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,AIRFRAME REPA13 MANUAL AEROPLA'aE . -

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L 4 1 0 UVP-E A 1 RFR.WE R E P A I R YANUAL

AEROPLANE .......................................

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L 110 UVP-E A I 2 F R A M E R E P A I R Y..ANUAL

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L 4 1 0 UVP-E A 1 RFFAVE R E P A I R MANUAL

AEROPLANE .......................................

CONTENTS

Page GENERAL Designation G e n e r a l philosophy Manual chapters Figures Revisions Repair general instructions Safety precaution

Page

. . .1. . . . . . ,

Sept 30/88 . . . . . . . . . . . . . . . a


L 410 UVP-Z AIRFRAME R E P A I 3 YANUL

Intentionally left blank

................ Page

2 ...........


L 410 UVP-E A 1 RFRA-YE REPAI R YANUAL

GENERAL .......................................

1. D E S I G N A T I O N T h e AIRFRAME REPAIR M N U A L h a s been elaborated according r 2 soviet standard G O S : 18675-73 / A . T . A . loo/. The manual includes instructions and technological proced~:?s for the repalro-f a i ? p l a n e zirframes; The r e p a i r s w h i c h a r a exacting and require application of complex f i x t u r e s , a r e n o t included in this manual. T h e AIRFRAME REPAIR MANUAL o f L 4 1 0 UVP-E shall b e supplemented with technological procedures for further repairs based o n e x p e r i e n c e of aircraft operation. -

-

-

-

NOTE: T h e Airframe R e p a i r M a n u a l i s v a l i d f o r t h e L 410 UVP, L 4 1 0 UVP-E, L 410 UVP-E9, L410 UVP-E20 a e r o p l a n e s .

Each aircraft assembly, having a specific f u n c t i o n h a s been covered in a separate c h a p t e r , a s shown in CHAPTER REVIEW. General technologica! p r o c e d u r e s and instructions commonly k n o w n , a s for example riveting p r o c e d u r e , twisting the r o p e s , welding and s l m i l a r , a r e not included in this Manual f o r L 410 UVP-E because it i s assumed that t h e servicins personnel has relevant q u a l i f i c a t i o n s .

3 . MANUAL CHAPTERS T h e AIRFRAME REPAIR N A N U A t f o r t -410-UtlP-' -1s di-vi-ded-to c h a p t e r s , which a r e f u r t h e r d i v i d e d to s e c t i o n s and subsections. The dividing i s expressed in a n u m b e r , which i s indicated on the page external lower e d g e .

. . .1. . . . . . . . . . . .May . . . . .3 ./ 9. 9. . .

?J;?


L

410 CiVP-E

A 1 RFRAME REPAI R YANUL

GENERAL

....................................... Example: D E I C I N G S Y S T E M (chapter) A I R F R A M E S U R F A C E (section)

(subsection) N u m b e r i n g of pages is independant for e a c h s u b s e c t i o n . F u r t h e r m o r e , in the numbering s y s t e m i s c o d e d internal d i v i d i n g of each subsection to individual s u b j e c t , which m a k e s t h e orientation and revisions easier. N u m b e r i n g o f pages i s carried out a s f o l l o w s : Page G E N E R A L D A T A AND R E P A I R S O R G A N I S A T I O N DISMANTLING C L E A N I N G AND W A S H I N G TECHNICAL CONDITIONS STATING (DEFECTS FIND-OUT) REPAIR A S S E M B L Y AND A D J U S T M E N T M O U N T I N G AND J O I N T S TESTS P R E S E R V A T I O N AND P A C K I N G S H I P M E N T A N 0 STORAGE L I S T OF TEST EQUIPIIENT, AND T O O L S

JIGS, F I X T U R E

T E C H N O L O G I C A L PROCEDURES AND E N C L O S U R E S


L 4 1 0 UVP-E AIRFFULVE R E P A I R Y A N U A L

GENERAL 4.

FIGURES

F i g u r e numbers a r e i n d e p e n d e n t f o r e a c h s u b s e c t i o n . I n i n d i v i d u a l s u b j e c t s t h e f i g u r e s n u m b e r i n g is i d e n t i c a l r 3 numbering of p a g e s , i . e. i n t h e s u b j e c t : GENERAL DATA AN0 REPAIRS ORGANISATION DISMANTLING CLEANING 5. R E V I S I O N S

1 101 201

-

100 200 300

Revisions in the A I R F R A M E R E P A I R MANUAL are carried out by means of replacement pages that are always accompanied by a new list of effective pages of the correspondlng chapter. The revision (the replacement pages) are sent to the holder of the A I R F R A M E R E P A I R MANUAL in the form of Documentation Bulletins (a list of issued bulletins is filed after the title page of Book 1). The holder of the A I R F R A M E R E P A I R MANUAL is oblicjed to make sure that the pages in his manual COrrespond to the list of effective pages that is filed on the beginning of each chapter. Pages that do not correspond to the list must be discarded. The r e v i s e d p l a c e s a r e i d e n t i f i e d w i t h a t h i c k v e r t i c a l

l i n e on t h e s i d e a n d t h e r e v i s e d o r a new p a g e i s p r c v i d e d with a new d a t e o f i s s u a n c e . I n c a s e t h a t o n l y t h e t e x t i s r e p l a c e d t o t h e new p a g e d u e t o t h e e n l a r g e m e n t o f r e v i s e d t e x t , s u c h t e x t i s n o t i d e n t i f i e d . I P t h e r e 1s n o o t h s r r e v i s l o n on t h e new z a g e e x c e p t o f t e x t r e p l a c e m e n t , t h e d a t e of i s s u e is p r o v i d e d w i t h l e t t e r " R " . The u s e r o f t h e M a n u a l , a f t e r r e c e i v i n g t h e r e v i s i o n a n d r e l e v a n t m c d i f ~ c a t i o no f t h e M a n u a l , s h a l l e n t e r i n t h e LIST OF TEST EQUIPMENT, J I G S , FIXTURE AN0 TOO!-S, w h i c h i s f l l e d b e h i n d t h e t i t l e p a g e o f Book n o . I , t h e d a t e o f r e v i s l c n s : i d s ~ g n a t u r eo f e m p l o y e e i n c h a r g e .


L 410 LVP-E A I X R A M E REPAIR YANUL GENERAL .......................................

REPAIR G E N E R A L INSTRUCTIONS The a i r f r a m e r e p a i r s u n d e r f i e l d c o n d i t i o n s a r e c a r r i e d o u t m a i n l y on t h e a p r o n . E x c e p t i o n s a r e s u c h r e p a i r s ( e . g . s t i c k i n g of rubber d e i c e r s and s i m . ) , whlch must be c a r r i e d o u t a t c e r t a i n and c s n s t a n t c l i m a t i c c o n d i t i o n s , which is w a r r a n t e d by r e p a i r s i n t h e h a n g a r . R e l e v a n t a t t e n t i o n is made on r e l e v a n t t e c h n o l o g i c a l p r o c e d u r e . M a i n t a i n i n g of a i r c r a f t aerodynamic p r o p e r t i e s must be s e c u r e d d u r i n g t h e r e p a i r , which d e t e r m i n e i t s f l i g h t

I

t e c h n i c a l p a r a m e t e r s . The r e p a i r must not reduce the margin of stength and a e r o e l a s t i c safety. S i n c e t h e r e p a i r q u a l i t y must conform t o above mentioned r e q u i r e m e n t s , i t i s ~ m p o r t a n tt o a d h e r e s t r i c t t o t h e t e c h n o l o g y and t e c h n i c a l c o n d i t i o n s , s p e c i f i e d i n t h i s Manual, a s well a s documentation.

to follow instructions given i n technical

D u r i n g t h e r e p a i r o f b o l t j o i n t s a n d m o u t i n g s t h e A L B U M OF BASIC JOINTS A N D RE?AIR TOLERANCES m u s t b e f o l l o w e d . I n c a s e t h a t t h e a i r c r a f t s p a r e p a r t s , a s s e m b l i e s and a g g r e g a t e s must b e o r d e r e d , t h e n t h e i r names and d r a w i n g numbers s h a l l b e f o u n o u t i n t h e I L - - 5 T R A T E D p?i?TS i:ATALU?IIE I n order to

followin:

/3arts

li_:/.

securs :ie aircrzft repair high q u a l i t y t : ~

c o n d i t i s - :- a r e n e c s s s a r y :

- good t r a i n i n g of s k i l l e d workers - t e c h n i c a l documw:ation

in the extent securing high

quality repair - good s t a t e and c x p l e t n e s s of a l l e q u i p m e n t , t o o l s and

f i xtures

- c o n t i n u o u s inspeztion of a l l r e p a i r o p e r a t i o n s and t e s t s o f a l l a g g r e g a t e s , s y s t e m s and t h e a i r c r a f t a s a whole

A . .p.r. . 2. .0./ 9. .6. . . . . .


L 4 1 0 UVP-E AIRF W E REPAIR MANUAL GENERAL .......................................

IT I S PROH13ITED T O REPAIR T H E AIRCRAFT IN CONOITIONS N O T SECURING A B O V E M E N T I O N E D REQUIREMENTS.

I n c a s e t h e AIRFRAME REPAIR M A N U A L d o e s n o t a l l o w f o r a r e p a i r , t h e damaged p a r t s , i n s t r u m e n t s a n d a g g r e g a t e s m u s t be replaced. A l l s p a r e i n s t r u m e n t s and a g g r e g a t e s mounted t o t h e a i r c r s i t

mustbe checked before t h e i n s t a l l a t i o n i n o r d e r t o v e r i f y . t h a t t h e i n s t a l l e d i t e m was n o t damaged d u r i n g t h e s t o r a ~ ? . I n s t r u m e n t s f o u n d o u t a s d e f f e c t i v e may b e i n s t r u m e n t s of t h e same t y p e o n l y .

replaced with

7.

SAFETY PRECAUTION

7.1

B a s i c r u l e s f o r u s i n g o f irnflarnmable m a t e r i a l s f o r t h e a i r f r a f t c l e a n i n q and r e p a i r When c l e a n i n g t h e a i r c r a f t w i t h g a s o l i n e a n d d u r i n g t h e works on t h e a i r c r a f t where t h e imflammables a r e used / e . g . s t i c k i n g of rubber p a r t s and o r upholstery) the f o l l o w i n g p r e c a u t i o n s must b e ahdered t o : ( 1 ) The a i r c r a f t m u s t b e e a r t h e d . E a r t h t h e a i r c r a f t by c o n n e c t i o n o f u n d e r c a r r i a g e c o n d u c t i v e c o m p o n e n t to the earth. ( 2 ) Smoking o r m a n i p u l a t i o n w i t h o p e n f l a m e a t a d i s t a n c e

of 10

m

around the a i r c r a f t is prohibited.

( 3 ) Operationable e x t i n g u i s h e r must be placed i n t h e aircraft vicinity.

................ 5 ? ~ s e........... S e p t 30!38 ................


L 410 UV?-E

A1 R F R A M E R E P A I R Y A N U L GENERAL .......................................

( 4 ) When t h e c l e a n i n g i s c a r r i 2 d o u t i n t h e h a n g a r , t h i s

m u s t b e g o o d v e n t i l a t e d , t h e a i r c r a f t m u s t s t a n d on w h e e l s and t h e g a t e must be f r e e o f o b s t a c l e s , p r e i e n t i - y * t h e a i r c r a f t quick transport o u t of t h e hangar i n zase of need. ( 5 ) Board accumulators must be d i s c o n n e c t e d . ( 6 ) No o t h e r w o r k s a r e a l l o w e d t o b e c a r r i e d o u t o n t h s

a i r c r a f t , e s p e c i a l l y c l e a n i n g t h e window made o f o r g a n i c glass. ( 7 ) I t i s s t r i c t l y p r o h i b i t e d t o u s e a t t h e same t i m e e l e c t r i c a p p l i a n c e s a s vacuum c l e a n e r s , e l e c t r i c d r i l l i n g m a c h i n e s a n d sim. U s e d p o r t a b l e e l e c t r i c t o r c h e s m u s t b e o f "explosion-proof" type. ( 8 ) Workers handling imflammables must weat a n t i s t a t i c s h o e s

a n d a r e n o t a l l o w e d t o h a v e on c l o t h e s made o f s y n t h e t i c s (danger of e l e c t r o s t a t i c c h a r g e s ! ) . ( 9 ) When w o r k i n g w i t h v a r n i s h , t h i n n e r s , e n a m e l s a n d o t h e r

imflammables, the s a f e t y precautions f o r I . grade imflammables must be a d h e r e d t o . ( 1 0 ) C l e a n i n g w i t h C r u s h e s a n d f a b r i c s m a d e o f s y n t h e t i c s 1s prohibited. ( 1 1 ) P r o v i s i o n s mus:

b e made t o p r e v e n t s p i l l a g e o f i m f l a m m a 3 l e

m a t e r i a l onto the c o n c r e t e f l o o r ( s p a r k i g n i t i o n danger when s t e e l t o o l s h i t t h e f l o o r , a n d s i m . ) . ( 1 2 ) No a o r e t h a n 1 ! o f c l e a n i n g l i q u i d i s a l l o w e d t o b e u s e d f o r t h e c13aning. G r e a t e r q u a n t i t y of l i q u i d for t h e c l e a n i n g mzst be s t o r e d i n c l o s e d t i n s h e e d v e s s e l s a t a d i s t a n c e z f 10 m f r o m t h e a i r c r a f t minimum.

Pase

. . . . . .b. . . . .

S e p t 30/88


L 410 UVP-E AIRFRAME REPAIR MANUAL

GENERAL .......................................

( 1 3 ) For a i r c r a f t ccmponents c l e a n i n g w i t h t h e g a s o l i n e , t h ? g a s o l i n e w i t h high f l a s h p o i n t is t o be used ( p e t r o l a ~ m s p i r i t A a c c o r d i n g t o CSN 6 5 6 5 4 1 , t e c h n i c a l g a s o l i n e 1 5 0 / 2 0 0 a c c o r d i n g t o TPO 3 3 0 3 7 - 6 1 , g a s o l i n e t h i n n e r a c c o r d i n g t o GOST 4 4 3 - 5 6 , t e c h n i c a l g a a o l i n e GOST 8 5 0 5 - 5 7 ) . When w o r k i n g w i t h g a s o l i n e , s a f e t y p r e c a u t i o n v a l i d f o r the workplaces w i t h t h e danger of e l e c t r o s t a t i c c h a r g e s a r i s e and t h e p r o t e c t i o n a g a i n s t d e t r i m e n t a l e f f e c t s must be s t r i c t l y observed. NOTE

:

These r e s t r i c t i o n s a r e n o t v a l i d f o r c o m p o n e n t s c l e a n i n g , which a r e d i s m a n t e l e d from t h e a i r c r a f t and c l e a n e d away a t a d i s t a n c e o f a t l e a s t 1 0 m f r o m t h e aircraft. 7 . 1 G e n e r a l r u l e s f o r t h e work w i t h s y n t h e t i c o i l 8-3V

( 1 ) P e r s o n n e l m a n i p u l a t i r g w i t h s y n t h e t i c o i l 8-3V must be i n s t r u c t e d about its t o x i c i t y and a c e o b l i g e d t o s t r i c t l y observe t h a s a f e t y p r e c a u t i o n and undergo r e g u l a r y t h e medical check. Only t r a i n e d workers a r e allowed t o manipulate with t h e o i l . ( 2 ) P l a c e s where t h e o i l is m a n i p u l a t e d must b e c l e a n and i n proper o r d e r . I t is s t r i c t l y p r o h i b i t e d t o Pour o u t t h e o i l from one vessel t o a n o t h e r w i t h t h e h e l p o f a h o s e by s u c k i n g w i t h t h e m o u t h .

( 3 ) ,411 m a n i p u l a t i o n w i t h t h e o i l m u s t b e c a r r i e d o u t i n s p e c i a l s u i t and w i t h p r o t e c t i v e means ( g l o v e s , p r o t e c t i v e apron o r a c o a t ) .

.S. e. p. .t . .3 .0./ .8 .0. . . .


5 410 UVS-E A I R F U M E R E P A I R YAXCL

GENERAL .......................................

F o r c l e a n i n g of a s p i l e d s k i n and s k i n d i s e a s e s i t i s a l l o w e d t o t a k e on and o f f t h e

protective gloves

d u r i n g t h e work. A f t e r f i n i s h i n g t h e work t h e h a n d s m u s t b e p r o p e r l y w a s h e d w i t h s o a p i n t h e warm w a t e r . ( 4 ) S p e c i a l s u i t f o r t h e m a n i p u l a t i o n w i t h 011 a n d

p r o t e c t i v e a i d s s h a l l be s t o r e d i n s e p a r a t e box ( s e p a r a t e l l y of n o r m a l w o r k i n g s u i t s and a i d s ) . I n c a s e t h a t during the manipulation the protective a i d s have been s p i l l e d , they must be r e p l a c e d and p r o t e c t i v e a i d s m u s t b e w a s h e d w i t h s o a p a n d warm w a t e r t h o u g h r o u g l y . ( 5 ) M a n i p u l a t ~ o nw i t h t h e o i l s y s t e m i s p o s s i b l e o n l y w h e n t h e p r e s s u r e drgps t o t h e b a r o m e t r i c one and t h e t e m p e r a t u r e f a l l s below -60

"c.

By

eventual pouring

o f h o t o i l t h e o p e r a t o r must s t a n d on o p p o s i t e s i d e . ( 6 ) Workers manipulating w i t h o i l 6-3V must undergo t h e

r e g u l a r medical check once a year. Medical check must b e c a r r i e d o u t i m m e d i a t e l y f o r t h e w o r k e r who

is

ordered to manipulate with o i l 8-3V. ( 7 ) In c a s e t h e a i r c r a f t covering h a s been s p i l l e d wlth

o i l 6-31,

t h e u l a c e m u s t b e c l e a n e d up w i t h a c l o t h

sosked i n techclcal using.

S e p t 30/88

g a s c l i n e . Replace the c l o t h a f t e r


L 410 UVP-E AIRFRA.YE RE P A 1 R MANUAL

GENERAL .......................................

7.3

Hazardous areas around the aircraft o n engine's run:

a) engine idle run

b ) e n g i n e run o n m a x .

take-off regime

. 0. ...o.o. .. o. .o. . . . . . . 9 Page ........... Sept 30.'88 ................


L 410 U-'?-E A I R F R A M E R E P A I R YANUL

GENERAL .......................................

7.4

B a s i c r u l e s for opeistion saiaty o n high-elevated areas (1) W h e n working on the w i n g . r u b b e r soled s h o e m u s t b e u s e d t o prevent slip-off.

(2) It i s not allowed to s t 3 3 o n t o stabilizer and elevator. (3) W h e n working on the stairs it is necessarr t o follow a l l safety regulations and a l l protection (railing) m u s t be utilized.

7.5

P r o v i s i o n s when the aircraf:

i s lifted on j a c k s

(1) W h e n the aircraft is lifted o n j a c k s , instructions o f Chapter 7 - Operation-technical manual m u s t be observed.

(2) W h e n the aircraft is lifted o n j a c k s s t a r t i n g the e n g i n e s is prohibited. (3) N o person is allowed to b e underneath the aircraft w h e n the aircraft is lifted o n j a c k s a n d the test of closing the undercarriage i s carried out.

.S. e. .p.t. .3. 0. /. .8.8. . . .


arm00_r03