2A753 Volume 3 Structural Maintenance Journeyman

Technical orders provide specifications and guidelines for various processes and procedures, including the use of mechanical-lock blind rivets. These orders outline the requirements for gaps between the rivet and the surface, ensuring that they meet specific standards and regulations. Therefore, technical orders would be the appropriate source to determine the permissible gaps between a mechanical-lock blind rivet and the surface.

A torch is not a suitable tool for cutting cables because it uses an open flame, which can cause damage to the cable insulation and potentially lead to a fire hazard. A cold chisel is a tool used for cutting and shaping metal, not cables. A cable swager is used for crimping and securing cable ends, not cutting them. A cutting machine, specifically designed for cutting cables, would be the most appropriate tool for this task.

To remove foreign material from inside a completed tubing assembly, flushing with a technical order (TO) approved solvent is the recommended method. This solvent is specifically approved by the TO, ensuring its compatibility with the tubing material and effectiveness in removing foreign substances. Flushing with water or immersion in water may not be sufficient to completely remove the foreign material, while blowing with compressed air only may not effectively dislodge or clean the tubing. Therefore, using a TO-approved solvent through flushing is the most appropriate method for removing foreign material from the tubing assembly.

The wing nut is used in assemblies that are frequently removed because it allows for easy tightening and loosening by hand. Its design with two large wings on opposite sides provides a larger surface area for gripping, allowing for quick and convenient adjustments without the need for tools. This makes it ideal for applications where the assembly needs to be frequently disassembled and reassembled.

To avoid stripping threads when installing a nut and bolt, it is important to torque the nut to proper specifications. Torque refers to the amount of force applied to tighten the nut and bolt. If the nut is not tightened enough, it may become loose and cause the threads to strip. On the other hand, if the nut is overtightened, it can also damage the threads. Therefore, following the recommended torque specifications ensures that the nut is tightened to the appropriate level, reducing the risk of thread stripping.

The fastener removal tool is primarily designed for use on a flat surface because it requires a stable and even surface to effectively remove fasteners. A flat surface ensures that the tool can be applied with equal pressure and prevents any potential damage or slipping that may occur on uneven or curved surfaces.

The correct answer is "Never" because reswaging a Dynatube swage is never permissible. This means that once a swage has been applied to a fitting, it should not be adjusted or reworked in any way. This is likely because reswaging could compromise the integrity and strength of the swage, potentially leading to failure or leaks in the system.

When a tube bender is not available, sand can be used as a method to bend a piece of tubing. This technique involves filling the tubing with sand and then heating it. The heated tubing can then be bent manually into the desired shape. The sand helps to prevent the tubing from collapsing or kinking during the bending process. This method is commonly used in situations where a tube bender is not accessible or for bending larger diameter tubing.

When all bolt hole locations are equally spaced around an opening, the nut style that is typically used is called a channel. A channel nut has a long, rectangular shape with threaded holes along its length. It is designed to fit into a channel or track and can be easily adjusted and positioned to align with the bolt holes. This allows for a secure and evenly distributed connection between the nut and the bolts.

A drill bushing fixture is not required to remove a tight Jo-bolt fastener. A punch is used to drive out pins or dislodge stuck fasteners, a hammer is used to provide impact force, and a pilot drill is used to create a small hole as a guide for drilling. However, a drill bushing fixture is not necessary for removing a tight Jo-bolt fastener as it is used to hold the drill in place and provide accuracy when drilling holes.

When a cable has a kinked area that has been straightened, it is important to repair or replace it. Straightening a kinked area can cause damage to the cable, such as broken wires or weakened insulation. This damage can lead to potential failures or malfunctions in the cable, which can be hazardous. Therefore, it is necessary to address the issue by repairing or replacing the cable to ensure its proper functioning and safety.

The correct answer is Nonmetallic insert. Nonmetallic inserts are used as a prevailing torque, self-locking nut locking device to provide resistance against loosening due to vibration or thermal expansion. These inserts are made of materials such as nylon or plastic, which have low thermal conductivity and can withstand high temperatures. They create friction between the nut and the bolt, preventing the nut from rotating and maintaining the desired level of torque. This ensures that the nut remains securely locked in place, even in high-heat environments where metal inserts may fail.

When a nut plate is clamped too loosely during installation, it can cause misalignment. The nut plate needs to be securely fastened in order to properly align with the pull-through blind rivets. If it is not clamped tightly enough, it can move or shift, resulting in misalignment. Therefore, the probable cause for the misalignment in this scenario is that the nut plate was clamped too loosely during installation.

Blue designates aluminum alloy Air Force-Navy (AN) and Military Specification (MS) fittings.

To prevent thick-wall aluminum tubing from slipping in the clamp block of the production tube bender, a piece of emery cloth can be placed between the tubing and the clamp block. The rough texture of the emery cloth provides friction, which helps to increase the grip between the tubing and the clamp block, preventing slippage. This ensures that the tubing remains securely in place during the bending process.

The probable cause of more inside chamfer on one side of a piece of tubing and more outside chamfer on the opposite side is misalignment between the spindle and vise jaw.

An inspection gage is used to inspect the ring position of a swaged Permalite (Deutschlite) fitting. This tool is specifically designed for this purpose and allows for accurate measurement and evaluation of the ring position. Using an inspection gage ensures that the fitting is properly swaged and meets the required specifications. It is the most suitable option among the given choices for this particular task.

Vinyl-coated is not a type of aircraft cable because aircraft cables are typically made of steel or stainless steel. The coating on aircraft cables is usually nylon, which provides additional protection against corrosion and abrasion. Vinyl coating is not commonly used for aircraft cables as it may not provide the same level of durability and protection as nylon coating.

Tubing flares need to be square and concentric in order to seat properly. The square shape ensures a tight fit between the flare and the corresponding fitting, preventing any leaks or disconnections. The concentricity ensures that the flare is aligned perfectly with the fitting, allowing for a secure and reliable connection.

Clamping all repair members in place is the correct answer because it ensures that the pieces being drilled are securely held together. This prevents any movement or misalignment during the drilling process, resulting in proper hole alignment. Using a reamer to upsize the hole, holding the drill at a right angle to the surface, and pilot drilling holes through all mating surfaces may be important steps in the drilling process, but they do not specifically address maintaining proper hole alignment.

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Cold-working hole expansion is a process that involves enlarging a hole by compressing the material around it. This compressive force helps to improve the fatigue strength of the hole, making it less prone to premature fatigue failure. By cold-working the hole, the material is strengthened and any potential stress concentrations or defects are mitigated, reducing the likelihood of fatigue failure. Therefore, cold-working hole expansion is used as a preventive measure against premature fatigue failure.

The first step in riveting parts together is to secure the parts to prevent slippage. This is important because if the parts are not properly secured, they may move or shift during the riveting process, resulting in misalignment or improper joining of the parts. By securing the parts, you ensure that they are held firmly in place, allowing for accurate and effective riveting.

When a rigid type camloc receptacle needs to be replaced, it should be replaced with a floating receptacle. This is because a floating receptacle allows for slight movement or misalignment between the mating parts, providing flexibility. This flexibility helps to prevent stress and damage to the fastener assembly and ensures proper functioning of the camloc mechanism. Replacing it with a rigid receptacle or a retaining receptacle may result in limited movement or misalignment issues, leading to potential damage or failure of the fastener assembly. Replacing the entire camloc fastener assembly may not be necessary if only the receptacle needs to be replaced.

Piloting the hole and using a reamer to finish is the correct method for drilling an interference fit hole for a fastener. This process involves first drilling a smaller pilot hole to guide the larger reamer. The reamer is then used to enlarge and smooth out the hole to the desired size and finish. This method ensures accuracy and precision in creating an interference fit, where the fastener is tightly secured in the hole without any gaps or play. Using only a reamer or only a drill bit may not provide the same level of precision and control in achieving the desired fit.

When substituting a corrosion resistant steel (CRES) cable for a carbon steel cable, the frequency of inspection is reduced to one-half the time of normal inspection. This is because CRES cables are more resistant to corrosion, which means they are less likely to deteriorate or require maintenance compared to carbon steel cables. Therefore, inspections can be done less frequently while still ensuring the cable's integrity and safety.

6061-T is the correct answer for repairing a hydraulic system that carries high pressures up to 3,000 psi. This type of aluminum alloy tubing is known for its high strength and excellent corrosion resistance, making it suitable for applications involving high pressure. The "T" in 6061-T indicates that the tubing has undergone heat treatment to further enhance its mechanical properties.

Excessive burrs while cutting tubing with a tube cutter can be caused by applying too much pressure on the cutting wheel at one time. When excessive pressure is applied, it can cause the cutting wheel to dig into the tubing, creating rough and uneven edges, resulting in burrs. Applying too little pressure may not effectively cut through the tubing, but it is unlikely to cause excessive burrs. The direction of rotation (clockwise or counterclockwise) is not mentioned as a factor that would cause excessive burrs.

To remove the tubing after making a flare with the double-flaring machine, you need to first move the operating lever to the no. 1 position. This likely disengages the mechanism that holds the tubing in place. Then, you push the lever toward the rear of the machine, which likely releases the tubing from the flaring tool. This sequence of steps ensures that the tubing is safely and effectively removed from the machine without causing any damage or compromising the flare that was created.

When cold working a hole, a combination gage is used to verify the hole before and after it has been cold-worked. A combination gage typically consists of a go/no-go gauge, which is used to check the size and shape of the hole, and a depth gauge, which is used to measure the depth of the hole. By using a combination gage, the operator can ensure that the hole meets the required specifications both before and after the cold working process.

Corrosion-resistant steel is used when the temperature of a certain area of the aircraft exceeds 750°F. This material composition is chosen because it can withstand high temperatures without losing its structural integrity and is also resistant to corrosion, which is important for maintaining the safety and longevity of the aircraft.

By using a washer-nut assembly on a taper-lok pin, you can eliminate the problem of washer fumbling. This means that the washer will not move or slip out of place during the assembly process or while in use. The washer will remain securely in position, ensuring proper alignment and preventing any potential issues that may arise from the washer becoming loose or dislodged.

A drill-bushing is not a procedure for drilling a mechanical-lock blind rivet hole. Drill-bushings are used to guide the drill bit and ensure accurate hole placement, but they are not specifically mentioned as a procedure for drilling a blind rivet hole. The other options, such as holding the drill 90 degrees to the surface, using the specified drill bit, and avoiding unnecessary pressure, are all valid procedures for drilling a blind rivet hole.

To properly pull-test a cable, it is necessary to keep the cable under tension for three minutes. This duration allows for a thorough evaluation of the cable's strength and durability. A shorter time may not provide enough stress on the cable to accurately assess its performance, while a longer time may lead to unnecessary strain or potential damage. Therefore, three minutes is considered an appropriate timeframe for conducting a pull-test on a cable.

The correct answer is 8,000 - 8,500 pounds per square inch gauge. When installing a fitting using the Rynglok© tooling, it is recommended to apply hydraulic pressure within this range. This amount of pressure ensures a secure and tight connection between the fitting and the hydraulic system, minimizing the risk of leaks or failures.

To properly locate the start point on a piece of tubing that will have only one bend, you estimate the amount of tubing needed to make the bend, plus additional material for the flare. This means that you calculate the length of tubing required to create the bend, taking into account the additional length needed for the flare at the end. By doing this estimation, you can ensure that you have enough tubing to complete the bend without running short.

6061-T6 aluminum alloy tubing is the appropriate replacement for 5052-0 aluminum alloy tubing when installing military specification fittings. This is because 6061-T6 has higher strength and better corrosion resistance compared to 5052-0. Additionally, 6061-T6 has good formability and weldability, making it a suitable choice for military applications where durability and reliability are crucial.

The correct answer is cross-pin because a cross-pin is a type of fastener that is designed to be permanently installed and not intended for reuse. Unlike other parts of an airlock assembly such as grommets, rigid receptacles, and floating receptacles, a cross-pin is not meant to be removed or replaced once it has been installed. Therefore, it is the only part that is never reused in an airlock assembly.

After installing pull-type lock bolts, the last step is to apply a corrosion preventative compound to the stem break off area. This is important to protect the bolt from corrosion, which can weaken its strength and durability over time. By applying the compound, it creates a barrier that prevents moisture and other corrosive elements from reaching the break off area of the bolt, ensuring its long-term performance and reliability.

The best results for Jo-bolt holes can be achieved by initially drilling them slightly undersized and then bringing them up to the final size by reaming. This process allows for precise control over the size of the hole and ensures a proper fit for the sleeve in steel structures. By starting with a slightly smaller hole and then enlarging it with reaming, any potential errors or deviations can be corrected, resulting in a more accurate and secure fit.

The correct answer is prevailing torque and free spinning. Prevailing torque nuts are designed to provide resistance to loosening caused by vibration or other external forces. They have a built-in mechanism that increases the friction between the nut and the bolt, ensuring that it stays securely in place. Free spinning nuts, on the other hand, allow for easy installation and removal without any resistance or friction. They are commonly used in applications where frequent disassembly is required.

Dynatube expanders designed for titanium are identified by stop collars painted yellow. This means that if a Dynatube expander has a yellow stop collar, it is specifically designed for use with titanium materials. The color coding helps to ensure that the correct expander is used for the intended material, in this case, titanium.

A bell-crank unit is mainly used to change the direction of a cable. It consists of two arms connected at a pivot point, with the cable attached to one arm and the force applied to the other arm. When the force is applied to the second arm, it causes the cable to change direction. This makes the bell-crank unit an essential accessory for changing the direction of a cable in various applications.

A mandrel is not used to preset a military specification sleeve onto a piece of tubing. A mandrel is a tool used for shaping or supporting a hollow tube during manufacturing processes. In this context, a sleeve is typically installed onto a piece of tubing using a jaw nut, wrench, or other similar tools. A mandrel is not involved in this specific process.

The alignment mark is not an inspection requirement for a Wiggins fitting. The other three options are all important inspection requirements. Ensuring that the ferrule is tight on the tube ensures a secure connection, while ensuring that the ferrule is square on the tube helps to prevent leaks. Checking that the sealing surface has not been disturbed is important for maintaining the effectiveness of the fitting. However, the presence or visibility of an alignment mark is not essential for the functioning of the fitting.

The Rynglok fitting can be positioned anywhere along the length of the positioning mark on the tube before swaging. This means that there is flexibility in where the fitting can be placed, as long as it is within the boundaries of the positioning mark. This allows for ease of installation and ensures a secure connection between the fitting and the tube.

The height requirement for newly formed solid rivet shop heads is ½ of the rivet's diameter, while the diameter requirement is 1½ times the rivet's diameter.

A cylindrical steel rod is commonly referred to as a wire. Wire is a term used to describe a thin, flexible, and cylindrical piece of metal, such as steel, that is often used for various purposes, including electrical conductors, fencing, and structural support.

To install Composi-Lok II fasteners, two nose assemblies are required. This means that for each diameter of the fastener, a separate nose assembly is needed. Therefore, to properly install the fasteners, two nose assemblies are necessary.

The correct answer is 20 percent of the tube diameter. This means that for a dent on a tubing assembly to be considered objectionable, it should be equal to or greater than 20 percent of the tube diameter.