SMR151

JET

FAA APPROVED HANDBOOK OF

OPERATING AND MAINTENANCE INSTRUCTIONS

THIS MANUAL HAS BEEN APPROVED BY THE FAA AS BEING IN COMPLIANCE WITH ACCEPTABLE PROCEDURES FOR STRUCTURAL REPAIR AND MAINTENANCE OF THE JETSTAR, HOWEVER, THE MANUAL IS PRIMARILY INTENDED AS A GUIDE FROM WHICH AN OPERATOR MAY DEVELOP PROCEDURES TO SUIT HIS OWN OPERATION, PROVIDED METHODS USED COMPLY WITH FAR 43. IT SHOULD NOT, THEREFORE, BE CONSTRUCTED THAT THE MANUAL SETS FORTH GUARANTEED OR VALIDATED PROCEDURES OR THE ONLY PROCEDURES WHICH MAY BE FOLLOWED. MANUFACTURER RESERVES THE RIGHT TO RECOMMEND REVISIONS TO THE MANUAL AS SEEM APPROPRIATE FROM TIME TO TIME.

Lockheed Martin Aircraft & Logistics Centers

GREENVILLE, SOUTH CAROLINA 29605
ALL DATA SUBMITTED CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN. DISCLOSURE TO OTHERS, USE OR COPYING WITHOUT EXPRESS WRITTEN CONSENT OF LMALC IS STRICTLY PROHIBITED. ALL DATA IS AND REMAINS THE PROPERTY OF LOCKHEED MARTIN AND IS TO BE RETURNED TO LMALC OR DESTROYED AS DIRECTED BY LMALC BUSINESS OFFICE UPON TERMINATION OF THE JETSTAR SUPPORT AGREEMENT. 2005 LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED.

1 MAY 1964
CHANGED 31 MAY 2005

HANDBOOK OF OPERATING AND MAINTENANCE INSTRUCTIONS

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

Note: The portion of the test affected by the changes is indicated by a vertical line on the outer margin of the page. Changes to illustrations are indicated by miniature pointing hands.

Page No.
Title *A BE F G H J *K L M N Blank i thru ii iii Iv Blank Table of Contents 1 Table of Contents 2 *Table of Contents 3 Table of Contents 4 Table of Contents 5 Added Table of Contents 6 Blank Added Introduction 1 Introduction 2 Introduction 2A Added Introduction 2B Added *Introduction 3 Introduction 4 thru Introduction 8 Introduction 9 thru Introduction 10B Deleted Introduction 11 thru Introduction 14 5-1 5-2 Blank *5-3 *5-4 Blank 5-5 5-6 Blank 5-7 Added

Issue
15 Dec 96 31 May 05 15 Dec 96 19 Oct 90 30 Dec 95 30 Dec 95 15 Dec 98 31 May 05 18 Nov 93 18 Nov 93 Original 1 Apr 68 1 Apr 68 20 Dec 91 30 Oct 87

Page No.
5-8 Blank Added 5-9 thru 5-10 5-11 *5-12 5-13 5-14 5-14A 5-14B Blank 5-15 *5-16 thru 5-17 5-18 5-19 *5-20 5-21 thru 5-22 5-22A *5-22B 5-23 5-24 5-25 5-26 5-27 5-28 5-29 5-30 5-31 *5-32 thru 5-33 5-34 5-35 5-36 Added *5-37 *5-38 thru 5-39/5-40 Added 6-1 thru 6-8 6-9 6-10 Blank 7-1 7-2 Blank 7-3 7-4 7-5 7-6 thru 7-7 7-8 thru 7-10 7-11 7-12 Blank 7-13 7-14 7-15 7-16 thru 7-18 8-1 8-2 Blank 8-3 thru 8-4 8-5 8-6 8-7 8-8 Blank

Issue
1 Feb 65 31 Aug 83 1 Oct 88 31 May 05 18 Nov 933 20 Dec 91 25 Oct 88 25 Oct 88 20 Dec 91 31 May 05 30 Dec 96 1 Oct 85 31 May 05 30 Dec 96 30 Oct 87 31 May 055 30 Dec 96 1 Oct 86 31 Aug 83 20 Dec 91 15 Dec 98 30 Oct 87 18 Nov 93 31 Aug 83 1 July 69 31 May 05 1 Oct 85 30 Dec 94 31 Aug 83 31 May 05 31 May 05 Original 31 Aug 83 31 Aug 83 1 July 69 1 July 69 19 Oct 90 15 Dec 98 Original 31 Aug 83 Original 30 Dec 95 30 Dec 95 1 July 69 1 Oct 85 16 Oct 89 1 July 69 Original Original Original 1 Feb 65 1 Jan 66 Original Original

Page No.
9-1 9-2 Blank *9-3 thru 9-4 9-5 9-6 Blank 9-7 9-8 10-1 10-2 Blank 10-3 10-4 Blank 10-5 10-6 Blank 10-7 thru 10-8 10-9 10-10 Blank 12-1 12-2 Blank 12-3 12-4 12-5 12-6 12-7 thru 12-8 12-9 12-10 12-11 12-12 Blank 12-13 12-14 12-15 12-16 Blank 12-17 12-18 12-19 12-20 12-20-1 Added 12-20-2 Blank Added 12-20A 12-20B thru 12-20D Added 12-21 12-22 thru 12-23 12-24 12-25 thru 12-26 12-27 12-28 12-29 12-30 12-30A Added 12-30B Blank Added 12-31 12-32 12-32A

Issue
Original Original 31 May 05 Original Original 19 Oct 90 Original 31 Aug 83 31 Aug 83 30 Oct 87 30 Oct 87 Original Original Original 16 Oct 89 16 Oct 89 31 Aug 83 31 Aug 83 1 Oct 85 Original 31 Aug 83 1 Oct 85 30 Dec 96 Original 1 Apr 68 1 Oct 85 1 Oct 85 16 Oct 89 1 July 69 Original Original 31 Aug 83 1 Oct 86 1 Oct 85 16 Oct 89 16 Oct 89 16 Oct 89 1 Oct 86 1 Oct 85 1 Oct 85 1 July 69 1 Apr 68 1 Oct 85 1 Dec 65 1 Apr 68 1 Oct 85 1 Dec 65 1 Dec 65

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31 May 05 31 Aug 83

31 Aug 83

31 Aug 83 Original Original 18 Nov 93

18 Nov 93 31 May 05 15 Dec 98

1 Jan 67

1 Oct 85 16 Oct 89 16 Oct 89 31 May 05 31 May 05 31 Aug 83 31 Aug 83 1 Feb 65

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1 Dec 65 28 Oct 88 18 Nov 93 16 Oct 89

*The asterisk indicates pages changed or deleted by the current change.

Changed 31 May 2005

SMR 151

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INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

Note: The portion of the test affected by the changes is indicated by a vertical line on the outer margin of the page. Changes to illustrations are indicated by miniature pointing hands.

Page No.
27-102 Blank 27-102A Added 27-102B Blank Added 27-102C Added 27-102D Blank Added 27-103 thru 27-104 27-104A 27-104B Blank 27-105 27-106 27-106A Added 27-106B Blank Added 27-107 27-108 Blank 27-109 27-110 thru 27-114 27-114A Added 27-114B Blank Added 27-115 27-116 27-117 27-118 Blank 27-119 27-120 Blank 27-121 27-122 Blank 27-123 27-124 thru 27-130 27-131 27-132 Blank 27-133 thru 27-134 28-1 28-2 Blank 28-3 28-4 28-4A Added 28-4B Blank Added 28-5 thru 28-6 28-7 thru 28-8 28-9 28-10 28-11

Issue
1 Oct 85 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 28 Oct 88 18 Nov 93 18 Nov 93 Original 15 Dec 98 15 Dec 98 15 Dec 98 31 Aug 83 31 Aug 83 Original 1 June 67 1 June 67 1 June 67 1 June 67 1 June 67 Original Original 1 Apr 68 1 Apr 68 1 June 67 1 June 67 1 July 69 1 June 67 1 Oct 86 1 Oct 86

Page No.
28-12 thru 28-13 28-14 28-15 28-16 Blank 28-16A Added 28-16B Blank Added 28-17 28-18 28-19 28-20 Blank 28-21 28-22 28-22A Added 28-22B Blank Added 28-23 28-24 28-24A Added 28-24B Blank Added 28-25 28-26 thru 28-27 28-28 28-29 *28-30 28-31 28-32 28-33 28-34 thru 28-37 28-38 28-39 thru 28-40 28-41 28-42 28-43 28-44 28-44A 28-44B Blank 28-45 28-46 28-46A 28-46B Blank 28-47 28-48 28-49 28-50 28-50A 28-50B

Issue
Original 31 Aug 83 Original Original 31 Aug 83 31 Aug 83 Original 1 Dec 65 30 Oct 87 30 Oct 87 16 Oct 89 1 Oct 85 31 Aug 83 31 Aug 83 Original 31 Aug 83 31 Aug 83

Page No.
28-51 thru 28-54 28-55 28-56 28-57 28-58 Blank 28-59 thru 28-60 28-60A Added 28-60B Blank Added 28-61 28-62 28-63 28-64 Blank 29-1 29-2 Blank 29-3 29-4 29-4A thru 29-4B 29-4-1 29-4-2 Blank 29-5 29-6 29-7 thru 29-8 29-8A 29-8B 29-8C Added 29-8D Blank Added 29-9 thru 29-12 29-13 thru 29-14 29-15 29-16 Blank 29-16A 29-16B Blank 29-17 29-18 Blank 29-18A 29-18B Blank 29-19 29-20 29-20A Added 29-20B Blank Added 29-21 29-22 29-22A Added

Issue
31 Aug 83 1 June 66 31 Aug 83 19 Oct 90 19 Oct 90 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 Original 16 Oct 89 16 Oct 89 Original Original 30 Oct 87 5 Oct 84 31 Aug 83 16 Oct 89 16 Oct 89 31 Aug 83 15 Dec 98 Original 16 Oct 89 30 Oct 87 30 Oct 87 30 Oct 87 Original 31 Aug 83 28 Oct 88 28 Oct 88 28 Oct 88 28 Oct 88 28 Oct 88 28 Oct 88 28 Oct 88 28 Oct 88 28 Oct 88 31 Aug 83 31 Aug 83 31 Aug 83 19 Oct 90 28 Oct 88 28 Oct 88

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31 Aug 83 Original Original 31 Aug 83 5 Oct 84 31 Aug 83 31 Aug 83 Original

31 Aug 83 Original 30 Oct 87 30 Oct 87

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31 Aug 83 31 Aug 83 5 Oct 84 Original 5 Oct 84 31 May 05 5 Oct 84 30 Oct 87 16 Oct 89 Original 1 Oct 86 31 Aug 83 1 Oct 86 Original 31 Aug 83 30 Oct 87 15 Dec 98 31 Aug 83 1 Oct 86 31 Aug 83 1 Oct 85 1 Oct 85 1 Oct 85 31 Aug 83 1 Oct 85 31 Aug 83 1 Oct 86 15 Dec 98

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*The asterisk indicates pages changed or deleted by the current change.

Changed 31 May 2005

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INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

Note: The portion of the test affected by the changes is indicated by a vertical line on the outer margin of the page. Changes to illustrations are indicated by miniature pointing hands.

Page No.
58-35 58-36 thru 58-49 58-50 58-51 thru 58-52 58-53 thru 58-54 58-55 thru 58-57 58-58 thru 58-60 58-60 58-61 58-62 thru 58-71 58-72 58-73 58-74 thru 58-75 58-76 58-77 58-78 thru 58-82 58-83 58-84 58-85 thru 58-94 58-94A thru 58-94H Added 58-94J thru 58-94N Added 58-94P thru 58-94T Added 58-94U 58-94V thru 58-94Z Added 58-94AA thru 58-94AC 58-94AD 58-94AE Added 58-94AF Blank Added 58-95 58-96 58-97 thru 58-126 58-127 thru 58-128 58-128A 58-128 B thru 58-128C 58-128D Added 58-128E 58-128F 58-128G thru 58-128H Added 58-129 58-130 thru 58-131 58-132 thru 58-133 58-134 58-135 thru 58-136 58-137 58-138 thru 58-141

Issue
1 Oct 85

Page No.
58-142 58-143 thru 58-154 58-155 58-156 thru 58-158 58-159 thru 58-160 58-160A thru 58-160H Added 58-160J thru 58-160N Added 58-160P thru 58-160T Added 58-160U 58-160V thru 58-160Z Added 58-160AA Added 58-160AB Blank Added 58-161 58-162 thru 58-164 58-165 thru 58-168 58-169 58-170 thru 58-175 58-176 58-177 thru 58-178 58-179 58-180 Blank 58-181 thru 58-182 58-183 thru 58-184 58-185 thru 58-188 59-1 59-2 Blank 59-3 59-4 Blank 59-5 59-6 59-7 59-8 59-9 59-10 59-10A thru 59-10B Blank 59-11 59-12 59-12A Added 59-12B Blank Added 59-13 59-14 thru 59-17 59-18 59-19 59-20

Issue
1 Oct 85

Page No.
*59-21 *59-22 Blank 59-23 thru 59-24 59-24A thru 59-24B Added 59-25 thru 59-26 59-27 thru 59-34 Added 59-35 59-36 59-37 59-38 59-39 59-40 59-4 thru 59-45 59-46 thru 59-47 59-48 thru 59-52 59-53 59-54 thru 59-55 59-56 59-57 59-58 Blank 59-59 thru 59-60 59-61 59-62 Added 59-62A Added 59-62B Blank Added 59-63 59-64 Blank 59-65 59-66 Blank 59-66A thru 59-66E 59-66F Blank 59-67 Deleted 59-68 Deleted 59-69 Deleted 59-70 Deleted 59-70A thru 59-70F 59-70G thru 59-70H Added 59-70J thru 59-70M Added 59-70N 59-70P 59-70Q 59-70R Added 59-71 59-72 Blank 59-73

Issue
31 May 05 31 May 05 5 Oct 84 5 Oct 84 5 Oct 84

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31 Aug 83 16 Oct 89 31 Aug 83 5 Oct 84

31 Aug 83 18 Nov 93 31 Aug 83 16 Oct 89 31 Aug 83 5 Oct 84 31 Aug 83 18 Nov 93 31 Aug 83 18 Nov 93 31 Aug 83 16 Oct 89 1 Oct 85 31 Aug 83 5 Oct 84 5 Oct 84

5 Oct 84 16 Oct 89 5 Oct 84

5 Oct 84 28 Oct 88 5 Oct 84

5 Oct 84 20 Dec 91 16 Oct 89 31 Aug 83 5 Oct 84 5 Oct 84 18 Nov 93 5 Oct 84 30 Dec 94 18 Nov 93 20 Dec 91 5 Oct 84 18 Nov 93 31 Aug 83 30 Dec 96 31 Aug 83 30 Dec 94 31 Aug 83

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31 Aug 83 28 Oct 88 31 Aug 83 5 Oct 84 5 Oct 84 5 Oct 84

5 Oct 84 16 Oct 89 5 Oct 84 5 Oct 84

5 Oct 84 5 Oct 84 18 Nov 93 31 Aug 83 16 Oct 89 31 Aug 83 30 Dec 94 18 Nov 93 31 Aug 83 31 Aug 83 5 Oct 84 31 Aug 83 18 Nov 93 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 1 Oct 85 1 June 67 1 Oct 85 30 Oct 87 30 Oct 87 1 Oct 86 5 Oct 84 5 Oct 84 1 Apr 68 1 Apr 68

1 Apr 68 19 Oct 90

31 Aug 83 19 Oct 90 18 Nov 93 1 June 67

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1 June 67 5 Oct 84 1 June 67 5 Oct 84 1 Oct 85 31 Aug 83 1 Oct 85 31 Aug 83 19 Oct 90

31 Aug 83 16 Oct 89 31 Aug 83 1 June 67 30 Oct 87 30 Oct 87 28 Oct 88 31 Aug 83 1 June 67 31 Aug 83 31 Aug 83 18 Nov 93 18 Nov 93 18 Nov 93 18 Nov 93 30 Dec 94 30 Dec 94 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 19 Oct 90 5 Oct 84 30 Oct 87 31 Aug 83 31 Aug 83 31 Aug 83 1 Oct 85

*The asterisk indicates pages changed or deleted by the current change.

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Changed 31 May 2005

HANDBOOK OF OPERATING AND MAINTENANCE INSTRUCTIONS

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

Note:

The portion of the test affected by the changes is indicated by a vertical line on the outer margin of the page. Changes to illustrations are indicated by miniature pointing hands.

Page No.
59-74 59-75 59-76 thru 59-77 59-78 59-79 thru 59-80 59-80A Added 59-80B Blank Added 59-81 59-82 thru 59-85 59-86 59-87 59-88 thru 59-91 59-92 thru 59-93 59-94 59-95 Deleted 59-96 Deleted 59-97 59-98 Blank 59-99 59-100 Blank 59-101 thru 59-102 59-103 thru 59-104 59-105 thru 59-106 59-106A Deleted 59-106B Blank Deleted 59-107 59-108 59-109 thru 59-117 59-118 59-119 thru 59-136 59-136A thru 59-136E Deleted 59-136F Blank Deleted 59-137 thru 59-145 59-146

Issue
31 Aug 83 1 Oct 85 31 Aug 83 5 Oct 84 28 Oct 88 28 Oct 88 28 Oct 88 5Oct 84 1 June 67 5 Oct 84 19 Oct 90

Page No.
59-150 59-151 59-152 59-153 59-154 59-155 59-156 59-157 59-158 59-159 thru 59-181 59-182 Blank 59-183 thru 59-21 59-211 thru 59-243 Deleted 59-244 Blank Deleted 71-1 thru 71-2 71-3 71-4 71-5 71-6 Blank 71-6A Added 71-6B Blank Added 71-7 71-8 71-9 thru 71-108 71-11 thru 71-12 Blank 71-13 71-14 Blank 71-15 71-16 Added 72-1 72-2 72-2A Deleted 72-2B Blank Deleted 72-3 72-4 72-4A Added 72-4B Blank Added

Issue
20 Dec 91 31 Aug 83 28 Oct 88 31 Aug 83 5 Oct 84 31 Aug 83 19 Oct 90 31 Aug 83 16 Oct 89 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 1 July 69 1 June 67 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 1 Dec 65 Original 31 Aug 83 5 Oct 84 1 July 69 1 July 69 16 Oct 89 1 June 67 1 June 67 1 June 67 1 June 67 1 June 67 1 June 67 16 Oct 89 1 June 67 1 June 67

Page No.
72-5 72-6 72-7 72-8 72-9 thru 72-10 72-11 72-12 72-12A Deleted 72-12B Blank Deleted 72-13 72-14 72-14A 72-14B Blank 72-15 72-16 72-17 72-18 72-18A 72-18B Blank 72-19 thru 72-20 72-21 72-22 72-23 72-24 Blank 72-25 72-26 Blank 72-27 72-28 72-29 Added 72-30 Blank Added 73-1 73-2 73-3 73-4 73-4A Added 73-4B Blank Added 73-5 73-6 Blank 74-1 74-2 Blank 75-1 75-2 Blank 76-1 76-2

Issue
1 June 67 1 June 67 1 Dec 65 1 Feb 65

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31 Aug 83 1 Apr 68 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 1 Dec 69 1 Dec 69 1 Dec 69 1 Apr 68

31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 19 Oct 90 31 Aug 83 16 Oct 89 31 Aug 83 31 Aug 83 31 Aug 83 31 Aug 83 1 Oct 85

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31 Aug 83 1 Apr 68 31 Aug 83 1 June 66 1 June 66 1 June 67 1 June 67 31 Aug 83 31 Aug 83 1 Oct 85 1 Dec 65 Original Original 31 Aug 83 31 Aug 83 31 Aug 83 Original 1 June 66 31 Aug 83 31 Aug 83 Original Original 1 June 67 1 June 67 1 June 67 1 June 67 31 Aug 83 31 Aug 83 Original 31 Aug 83 31 Aug 83 31 Aug 83 1 Dec 69 1 Dec 69 Original Original Original Original 31 Aug 83 1 June 67

*The asterisk indicates pages changed or deleted by the current change.

Changed 31 May 2005

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TABLE OF CONTENTS (Cont) GROUP AIRFRAME SYSTEMS (Cont) CHAPTER 30 ICE AND RAIN PROTECTION

Section 30.0 Section 30.1 Section 30.2 Section 30.3 Section 30.4 Section 30.5 Section 30.6 Section 30.7
CHAPTER 31 CHAPTER 32 INSTRUMENTS LANDING GEAR

General Wing and Empennage De-Icing System Windshield Anti-Icing System Windshield Wiper System Pitot Tube and Static Port Anti-Icing System Windshield De-Fog System Cabin Window De-Fog System Engine & Nacelle Ice Protection

Section 32.0 Section 32.1 Section 32.2 Section 32.3 Section 32.4 Section 32.5
CHAPTER 33 LIGHTING

Landing Gear and Landing Gear Doors Emergency Gear Release System (Airplanes 5001 through 5085) Landing Gear Indicating and Warning System Brake and Anti-Skid Systems Nose Steering System Emergency Gear Release System (Airplanes 5086 and up) Aircraft Lighting Warning Circuits

Section 33.0 Section 33.1

CHAPTER 34

NAVIGATION SYSTEMS

Section 34.0 Section 34.1 Section 34.2 Section 34.3 Section 34.4 Section 34.5 Section 34.6 Section 34.7 Section 34.8 Section 34.9 Section 34.10 Section 34.11 Section 34.12
CHAPTER 35 CHAPTER 38 CHAPTER 39 GROUP STRUCTURES CHAPTER 51 STRUCTURES Section 51.0 Section 51.1 OXYGEN SYSTEM WATER/WASTE DRAG CHUTE

General VHP Navigation Systems (VOR) Flight Director Systems Glideslope Systems Marker Beacon System Automatic Direction Finder Gyrosyn Compass Systems Weather Radar Distance Measuring Equipment System Air Traffic Control Transponder System Air Data, Attitude, and Direction Instrumentation (Pitot-Static System) Alternate Electronic Systems Doppler Navigation and Computer
System

DELETED

General

Section 51.2

Alignment and Symmetry Check Airframe Sealing

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HANDBOOK OF OPERATING AND MAINTENANCE INSTRUCTIONS

REVISIONS Revisions to this handbook are issued to cover changes in the JetStar Models 1329-23A, 1329-23D, and 1329-23E, and improved maintenance procedures. Each revision includes a list of effective pages. Check list to be sure your copy is up to date. Pages added by revision which fall within a chapter are identified as lettered suffixes of the original page number preceding them, and should be inserted to follow the existing page of the same basic number. Pages added by revision which fall at the end of a chapter are identified as continuing numbers of the existing page numbers, and should be inserted to follow the existing pages. STANDARD TORQUE VALUES Bolt and screw torque values are specified in Section 51.0 of this manual. Torque values for flareless tubing are specified in Section 29.0 of this manual. Torque values for wire terminal installation are specified in Section 24.3 of this manual. The flexible Wiggins type fuel line coupling torque values are specified in Section 28.0 of this manual. The torque values for oxygen tubing are specified in Chapter 35 of this manual. Flared tube fitting torque values are specified in figure 28-4A in this manual. These include the rigid NAS connectors used primarily in the fire extinguishing system. These torque values should not be construed to supersede any special torque requirements that may be specified elsewhere in this manual. TECHNICAL INFORMATION All technical inquiries and other general information questions should be directed to: Lockheed Martin Aircraft & Logistics Centers 107 Frederick Street B270 Greenville, SC 29605 Technical support is available Telephone: (864) 422-2179 Fax: (864) 422-2184 Services: Troubleshooting assistance and engineering, OMR, Service Bulletin update, HOMI revision, JetStar program matters. The above phone hot line number is also good for emergency after-hours technical support. Order Technical Manuals and HOMI revisions: Telephone: (864) 422-2171 Fax: (864) 422-2183 SPARE PARTS/MATERIALS All inquires concerning parts availability and/or pricing should be directed to: Hi-Tech Aero Spares 3436 Meridian Way West Chester, OH. 45069 Spares Support is available during normal business hours (8:00am to 5:00pm Eastern Time) and AOG at: Telephone: (513) 942-4541, Ext. 120 REFERENCE PUBLICATIONS In addition to this handbook, other Lockheed Martin Aircraft & Logistics Center publications concerning the JetStar airplane are: FAA Approved Airplane Flight Manual for Lockheed Model 1329 JetStar (Publication No. SMR-150) JetStar Illustrated Parts Breakdown Hot Line: (864) 422-6265

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SECTION 5.0 GENERAL

5.0.1 MANUFACTURER'S RECOMMENDATIONS. These inspections are Lockheed's recommendations to the operator and are based on average operating conditions. They have been derived to comply with the current requirements of FAR Part 91, Subpart E, to serve as "a current inspection program recommended by the manufacturer." The listing of an inspection here does not make it mandatory; however, it may be invoked as mandatory by the FAA at the time the individual operator files his program or at some later time. Possible discrepant conditions in systems, components and areas have been defined in general terms rather than by detail listing. These data should enable an operator to establish a record system or checklist for each inspection to suit his own operation. When setting up such a program or planning for a particular inspection, the operator should be cognizant of the information given in Section 5.6 Overhaul and Replacement Schedule, and include relevant items in his program to avoid unnecessary duplication of maintenance work. Routine servicing and lubrication as specified in Chapter 12 can also be phased into an inspection work package where applicable. The omission of an inspection from this program does not relieve the operator from complying with all current requirements and future revisions of FAR Part 43 and FAR Part 91. Note An individual operator may elect to use the information contained in this program to develop his own program of another type, such as a progressive inspection program in accordance with FAR Part 91 and approved by the FAA. 5.0.2 OWNER/OPERATOR RESPONSIBILITIES. The JetStar owner/operator has the responsibility to maintain the airplane in an airworthy condition, including compliance with FAA FAR Part 39. Maintenance should be performed in accordance with FAA FAR Part 91, Subpart E, and any other applicable regulation. Refer to FAA FAR Part 91.403, FAR Part 121.363, and FAR Part 135.413, as applicable. The airplane should be maintained in accordance with instructions in the HOMI and/or other applicable documents. 5.0.3 REPLACEMENT PARTS. Hi-Tech Aero Spares maintains a reasonably adequate stock of parts for maintenance and repair of JetStars. Some JetStar functional components are available from holders of Parts Manufacturer Approval (PMA). Used and repaired parts and assemblies are available from Hi-Tech Aero Spares and other sources. The supplier of new/used/surplus/spare JetStar components should execute an FAA Form 8130-3, "Authorized Release Certificate Approval Tag", for each part or assembly; several parts may be listed on a single form provided each is fully documented. "User/Installer Responsibilities" are listed on the FAA Form 8130-3. Useful guidance material is provided by FAA Advisory circulars AC No. 20-62C, "Eligibility, Quality, and Identification of Approved Aeronautical Replacement Parts", and AC No. 21-29A, "Detecting and Reporting Suspected Unapproved Parts".

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5.3.9 (Cont). k. Speed brake including blow-in doors, hinge points, actuators and their attachment points for wear. 1. Speed brake uplock and switch for wear. m. Compartment overheat warning. n. Fire extinguisher control valves. o. Deleted. p. Air pressure regulator. q. Clean water separator filter and drain line filter. r. s. Stowage box if fitted. Hydraulic system accumulators and thrust reverser accumulator. No. 1 and No. 2 system accumulators 1700 PSI. Thrust reverser accumulator 1200 PSI. (Nitrogen or dry air.) The following hydraulic system valves: Enginedriven pump inlet and outlet shut-off valves and relief valves for system No. 1 and No. 2, speed brake selector valve and thrust reverser selector valves.

1. Wheel for damage and need of cleaning. m. Gear actuator, steering actuator and gear door actuator including damage to the sliding surfaces. n. Gear supporting structure for cracks and loose or missing attachments. o. Brake selector valve and steering selector valve. p. Pressure lines from the emergency extension air bottle. q. Aft side of FS 164 bulkhead structure. r. Static lines and check drain point for condensation. s. Check insulation. t. Visually inspect steering actuator for cracks, distor tion, corrosion and hydraulic leakage. 5.3.11 MAIN LANDING GEAR WHEEL WELLS. a. All landing gear components and all wheel components for evidence of damage and obstruction. b. All hydraulic and fuel lines. c. All cables and pulleys. d. All landing gear doors and their hinge and attachment points for excessive wear. e. Landing gear and landing gear door actuators. f. Landing gear uplock mechanism for wear and cracks. g. Landing gear door uplock mechanism for free release and lack of binding. h. Emergency gear release system including cables, pulleys, and air bottle for service. 1800 to 2500 PSI. (Nitrogen or dry air.) i. Shock struts, exposed surface for damage and service. j. Brakes: Wear indicators and leakage. k. Tires including pressure. Dash 6, 205 5 PSI; Dash 8, 220 5 PSI. (Nitrogen or dry air.) 1. Pressure lines from the emergency extension air bottle. m. Side brace actuators. Check moisture drain for obstructions. n. Drain safety valve static line (left wheel well, Airplanes 5001 through 5125 only). See Section 21.1.
Note

t.

u. De-icer distributor valve and the regulator and pressure relief valve. v. Check reservoir of turbine fan assembly for water contamination. By using syringe and tube remove water as required and replace with oil per instructions in Section 12.8, paragraph 12.8.1.1. w. On airplanes 5126 and up, check safety valve static sense lines (Fuselage Station 570 Bulkhead). Openings shall be free of obstruction. 5. 3.10 NOSE LANDING GEAR WHEEL WELL. a. Scissors and disconnect pin, including excessive wear. b. Nose wheel steering, including excessive wear. c. All hydraulic lines, fittings and units. d. All electrical wiring, switches and connectors. e. Brake accumulator, including correct pre-load. (800 50 PSI nitrogen or dry air). f. Wheel well doors and hinges and all linkages. g. Nose wheel emergency bottle for service. 1800 to 2500 PSI (Nitrogen or dry air.) h. Tires including correct pressure. Dash 6 aircraft 180 5 PSI, Dash 8 aircraft 220 5 PSI. (Nitrogen or dry air.).
i. Landing light .

Static line should be drained every 100 hours. o. Inspect wiring in trunnion joint area in accordance with Section 32.0. p. Main gear uplock accumulators, 500 PSI on Aircraft 5041 and up and aircraft modified by Service Bulletin 329-25B.

j.

Shock strut, exposed surface for damage and service. k. Remove at least one right and one left vertical sidewall access plate and check brake valves, cables, pulleys, plumbing, and wiring.

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5.4.8

(Cont).

c. Anti-skid selector valves. d. Main, standby and windshield inverters. e. Check all drain holes under floor, including thru longeron and frames. f. Cabin pressurization pneumatic relay and filter, outflow valves, jet pump and jet pump pressure regulator and pneumatic relay. Clean outflow valves (nicotine on knife edges). Airplanes 5001 through 5045: Located between FS 330 and FS 350 under center aisle floor; Airplanes 5046 and up, and those incorporating Service Bulletin 329-61: Forward face of FS 570 bulkhead. g. Check alumina desiccant in cabin window de-mist tubes. h. Check installation of the flight station high limit thermostat and the flight station temperature anticipator (over right-hand wheel well). i. j. k. 1. Pitch-trim relays. Aileron tension regulator. All air-conditioning ducting. Insulation and sound-proofing for moisture.

temperature control box, low limit thermostat (except on airplanes 5086 through 5092, and 5094 through 5096 not having Service Bulletin 329-234 incorporated), cabin high limit thermostat, cabin temperature anticipator and all of the system valves and ducting. f. Refrigerator unit oil reservoir for need of servicing. Check for corrosion on bottom of refrigerator core. g. Visual check of the electric motor-driven hydraulic pump and the hydraulic pressure transmitters. h. Hydraulic reservoir pressure regulator. i. Structural check of the underside of the shelf under the vertical stabilizer between Fuselage Stations 690 and 760. j. Doppler antenna, if fitted. k. Elevator tension regulator. 5.4.10 NOSE LANDING GEAR WHEEL WELL. a. Remove all vertical sidewall accessplates (2 left and 2 right) for detailed inspection including structural check. b. Check side play in gear. c. Upper trunnion mount. d. Check clearance of landing gear to overhead floor support structure. e. Inspect wheels and tie bolts per 5.5.21. f. Visually inspect all outside surfaces of the shock strut. On aircraft 5001 through 5157 not provided with a JL1666 NLG cylinder, perform the NDE inspection in paragraph 58.5.4. If defects are found, replace the defective cylinder with a JL 1666 cylinder (7049-T73 alloy) or see Technical Information, page Introduction-3. This NDE inspection is not required on JL1666 cylinders. g. Inspect upper drag link in accordance with paragraph 58.5.2. To report defects see Technical Information, page Introduction-3. Note: This inspection is not required on link Part No. JL1805 (7049-T73 alloy). h. At each third (3-year intervals) annual inspection, fluorescent penetrant inspect the shock strut internal surfaces per sections 58.5.4.4 and 58.5.4.5. Refer to figure 32-10 for packing instructions with emphasis on step 17. i. Visually inspect steering actuator for cracks, distortion, corrosion and hydraulic leakage.

m. Check forward face of Fuselage Station 570 bulkhead structure. n. Inspect cabin windows for cracks or separation in or near the rabbet radius in the outer panel. (See figure 56-11.)
5.4.9 AFT EQUIPMENT COMPARTMENT.

Note As used in this paragraph, "Structural check" is defined as a visual check of subject structure for cracks, buckling, distortion, loose, damaged or missing attachments, and corrosion. When conditions warrant, refer to Chapter 58 for more detailed inspections. a. Check aft face of FS 570 bulkhead structure. b. All plugs, grommets and seals, etc. at pressure bulkhead, Fuselage Station 570. c. Structural check of the engine support frames at Fuselage Stations 589 and 608, and the bulkheads at Fuselage Stations 682 and 739. d. Structural check of generator control panel rack. Also, check for illegible markings and mounting of the attached equipment. e. The following components of the air conditioning and pressurization system: Water separator, refrigerator assemblies, emergency pressurization heat exchanger, bleed air inflow control, cabin

5.4.11 MAIN LANDING GEAR WHEEL WELLS. a. Gear support structure.

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5.4.11 (Cont). b. Landing gear selector valve and gear doors selector valve. c. Fore and aft play in gear through shimmed upper attach bearings. (See paragraph 32.0.4.4.) d. Uplock adjustment: Check landing gear uplock and landing gear door (Reference: Section 32.0). e. Play in side brace actuators. f. Remove anti-skid generator and check for axle corrosion.

g. Check all skins in jet blast areas for cracks. h. Bonding jumpers - all control surfaces. i. Structural check of empennage pivot fitting (JE24) at lower end of vertical stabilizer rear beam through the access panel. (See Figure 52-5, Item 24, C.)

5.4.13 WINGS. a. Drop L.E. flaps for thorough inspection of wing L.E. b. Wing front and rear beams for cracks, loose and missing attachments, and evidence of fuel leakage. c. All electrical wiring along front beam for evidence of chafing. d. L.E. and T.E. flap jackscrew actuators and support fittings. e. L.E. and T.E. flap torque tubes for clearance to structure and universal mechanisms for condition. f. Remove wing tip: Check flux valve and end rib for cracks. g. Aileron trim tab position transmitter. h. Aileron counterbalance weights for loose or missing attachments. i. Aileron push-pull rods and supports for binding, looseness and need of cleaning.

g. Wheel well box structure. On aircraft 5001 through 5146 not modified by Service Bulletin 329-265, perform the NDE inspection in paragraph 58.4.2. If defects are found, install the kit provided by Service Bulletin 329-265. h. Inspect wheels and tiebolts per 5.5.21. i. Visually inspect all outside surfaces of the shock strut. On aircraft 5001 through 5159 not provided with a JL1174 MLG cylinder, perform the NDE inspection in paragraph 58.5.4. If defects are found, replace the defective cylinder with a JL1174 cylinder (7049-T73 alloy) or see Technical Information, page Introduction-3. This inspection is not required on JL1174 cylinders. At each third (3-year intervals) annual inspection, fluorescent penetrant inspect the shock strut internal surfaces per sections 58.5.4.4 and 58.5.4.5. Refer to figure 32-11 for packing instructions with emphasis on step 17. EMPENNAGE.

j.

5.4.12

j. Check for excessive play in ailerons, and L.E. and T.E. flaps. k. Inspect Part No. JW290-1L/R, -2L/R, -3L/R, 4IL/R and -5L/R; -11L/R, -12L/R. -13L/R, -14L/R, -15L/R, -21L/R, -22L/R, -23L/R, -24L/R and -25L/R wing root rib lower shear fittings, in accordance with paragraph 58.2.3 on airplane serial 5001 through 5059, 5061 and 5064. Defects reported are to be repaired or pans replaced in accordance with Service Bulletin 329-190. 1. Check samples of liquid from fuel sumps for presence of contamination or microbiological growth (Refer to Section 51.7 Corrosion Control and Protection). m. MLG actuator and auxiliary spar outboard support fitting per paragraph 58.2.6. This inspection is not required on parts with less than 5000 hours service or on replacement 7075-T73 alloy parts (Part No. JW60-5L/R or JW60-7L/R). Refer to Section 59.2 for defect repairs. n. Make inspection as required by paragraph 5.5.8.1. o. MLG aft support spar inboard (clevis) end in the area of bushed bolt holes (forward and aft faces). If conditions warrant, refer to paragraph 58.2.4 for more detailed inspection.

Note
As used in this paragraph, "Structural check" is defined as a visual check of subject structure for cracks, buckling, distortion, loose, damaged or missing attachments, and corrosion. When conditions warrant, refer to Chapter 58 for more detailed inspections. a. De-icing system flexible air supply tubing. b. Structural check of the vertical and horizontal stabilizer rear spars. If any indication of structural or corrosion damage is found, remove leading edge and perform structural check of front spars. Check left and right vertical stabilizer spar caps for cracks. c. Rudder and elevator counterbalance weights for secure mounting. d. Structural check of the entire exterior surface of the vertical and horizontal box structure and leading edges. e. Rudder and elevator hinge pins for damage and excessive wear and the hinge support structure. f. Elevator support bearings for wear and the bearing support structure.

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5.5.2 (Cont). d. Inspect the radome rollers, tracks, and latches for damage. e. Visually inspect all protruding antennas for damage. f. Inspect the entire exterior surface of the airplane for pitting, dents, holes and popped rivets. g. If popped rivets are found in the exterior surface, also inspect the interior structure in the affected area for damaged attachments. h. Inspect all leading edge de-icing boots for pin holes. i. Inspect the fuel vents, drains and flame arrestor for damage. j. Inspect all bonding wires to ensure that they are intact. k. Inspect all exterior lights for burned bulbs. 5.5.3 SPECIAL INSPECTION-AFTER OVERWEIGHT OR HARD LANDING. 5.5.3.1 Inspect all exterior skin and the areas specified below for cracks, distortion, buckling, loose, damaged or missing attachments, security of components, and evidence of fuel leakage. When conditions warrant, refer to Chapter 58 for more detailed inspections. a. Wing rear beam, particularly from the inboard end to a point approximately 12 inches outboard of the main gear aft beam attachment fitting, with emphasis at attachments for the main gear forward trunnion fitting. b. Main gear support beam entire length, with emphasis around the inboard and outboard end attachments and at the main gear aft trunnion fitting. c. Forward and aft trunnion fittings for the main gear. d. Inboard and outboard attachment fittings for main gear aft support beam. Inboard attachment fitting is on the fuselage and the outboard fitting is on the wing rear beam. e. Main landing gear wheel well structure aft wall, fuselage station 526, inside and outside of aircraft. f. Visually inspect the main gear for damage. If damage is in evidence or is suspected, disassemble and inspect per paragraphs 58.5.3 and/or 58.5.4. g. Inspect the wing trailing edge alignment pin for sheared pin, and inspect the alignment pin fittings for sheared fasteners. h. Wing-to-fuselage attachment fittings at fuselage stations 410, 430, 450, 470, and 490 for cracks and attachment failure.

i. Wing upper surface from wing station 41.5 to wing station 120 between rear and mid beams. j. Wing lower surface from wing station 41.5 to wing station 120. k. Visually inspect the nose gear and drag link for damage. If any evidence of damage is suspected, disassemble and inspect per paragraphs 58.5.3. and/or 58.5.4. l. Entire nose gear wheel well structure with emphasis around the nose landing gear trunnion fitting and trunnion support structure. m. Nacelle-to-fuselage attachment fittings for cracks and attachment failure. 5.5.3.2. In the event that the landing was unduly severe or if considerable damage is evident, it is recommended that all the NDE inspections referenced in paragraphs 5.5.3.1. be accomplished and the following additional operations and inspections be performed. a. Alignment and symmetry check. Refer to Section 51.1. b. Inspect both fuselage lower longerons from fuselage station 490 to 600. c. Inspect wing-to-fuselage attach bolts (40 places) per paragraph 58.2.2. d. External tank forward and aft attach bolts and fittings. See paragraph 58.2.8. e. Inspect landing gear wheels per paragraph 58.5.5. Refer to B.F. Goodrich Maintenance and Overhaul Manual 667. f. Perform inspection of nacelle-to-fuselage attachment fittings and bolts. See paragraph 58.6.2. g. Inspect engine mount fittings and bolts. See paragraph 58.6.3. h. All fuselage-to-empennage attachments including pitch trim actuator. See paragraphs 58.3.2, 58.3.3, and 58.3.4. i. Horizontal stabilizer box beam to horizontal stabilizer center section attachments. See paragraph 58.3.5. j. Inspect rudder bearings and support structure. k. Contact engine manufacturer's representative for any special engine inspection. 1. It is recommended that the NDE inspections of paragraph 58.2.4 MLG aft support to fuselage attachment and paragraph 58.2.6 MLG actuator to auxiliary spar outboard support fitting be accomplished. m. Visually inspect steering actuator for cracks, distortion, corrosion and hydraulic leakage.

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Note

c. d.

The following inspection in step c is not required prior to 20,000 hours. c. Inspect horizontal stabilizer center section aft lower attachment in accordance with paragraph 58.3.8.
Note

Inspect wing lower surface spanwise splices in accordance with paragraph 58.2.11. Inspect frame outer cap at aft engine nacelle mount, F.S. 608, in accordance with paragraph 58.4.11.
Note

The following inspection in step d is not required prior to 4,000 hours. d. Inspect wing upper and lower panel to root rib attachment in accordance with paragraph 58.2.15. This inspection should be coordinated with the inspections in paragraph 5.5.8. 5.5.23 6,000 HOUR INSPECTIONS.
Note

The following inspections in steps e, f, g and h are not required prior to 24,000 hours. e. f. g. Inspect fuselage main frame to pressure skin attachment in accordance with paragraph 58.4.10. Inspect emergency exit cutout upper corners in accordance with paragraph 58.4.12. Inspect upper 30-degree longeron attachment, F.S. 483 to F.S. 496, in accordance with paragraph 58.4.13.

The following inspections in steps a, b, c and d are not required prior to 12,000 hours. a. Inspect wing panel to rear beam lower cap spanwise splice in accordance with paragraph 58.2.12. This inspection should be coordinated with the inspecttions in paragraph 5.5.8. Inspect wing lower panel drain holes in accordance with paragraph 58.2.14. This inspection should be coordinated with the inspections in paragraph 5.5.8.

h. Inspect top longeron splice in accordance with paragraph 58.4.14. 5.5.24 2,500 HOUR, 5 YEARS MAXIMUM, INSPECTIONS. a. b. Remove leading edge, and perform structural inspection of the horizontal stabilizer front beam. Remove leading edge, and perform structural inspection of the vertical stabilizer front beam.

b.

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5.6.10 LANDING GEAR PART NAME Nose Landing Gear Steering Actuator Nose Wheel Steering Valve Nose Landing Gear Shock Strut Nose Landing Gear Retract Actuator Main Landing Gear Shock Strut Main Landing Gear Side Actuator MANUFACTURER Menasco PART NUMBER JL1500-3 JL1500-20 JL1501-4 141V9-8 50100-303 JL 1600-11 JL-1900-3 JL 1100-5 JL 1100-7 JL 1400-13 JL 1400-13 JL1400-9 JL1400-11 JL1400-7 T.B.O. 3 Yrs.
NOTES CAT. A

Consolidated Controls Bertea Menasco Menasco Menasco

3 Yrs. 6000 Hrs. 13000 Hrs. 13000 Hrs. 13000 Hrs.

B
A

Rovalco Royal Industries

10000 Hrs. 13000 Hrs. 10000 Hrs. 13000 Hrs. 13000 Hrs. 6000 Hrs.
A

Menasco

NOTES:

IF ACTUATORS INCORPORATE STEEL BARRELS.

REFER TO SERVICE BULLETIN 329-300B.

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5.6.11 OXYGEN PART NAME Pressure Reducer and Cylinder Assy

MANUFACTURER PART NUMBER

T.B.O.

NOTES

CAT.

Portable Oxygen Cylinder

Carleton Life Support Technologies, Ltd. 1-1200 Aerowood Drive L4W 257 Mississauga, Ontario, Canada 1-905-629-3245 Litton, Clifton Precision

F5038350-7 F5038350-9 F5038350-11 F5038350-17 F5038350-19 F5038350-21

2 Yrs.

29612-A1 29612-B1 29612-C1 29612-D1 900-002-035 900-002-035 15830-3 15830-4 29274-13A-A1 29274-13A-A2 7300-3 7300-5 GU-313-B1 GU-313-B3 61582-10 170110 23809-30 170059 F6022200-3

3 Yrs.

Crew Regulator

Robertshaw Sabre Industries Carleton Life Support Technologies, Inc. Litton, Clifton Precision American Safety Flight Systems Litton, Clifton Precision Carleton Life Support Technologies, Inc. Puritan-Bennett Aero Systems Carleton Life Support Technologies, Inc. Puritan-Bennett Aero Systems Carleton Life SupportTechnologies,

2 Yrs. A 3 Yrs. 2 Yrs.

Passenger Control Panel

Door Actuator Valve Passenger Mask Container Lanyard Valve Passenger Mask

3 Yrs. A

3 Yrs. A

Passenger Mask and Regulator

NOTES:

3 Yrs.

OVERHAUL MUST INCLUDE REPLACEMENT OF HIGH PRESSURE BURST DISC. HYDRO STATIC TEST TO 3085 PSIG IS DUE EVERY 3 YEARS PER FEDERAL REGULATION, TITLE 49, PARAGRAPH 173.34 FOR 3HT CYLINDERS. IF CONTAINER IS CHARGED WHEN TEST IS DUE, THE TEST MAY BE DEFERRED UNTIL CONTAINER IS RECHARGED OR UNTIL THE' NEXT ANNUAL INSPECTION, WHICHEVER OCCURS FIRST. MAXIMUM LIFE OF CYLINDER IS 24 YEARS. HYDRO STATIC TEST TO 3335 PSIG IS DUE EVERY 5 YEARS PER FEDERAL REGULATION, TITLE 49, PARAGRAPH 173.34 FOR 3AA CYLINDERS. IF CONTAINER IS CHARGED WHEN TEST IS DUE, THE TEST MAY BE DEFERRED UNTIL CONTAINER IS RECHARGED OR UNTIL THE NEXT ANNUAL INSPECTION, WHICHEVER OCCURS FIRST. THIS ITEM OVERHAULED BY PURITAN-BENNETT AERO SYSTEMS, 111 PENN. ST., EL SEGUNDO, CA 90245, PHONE 213-772-1421. IT IS NOT RECOMMENDED THAT THIS COMPONENT BE OVERHAULED IN THE FIELD. A ZERO TIME EXCHANGE PROGRAM IS AVAILABLE FROM THE MANUFACTURER. CONTACT THE CARLETON LIFE SUPPORT TECHNOLOGIES, INC., 1-1200 AEROWOOD DR., MISSISSAUGA, ONTARIO, CANADA L4W 257, PHONE 1-905-625-3245.

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SECTION 5.7 CONTINUED AIRWORTHINESS Contents GENERAL Page

........................................................................................... 5-37 100/300-HOUR AND ANNUAL INSPECTIONS ............................................................. 5-37 SPECIAL INSPECTIONS................................................................................ 5-37 AIRWORTHINESS DIRECTIVES ........................................................................ 5-37 INFORMATION ...................................................................................... 5-37 LIFE LIMITED COMPONENTS ......................................................................... 5-38
5.7.1 GENERAL. Service experience has shown that aging airplanes need more care and special attention during the maintenance processes. At times, more frequent inspection of structural components is required. Inspection programs in this publication have been prepared to meet the recommendations of FAA Advisory Circular 91-60. 5.7.2 100/300 HOUR and ANNUAL INSPECTIONS. The inspections in Section 5.3 and Section 5.4 have been prepared to provide safety of operation. These inspections will be revised as new situations arise. Overhaul and replacement periods in Section 5.6 and the lubrication/servicing recommendations in Chapter 12 should be maintained and insofar as possible should be incorporated in the normal scheduled inspections. 5.7.3 SPECIAL INSPECTIONS. Some of the inspections in Section 5.5 are provided for special situations and conditions. The remaining inspections are for the purpose of providing continued airworthiness for aging airplanes and generally meet requirements of the Supplemental Inspection Document (SID) described in FAA Advisory Circular 91-56. AC91-56 is not presently a requirement for JetStar airplanes; however, the concept of a SID is useful to operators and therefore, the information has been provided by the Lockheed Martin Aircraft & Logistics Centers. 5.7.4 AIRWORTHINESS DIRECTIVES. FAA Airworthiness Directives (AD) should be complied with promptly. Structural improvements are usually directed to lowering working stresses, and the sooner they are made, the better they are to slow the onset of cumulative damage to the original structure. In some instances, this publication may require more frequent inspections than are specified in a particular AD. In such cases, the more frequent inspections are necessary for continued airworthiness. 5.7.5 INFORMATION. A free exchange of data and sharing of operational experience is required for continuing success of the continued airworthiness program for JetStar airplanes. To report peculiar operational conditions, see Technical Information, page Introduction-3.

Lockheed Martin publications will be updated when the need is indicated by experience and reports from operators.

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5.7.6 LIFE LIMITED COMPONENTS FAA Airworthiness Limitations Instructions Life Limited Components Part Number JL1955-3 JL1955-7 Nomenclature Qty Chapter 32 Landing Gear Cylinder, Nose Landing Gear 1 Steering Cylinder, Nose Landing Gear 1 Steering Chapter 55 Stabilizers JE24-2 JE24-4 JE24-6 Fitting, Empennage Pivot Fitting, Empennage Pivot Fitting, Empennage Pivot 1 1 1 Discard Use JE24-6 Discard Use JE24-6 No Life Limit 55.1 55.1 55.1 (Discard) Discard Use JL1955-7 3600 Flights HOMI Sec Ref 32.4 32.4

Chapter 57 Wings MS20008-20 MS20010-22 Bolt, Wing Attach, Upper Bolt, Wing Attach, Upper (AC w/o SB329-157) (AC w/SB329-157) Bolt, Wing Attach, Lower Bolt, Wing Attach, Lower Bolt, Wing Attach, Lower
(5056-5200 and AC w SB329-157)

4 6 4 4 4 2 4 6 4 4 2 1 1

1900 Hrs 1900 Hrs 1900 Hrs 1900 Hrs 1900 Hrs 1900 Hrs 1600 Hrs 1600 Hrs 1600 Hrs 1600 Hrs 1600 Hrs 4024 Flights 4024 Flights

57-1 57-1

MS20012-28 MS20010-22 MS21250-100022 2752-080 2752-108 2752-108 2752-126 NAS577-12AX JW121-6L JW121-6R

57-1 57-1 57-1 57-1 57-1 57-1 57-1 57-1 57-1 57-1

Nut, Barrel - Upper Nut, Barrel - Upper Nut, Barrel - Lower Nut, Barrel - Lower Nut, Barrel - Lower Fitting Actuator, T.E. Inboard Flap Fitting Actuator, T.E. Inboard Flap

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5.7.6 LIFE LIMITED COMPONENTS (CONT) FAA Airworthiness Limitations Instructions Life Limited Components Part Number JW121-8L JW121-8R JW123-6L JW123-6R JW123-9L JW123-9R NAS630-24 Qty Chapter 57 Wings (Cont) Fitting Actuator, T.E. Inboard 1 Flap Fitting Actuator, T.E. Inboard 1 Flap Fitting Actuator, T.E. Outboard 1 Flap Fitting Actuator, T.E. Outboard 1 Flap Fitting Actuator, T.E. Outboard 1 Flap Fitting Actuator, T.E. Outboard 1 Flap Bolt, Pylon Attach 8 Nomenclature (Discard) 4024 Flights 4024 Flights 4024 Flights 4024 Flights 4024 Flights 4024 Flights 3125 Flights HOMI Sec Ref 57-1 57-1 57-1 57-1 57-1 57-1 57.7

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SECTION 9.0 TOWING

Contents GENERAL Page

...................................................................................................9-3 NOSE GEAR TOWING ........................................................................................... 9-3 MAIN GEAR TOWING ............................................................................................ 9-3 TOWING PRECAUTIONS ...................................................................................... 9-3 FIGURES 9-1. Towing Provisions .......................................................................... 9-5
9.0.1 GENERAL. Towing on a hard level surface is best accomplished with a nose gear towbar. When the airplane is on soft ground, deep snow, or when towing up a steep grade, tow with cables at the main landing gear instead of the towbar. 9.0.2 NOSE GEAR TOWING. Two steel lugs on the front of the nose landing gear (figure 9-1A) provide attachment for a Lockheed 1000-MEU-2 towbar or a Lockheed 11013-MEU towbar adapter kit. Always disconnect nose gear scissors when towing from the nose gear. To disconnect the scissors, simply remove the connection pin (figure 9-1B), separate the two scissor arms, and reinsert the connection pin in the upper arm as shown in figure 9-1C to keep the arm out of the way. Safe towing limit is 10,000 pounds maximum straight pull and 5,000 pounds at 45 degrees. Allowable tow loads with one flat tire are 6,000 pounds fore and aft and 3,000 pounds with nose gear swiveled 45 degrees to airplane center-line. 9.0.3 MAIN GEAR TOWING. Towing with cables at the main landing gear lugs (figure 9-ID) is accomplished with stranded steel tow cables, 3/8-inch in diameter or larger, about 50 feet long. This puts the tug at a minimum safe distance of about ten feet ahead of the nose. To avoid overloading the main gear structure, safe towing limits should be observed. Do not exceed a 7,500-pound straight pull or a 30-degree tow cable angle from the fore and aft direction. Allowable tow load with one flat tire is 4,500 pounds fore and aft, at a 30-degree tow cable angle. 9.0.4 TOWING PRECAUTIONS.

WARNING
Failure to observe any of these safety precautions may result in damage to the airplane or injury to personnel. a. Never tow the airplane while any of the engines are operating. b. Never tow the airplane without having someone in the pilots' compartment to operate the brakes. Hydraulic power must be available to operate the brakes. The battery switch must be ON, the landing gear selector handle in the LG DOWN position, and the normal (No. 1) hydraulic system selected on the Hydraulic Power Selector Switch. Make sure the brakes are in good operating condition, the pressure gage on the accumulator in the nose wheel well indicates a charged accumulator, and brake system pressure is built up by operating the electrically driven No. 3 hydraulic pump. During towing, operate the No. 3 hydraulic pump as necessary to keep hydraulic pressure above 1,250 PSI (operate whenever the brake low pressure light is on).

On airplanes 5001 through 5045, not having detented landing gear selector valves, electrical power MUST be applied to the down side of the landing gear selector valve for the brakes to be operated with the electric pump.

SMR 151

Changed 31 May 2005

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HANDBOOK OF OPERATING AND MAINTENANCE INSTRUCTIONS

9.0.4 (Cont). c. When towing, wait until the airplane has started moving before turning the nose gear. A large force is required to overcome the inertia of the airplane when it is standing still. This force might place dangerous side loads on the landing gear structure if a start is attempted while the nose wheel is at an angle. Never tow the airplane faster than a slow walk. Avoid quick stops and starts. Never tow the airplane near obstacles without having someone walking at each wing tip and at the empennage to guard against collision. Make sure an adequate system for relaying signals is understood by everyone involved in the operation. Use candle type signal lights at night.

f.

Never allow anyone to enter or leave the airplane or to ride on the outside of the airplane while it is moving. Never remove the chocks until ready to tow the airplane. Make sure the person in the flight station is ready to operate the brakes and that brake pressure is available. The normal (No. 1) hydraulic system must be selected by the switch on the instrument panel.

g.

d.

e.

h. When towing from the nose gear, disconnect the nose gear scissors. Steering actuator damage can occur if the nose gear scissors are left connected and turning angle of 53 degrees is exceeded. i. Check to see that landing gear downlocks have been installed. (See Chapter 32.) Note Scissors disconnect pin should be installed on RH side of nose gear as shown in View B, Figure 9-1.

9-4

Changed 31 May 2005

SMR151

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28.2.3.4 (Cont). b. CLEANING. After the source of the fuel leak is determined, clean away the old sealant before the new repair material is applied. The surfaces must be thoroughly cleaned before applying any new sealant. Oil and dirt from hands, hair, or other foreign substances will prevent the sealant from adhering to the metal. Use the following procedure for cleaning: 1. Scrape the surface around the leak with a micarta, wood, or phenolic scraper to remove the old sealant. Taper the edges of the fillet seals back from the cleaned area at about a 45-degree angle.

Note
On airplanes 5001 through 5045 the inside surface of all fuel tanks is coated with Buna-N (MIL-S-4383). This was changed, starting with airplane 5046 and airplanes in compliance with Service Bulletin 329-168, to a polyurethane sealant topcoat (MIL-C83019). The basic sealant used in the tank is MIL-S-8802. In recent years a corrosion inhibited sealant, MIL-S-81733, has been developed which provides better protection in fay surface joints, with wet installed fasteners, and in confined areas. MIL-S8802 continues to be used for fillets, edge seals, and exposed fasteners. MIL-S-81733 should be used with new parts for fay surfaces and in injection holes, but MIL-S-8802 is used for leak and sealant repairs for parts in place. The two sealing materials are very compatible and their use together or, in an emergency, one in place of the other will cause little or no difficulty. MIL-S8802 has better fuel resistance and, for this reason, it is best to use this on all surfaces that are exposed to fuel. The MIL-C-83019 topcoat is then applied over all new sealant to prevent degradation by the fuel. A polyurethane (MIL-C-27725) coating is applied to the inside of wing panels and to other aluminum parts used inside the tank prior to sealing starting with airplane 5046. Because of inferior intercoat adhesion after fuel aging, repairs to damaged or deteriorated MIL-C-27725 are not made with this same material. Here a coating of MIL-S-81733 sealant is used in the exposed area with a MILC-83019 topcoat because more weight is given to the corrosion protection provided than to the inferior fuel resistance. Special attention should be given to assure a good topcoat when this is done. It should be noted that MIL-C-27725 is used only to coat parts before installation. It is never applied to surfaces inside the tank after installation. All applications of sealant should be preceded with the application of an adhesion promoter as indicated. The use of a tack free time accelerator is not recommended. Cleanliness cannot be overemphasized. a. Observe all of the safety precautions contained in Section 12.1 and paragraph 28.2.1.4 of this chapter.

Do not use metal or plexiglass scrapers. Use only tools fabricated from micarta, wood, or phenolic materials. 2. Remove the corrosion protective coating of Buna-N or MIL-C-83019, as necessary, so reapplication of sealant will not be made over the old coating. Buna-N may be removed with cloths dampened with TT-M268 Methylisobutylketone (MIBK). The softened Buna-N must be scraped off with a phenolic tool. Remove residual Buna-N with clean rags dampened with MIBK and wipe dry. MIL-C-83019 topcoat is removed by scraping and abrading with care not to damage any tank structure. Never apply sealant on Buna-N or MIL-C-83019 topcoat. Sealant must be applied only to adhesion promoter covered, solvent cleaned bare or MIL-C-27725 coated metal.

WARNING
Exercise extreme care; some of the following solvents are flammable. Provide adequate ventilation. Avoid skin contact and prolonged breathing of vapors. 3. Thoroughly clean the area to be sealed using one of the following solvents: (a) Aliphatic naphtha TT-N-95 (b) Trichloroethane O-T-620 (Alt. Degreaser MIL-T-81533) (c) Methylethylketone (MEK) TT-M-00261 (d) Methylisobutylkeytone (MIBK) TT-M268 (e) Dry cleaning solvent P-D-680, Type II (f) High flash Stoddard solvent P-S-661 Apply the fluid with clean cellulose sponges and wipe dry immediately with clean, dry cellulose sponge. On airplanes 5046 and up and those airplanes that have Service Bulletin 329-168 incorporated, areas to be sealed after thorough

28-30

Changed 31 May 2005

SMR 151

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59.1.19.6 (Cont) . bushings. Use instructions in this section as necessary to determine the material and strength of the original bushing. Where bushing alignment is critical, line-ream the bushing blank after installation. Surface finish should be 40 micro-inches at movable or rotating connections. Duplicate shoulders and oil grooves in replacement bushings, when such are provided in original bushings. The ends of a shoulderless bushing must not extend beyond the surface of the fitting; no end thrust on this type bushing is permissible. b. The three methods for bushing installation are listed according to preference: the arbor press, the drawn-in, and the vise methods. The arbor press method is most desirable because it provides greater control of the driving force with less danger of damaging the bushing or assembly. Note Installation of bushings by any of the three methods can be facilitated by cooling the bushing. Do not apply heat to the assembly unless approved by the aircraft manufacturer. c. The arbor press method for installing bushings is accomplished as follows: 1. Place the assembly on an arbor press, and center the hole which is to receive the bushing over the press bed. 2. Place the chamfered edge of the bushing in the hole in the assembly. Carefully align the bushing with the sides of the hole so that when driving pressure is applied, the bushing will be squarely started into the hole. 3. Place a mandrel or other installing device in the new bushing. 4. Operate the actuating lever of the arbor press to bring the ram down against the mandrel. 5. Hold the assembly firmly in place on the press bed, and with a steady pull on the actuating lever, press the bushing into place. 6. Release pressure and remove the mandrel. d. The draw-in method for installing bushings is accomplished as follows: 1. Use a puller or pusher arrangement comparable to that shown in figure 59-21. 2. If a puller or pusher is not available, use a combination of stud or bolt, with appropriate size washers and nut, and tighten with a wrench. Align the bushing with the sides of the hole.

e. The vise method for installing bushings is accomplished as follows: 1. Perform steps (1), (2), and (3) of paragraph c, using a machinist's vise instead of an arbor press. Note Due to the limited opening of the jaws of most machinists vises, the mandrel must be relatively shorter or must be eliminated entirely. The shape of the part will regulate the use of the mandrel. To prevent damage to the part or to the bushing, it is preferable to use jaw pads of soft material. Be sure the bushing is started in an aligned position or damage to the bushing and assembly will result. 2. Operate the handle of the vise until the bushing is pressed into place. 3. Open the vise and remove the part. 59.1.20 REPLACEMENT ITEMS. Cotter pins and lockwire are not to be reused; they should be replaced whenever a component is disassembled. All fasteners, pins, and parts damaged beyond repair or rework will be replaced with like components of the same or comparable material and heat-treat specification. When any component is replaced, all clearances and tolerances must be checked for conformance to the original part or to the design value. Note Do not reuse lockbolt fasteners. Undamaged HiLock pins may be reused with new collars. 59.1.21 EPOXY INSTALLATION OF BEARINGS. a. The journal ID where the bearing is to be bonded shall be 0.001 to 0.005 inch larger than the OD of the bearing. b. Surfaces to be bonded will be lightly sanded with 220 to 280 grit sandpaper and cleaned with methylethylketone (MEK). Cleaning of pre-lubricated bearings will be done with care to prevent the cleaner from entering the lubricated area of the bearing. Cleaned areas will be handled with clean, cloth gloves rather than with bare hands. c. Mix and handle 3-M Corp., EC 3569, epoxy adhesive (Alt BF Goodrich 1177, EA9309.1) in accordance with the manufacturer's instructions, observing limits on work life and storage. d. Apply adhesive to outer bearing surface and to housing bore as shown in figure 59-22. e. Allow adhesive to cure in accordance manufacturer's recommendations. with

SMR 151

Changed 31 May 2005

59-21/59-22