replacement of parts 1 Ea. - Precision drill press 200.00 1 Ea. - Precision lathe (South Bend). . . . 350.00 1 Ea. — Bench arbor press 40.00 1 Set - Hand lifters 5.00 Assorted special wrenches and adapters 50.00 Assorted special screw drivers. . 15.00 Punches (Assortment) 25.00 Broaches (Assortment) 65.00 Bell jars (Assortment) 50.00 1 Ea. - Staking set 40.00 1 Ea. - Machinist vise 25.00 Soldering irons (Assortment). . . . 30.00 1 Ea. - Surface plate 75.00 1 Set — Inside & outside micrometers. . . 75.00 1 Ea. — Surface gauge 1 2.00 1 Ea. — Steel scale & combination square 12.50 2 Sets - Dividers 3.00 1 Ea. - Dial indicator 25.00 Assorted files, taps, drills, dies & reamers 75.00 Storage cabinets and complete stockroom 300.00 1 Ea. — Cleaning unit 75.00 2 Ea.- Stools 15.00 Engraving equipment 350.00 Paint spraying equipment includ- ing compressors and regulators 1 800.00 Spray booth 500.00 Grinder (Portable, large, & small) 200.00 Magnet keeper (Assortment)... 10.00 31 Appropriate fixtures and R assembly stands 300.00 Work benches 75.00 Lubricants 15.00 Liquids & supplies (Naphtha, compass liquid, sealing compounds, pit wood) 15.00 3. Inspect, test, and calibrate instruments 1 Ea. — Water and mercury manometers. 120.00 Rubber tubing (Assortment). . . . 20.00 2 Ea. — Vacuum and air pressure supply source 1 800.00 1 Ea. — Pressure chamber 50.00 1 Ea. - Dead weight tester 75.00 1 Ea. — Calibration vibrator 1 50.00 1 Ea. — Temperature chamber 250.00 1 Ea. — Barometer, mercurial 300.00 1 Ea. — Stroboscope 1 35.00 1 Ea. — Tachometer test stand & variable speed motor 350.00 1 Ea. - Wheatstone bridge 1 35.00 1 Ea. — Magnet charger 1 70.00 1 Ea. — Demagnetizer 50.00 1 Ea. — Pelorus & compass rose 50.00 1 Ea. — Thermometer, laboratory type. . 25.00 1 Ea. - Stop watch & clock 50.00 1 Ea. — Tilting compass turntable 1 50.00 1 Ea. — Decade box (Resistance, capacitance) 25.00 2 Ea. - Millivoltmeter - DC 35.00 1 Ea. — Autosyn test stand and power supply 50.00 1 Ea. — Selsyn test stand and power supply 50.00 1 Ea. — Magnesyn test stand and power supply 50.00 1 Ea. - High Potential tester 35.00 Shunts (Assortment) 15.00 1 Ea. - Null balance potentiometer. .. . 35.00 2 Ea. -Milliammeter AC 7 DC tester. . . 35.00 1 Ea. - Vacuum tube voltmeter 65.00 32 R O A 1 Ea. - Battery charger 60.00 Voltmeters (Assortment) 35.00 Bank & turntable 150.00 1 Ea. — Gyro rotor balance stand 1000.00 1 Set - Gyro fixtures (Sperry) 1 500.00 1 Ea. - Air-flow meter 50.00 1 Ea. -Air filter & moisture trap 20.00 1 Ea. - Oscilloscope 1 35.00 2 Ea. - Signal generators 320.00 1 Ea. — Frequency meter (Miller absorption) 65.00 1 Ea. - Tube tester 1 55.00 1 Ea. — Compass card balance fixture. . 25.00 33 ACCESSOREES RATING Figures which appear in boldface type denote equipment which has been listed previously. Diagnose accessory malfunctions R O A (See item 3 below) Maintain, repair, and alter accessories, including installation and the replace- ment of parts 1 Ea. - Precision drill press 200.00 1 Ea.- Metal lathe (South Bend) 350.00 1 Ea. — Mica undercutter 75.00 Gear and bearing pullers (Assortment) 1 50.00 1 Ea. — Magnet charger 1 70.00 1 Ea. - Arbor press 40.00 Cleaning facilities 100.00 Paint spraying facilities, including compressor and regulators. . . 1800.00 1 Ea. — Grinder and buffer 75.00 Tape and dies (Assortment). . . . 100.00 Reamers (Assortment) 100.00 Special accessory tools (Gener- ators, magneto, starter, carburetor, and voltage regulators) 200.00 Lubricants 1 5.00 2 Sets - Easy outs 25.00 Engraving equipment 350.00 Soldering equipment (Guns, irons, and torch) 30.00 1 Ea. - Surface plate 75.00 1 Ea. - Volt milliammeter 35.00 Thread & plug gauges (Assortment) 50.00 1 Ea. - Air & electric drill motor 35.00 Battery charger and battery service equipment 100.00 Work benches, racks, and storage cabinets & vises 200.00 Inspect, test, and calibrate accessories 1 Ea. - Surface plate 75.00 1 Ea. - Magnet charger 1 70.00 34 1 Ea. — Magnaflux machine and R O A demagnetizer 1 500.00 2 Ea. — Magnifying glasses 1 0.00 1 Ea. - Growler 50.00 1 Ea. - Megger 200.00 1 Ea. - Coil tester 65.00 1 Ea. — Condenser tester 65.00 1 Ea. - Accessory test stand (Allen) .... 1 02 1 .00 1 Ea. - Spark plug tester 50.00 1 Ea. — High tension ignition harness tester 60.00 1 Ea. - Carburetor flow bench 1 500.00 1 Ea. — Float type carburetor bench .... 1 50.00 1 Ea. - Dial gauge 25.00 1 Set - Height gauges 65.00 1 Set — Telescoping gauges 20.00 1 Set — Inside & outside micrometers. . . 75.00 1 Ea. — Combination square 1 2.50 2 Ea. - Levels 5.00 1 Ea. — Surface gauge 1 2.00 1 Ea. - Volt - Ohm - Milliammeter 35.00 1 Ea. — Frequency meter 60.00 1 Ea. - Oscilloscope 1 35.00 2 Ea. - Signal generator 320.00 1 Ea. - Tube tester 1 55.00 1 Ea. - AC power supply Local Supply 1 Ea. - DC power supply 1 70.00 35 TOTALS The following totals list the estimated costs for the required, optional, anc available equipment for the six individual ratings starting with the airframe. Since it is possible to use some of the equipment for more than one rating, th( table indicates the decreasing cost totals as the additional ratings are added, e.g., the estimated cost of required equipment for the Accessories Rating alone is $8430, but the cost is only $300 if it is added to the other five ratings. Rating Airframe Powerplant Propeller Radio Estimated Costs for Required Equipment for Indi- vidual Rating $13,240.00 9,671.50 7,378.00 3,094.00 11,282.50 8,430.00 Estimated Costs for 1 Required Equipment for Six E Ratings $13,240.00 $ 8,066.50 4,160.00 2,434.00 5,192.00 300.00 istimated Costs for Optional quipment 250.00 Estimated Costs for Available Equipment for Indi- vidual Rating $12,955.00 3,825.00 3,000.00 5,865.00 1,350.00 1,850.00 Estimated Costs for Available Equipment for Six Ratings $12,955.00 700.00 515.00 Instrument 1 ,000.00 Accessories 36 <3 V C J dOHS\ M.jj_i$. it --' — * — i lJfr_.Q2._5. 83 z 3 s- < < 5* z ^ A ^_i J a cc --> 5-8 < _ _ n < fi- ll y_ UJ ">< a. f_1 _j "'J _i 56 NOU.D3S ONIQ13MI I -I _! -Si woo-vocus I "I 1 HWOMQOOM __v_o_iv I 30I3JO | wmrotaard : ONVN3J.NIVIAI uvto aiv #1 __0"i 3_ni-ov.vd < 5 r mE z - IP a' _ II .So §i_ -•i shooo ONians Appendix C — Aircraft Maintenance Forms and Their Uses Following is a brief explanation of the forms used by the Aircraft Maintenance Department and samples of these forms. FORM NO. AMO 19 This form is the standard work order used by the Aircraft Maintenance Department for all work performed in the shop or by the department. The form is issued by the Aircraft Maintenance Engineer who keeps a ledger of all work orders issued, date issued, job performed, date completed, material used, and labor charged. The work order is issued to the Shop Foreman who in turn assigns mechanics to the job. Upon completion of work, the work order is signed by the mechanic (Inspector) supervising or performing the work and returned to the Shop Foreman, v/ho, if necessary, makes a final in- spection prior to releasing the aircraft and then returns the work order to the office. Material will not be issued from the stockroom for use on a job unless a work order is presented. The Storekeeper will then issue the material and list it on the work order by quantity and part number as well as by name. After return of work order to the office, the Cardex Clerk will price the material used and remove the used material from the perpetual Cardex. Labor charge is made according to hours indicated on the work order, and a cash or charge sales ticket is then made up. Work order ledger entries are then completed and the work order filed except in case of University Aircraft work order, in which case entries are made in the University Aircraft Main- tenance Ledger prior to filing of the work order. *,.„* MO 11 RECORD OF MATERIAL USED UNIVERSITY OF ILLINOIS INSTITUTE OF AVIATION AIRPORT SAVOY, ILLINOIS CAA Approved Repair Station No. 3708 REPAIR ORDER «»• PartN.. D..c„p., n Call ,.,, TIME IECEIVED N? 5001 | TIME mOMISED | TERMS Data Cud Name Address Char,. Infernal •r Phone L.d 9 „ »„o>u...».d.l 1 NCNumb.t 1 Eitgln. Ml and Mad.l l.iMH..*., A/C INSTRUCTIONS ft* Initial »,. "mci Total Hours . Th. ob... w..k ho. b..n c-pUM In murium with Mr*. T.tal laWf C.t IMIMMM T.tal Job Oil Tolol Malarial ■.•In. Owcli.il by 38 o °- E X P u -O c tt) c O « E c £ '6 _ ^ o P < o — ! • c U "P. Si 3 — 3 4> -c ! © 0> ° TO o *> o ■ iB * < Z ^: o 2 ^o co X _J £ < 1- O i- ttl LU Q O o z w> <~> * "7 o CN Ooa « £ ■"" o Q o CM o ^ o 111 o III o X •"" (A o m* a. oo O z o z in z 00 O < 1- > z < u-> O >- _l Q in O 5 3 D Q LU t- fh >■ lu aj U U < Z o »- < >- > < o CN < o u. u_ o O >- 111 ►- o z Q LU CO 3 < 3 I— O o z z u_ o co z ^ o LU CO ct o z LU to 1- Q LU »- O z < •=> < z 111 in Z o Q Q LU CO CO O >• ac O t- Z LU -J u. 00 o z < I CO < X u CO 1- z Z < X o >- »— >- z o at ■=> a. 3 o < Z > z h- u 1— h- LU < CO u-> < z 3 Z 3 u LU Q m 3 o S — 1 z u > o o 2 < < CO >- z 3 2 o < X 3 «/> co < < »- CO a. 39 FORM NO. AMO 23 No material is to be issued from the Stockroom without a work order which will indicate where the material is used and by whom. In the case of shop overhead maintenance, work and material used by other departments within the Institute of Aviation, Form No. AMO 23, Stockroom Material Report, is used. Material issued in duplicate by way of this form must be initialed by the employee receiving the material. When the form is full, it is forwarded to the Maintenance Office, where the material will be priced and items removed from the Cardex. The form is issued in duplicate and. after pricing is complete, both copies are forwarded to the individual department head for signature. The original is returned to the Maintenance Office where it is filed. UNIVERSITY OF ILLINOIS INSTITUTE OF AERONAUTICS, U. OF I. AIRPORT STOCKROOM MATERIAL REPORT The following material has been issued to during the period to Department QUANTITY ARTICLE UNIT COST TOTAL RECEIVED BY Total I have checked and approve the above list of material issued to my Department Return original to Aircraft Maintenance Office. Carbon copy to be retained by Department. oigna ure FORM NO. FM 8 The Institute has continuous orders with several local companies and can also get material from other University Storerooms. When this is done, Form No. FM 8 is used, but material purchase authorization must be approved by the Aircraft Maintenance Engineer or Shop Foreman. UNIVERSITY OF ILLINOIS INSTITUTE OF AVIATION MATERIAL PURCHASE AUTHORIZATION VENDOR Please deliver the following material to and charge to P.O. Authorized by Date Department FORM NO. AMO 30 This form (heading only shown) accompanies the Daily Flight Record Sheets to indicate to the Chief Pilot what airplanes are being withheld by the Maintenance Department and why. UNIVERSITY OF ILLINOIS INSTITUTE OF AVIATION DAILY FLIGHT RECORD SHEETS for PLANES NOT FLYABLE REASON FORM NO. AM 3 This form is used after all major repairs and 100 hr. inspections and is issued to the Flight Department by the Aircraft Maintenance Engineer or Shop Foreman as notice that the aircraft is ready for test hop and must be test hopped prior to release for flight training or charter use. UNIVERSITY OF ILLINOIS INSTITUTE OF AERONAUTICS AIRCRAFT MAINTENANCE DEPARTMENT NOTICE FOR TEST HOP Aircraft Model and Make NC Numbe Date Time- Reason for Test Hop Items to Be Checked Released By (Foreman or Inspector^ FLIGHT DEPARTMENT Pilot — — T 'me Up Time Down Date- Pilot's Report on the Flight ORM NO. AM 1 lis form is used by the Flight Department to indicate malfunctions of all types. When maintenance ;eded is of very minor nature, it is remedied by a line mechanic without grounding of the aircraft, Jt when it is necessary to bring the aircraft to the shop for inspection or repair, the pilot brings the 3ily Flight Record Sheet along with Form No. AM 1 to the Aircraft Maintenance Office where the ircraft is officially grounded and a regular work order issued to cover the complaint or complaints ted. The aircraft remains grounded until the work order is officially completed. UNIVERSITY OF ILLINOIS INSTITUTE OF AVIATION MALFUNCTION REPORT Aircraft Model & Make NC Number.^ _Date. The following defects were noted . By Signature 41 FORM NO. ACA 337 This is the standard C.A.A. form which must be filled out when major repairs or alterations are made on a licensed aircraft and the repair or alteration approved by C.A.A. or representative prior to release of the aircraft involved. U. S. DEPARTMENT OF COMMERCE Budget Bureau No. 41-ROM.4 Civil Aeronautics Administration MAJOR REPAIR AND ALTERATION FORM (AIRFRAME, POWERPLANT, PROPELLER OR APPLIANCE) NATIONALITY ANO REGISTRATION MARK NAME (First, middle, loll) (Strut and number, citt. tone ant State) DESCRIBE WORK ACCOMPLISHED ON REVERSE IN AC- MAJOR RCTAIR MAJOR ALTERATION ********»*****•**»*•*• (As described in item I above) e>**»*******»*e*******, b. POWERPLANT PROPELLER d. APPLIANCE AIRCRAFT WEIGHT AND BALANCE DATA This item must be completed by repair or alteration agency. However, in the 'AFTER the repairs tmdior alterations case of a spare component, it will not be completed until such component is in- "• stalled in an aircraft. At this time, it will be completed by the installing agency, if applicable. described below i EMPTY WEIGHT (Pounds)* ■ CENTER OF GRAVITY (Inches from dalu USEFUL I >