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SMR151

JET

FAA APPROVEDHANDBOOK

OF

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HANDBOOK OF OPERATING AND

MAINTENANCE INSTRUCTIONS

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.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 indi-cated by miniature pointing hands.

Page No. Issue

Ti . 15 Dec 96tle ..................*A .. 31 May 05..................B 15 Dec 96 E.....................G 30 Dec 95

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N Nov 9318.................

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hru ii...................iii.... 1 Apr 68..................Iv Blank..................1 Apr 68Table of

Contents 1 .............20 Dec 91Table of

Contents 2 ............. 30 Oct 87*Table of

Contents 3

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Table ofContents 4 .............31 Aug 83

Table ofContents 5

Added................31 Aug 83Table of

Contents 6Added... Aug 83Blank.............

Introduction 1 Original

31..............Introduction 2 .............. Original

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5-8 B . 1 Feb 65lank Added..............35-11 . 1 Oct 88

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*59-21 .... 31 May 05..............*59-22 Bla .............. 1 May 05nk 3

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TABLE OF CONTENTS (Cont)

GROUP AIRFRAME SYSTEMS (Cont)

CHAPTER 30 ICE AND RAIN PROTECTION

Section 30.0 GeneralSection 30.1 Wing and Empennage De-Icing

System

Section 30.2 Windshield Anti-Icing SystemSection 30.3 Windshield Wiper System

Section 30.4 Pitot Tube and Static Port Anti-IcingSystem

Section 30.5 Windshield De-Fog SystemSection 30.6 Cabin Window De-Fog System

Section 30.7 Engine & Nacelle Ice Protection

CHAPTER 31 INSTRUMENTS

CHAPTER 32 LANDING GEAR

Section 32.0 Landing Gear and Landing Gear

Doors

Section 32.1 Emergency Gear Release System

(Airplanes 5001 through 5085)

Section 32.2 Landing Gear Indicating and

Warning System

Section 32.3 Brake and Anti-Skid Systems

Section 32.4 Nose Steering System

Section 32.5 Emergency Gear Release System

(Airplanes 5086 and up)

CHAPTER 33 LIGHTING

Section 33 0 Aircraft Lighting

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REVISIONS

Revisions to this handbook are issued to cover changes in the JetStar Models 1329-23A, 1329-23D, and 1329-23E, andimproved maintenance procedures. Each revision includes a list of effective pages. Check list to be sure your copy is upto date. Pages added by revision which fall within a chapter are identified as lettered suffixes of the original pagenumber preceding them, and should be inserted to follow the existing page of the same basic number. Pages added byrevision which fall at the end of a chapter are identified as continuing numbers of the existing page numbers, andshould beinserted 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 connectorsused primarily in the fire extinguishing system.These torque values should not be construed to supersede any special torque requirements that may be specifiedelsewhere 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 Hot Line: (864) 422-6265

Fax: (864) 422-2184

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SECTION 5.0

GENERAL

5.0.1 MANUFACTURER'S RECOMMENDATIONS.These inspections are Lockheed's recommendations tothe operator and are based on average operatingconditions. They have been derived to comply with thecurrent requirements of FAR Part 91, Subpart E, toserve as "a current inspection program recommended

by the manufacturer." The listing of an inspection heredoes not make it mandatory; however, it may beinvoked as mandatory by the FAA at the time theindividual operator files his program or at some latertime. Possible discrepant conditions in systems,components and areas have been defined in generalterms rather than by detail listing. These data shouldenable 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 aparticular inspection, the operator should becognizant of the information given in Section 5.6Overhaul and Replacement Schedule, and includerelevant items in his program to avoid unnecessaryduplication of maintenance work. Routine servicingand lubrication as specified in Chapter 12 can also bephased into an inspection work package where

5.0.2 OWNER/OPERATOR RESPONSIBILITIES.The JetStar owner/operator has the responsibility tomaintain the airplane in an airworthy condition,

including compliance with FAA FAR Part 39.Maintenance should be performed in accordance withFAA FAR Part 91, Subpart E, and any otherapplicable regulation. Refer to FAA FAR Part91.403, FAR Part 121.363, and FAR Part 135.413, asapplicable. The airplane should be maintained inaccordance with instructions in the HOMI and/orother applicable documents.

5.0.3 REPLACEMENT PARTS. Hi-Tech AeroSpares maintains a reasonably adequate stock of

parts for maintenance and repair of JetStars. SomeJetStar functional components are available fromholders of Parts Manufacturer Approval (PMA).Used and repaired parts and assemblies are availablefrom Hi-Tech Aero Spares and other sources. Thesupplier of new/used/surplus/spare JetStarcomponents should execute an FAA Form 8130-3,"A th i d R l C tifi t A l T " f

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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. Stowage box if fitted.

s. Hydraulic system accumulators and thrust reverseraccumulator. No. 1 and No. 2 system accumulators1700 PSI. Thrust reverser accumulator 1200 PSI.(Nitrogen or dry air.)

t. The following hydraulic system valves: Engine-driven pump inlet and outlet shut-off valves andrelief valves for system No. 1 and No. 2, speed brakeselector valve and thrust reverser selector valves.

u. De-icer distributor valve and the regulator andpressure relief valve.

v. Check reservoir of turbine fan assembly forwater contamination. By using syringe and tuberemove water as required and replace with oil

per instructions in Section 12.8, paragraph12.8.1.1.

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 looseor missing attachments.

o. Brake selector valve and steering selector valve.

p. Pressure l in es from the eme rgency exte nsionair bottle.

q. Aft side of FS 164 bulkhead structure.

r. Static lines and check drain point forcondensation.

s. Check insulation.

t. Visually inspect steering actuator for cracks, distortion, corrosion and hydraulic leakage.

5.3.11 MAIN LANDING GEAR WHEEL WELLS.

a. All landing gear components and all wheel com-ponents for evidence of damag e and obstruction.

b. All hydraulic and fuel lines.c. All cables and pulleys.

d. All landing gear doors and their hinge and attach-ment points for excessive wear.

e. Landing gear and landing gear door actuators.

f. Landing gear uplock mechanism for wear andcracks

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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 thrulongeron and frames.

f. Cabin pressurization pneumatic relay and filter,outflow valves, jet pump and jet pump pressure re-gulator and pneumatic relay. Clean outflow valves(nicotine on knife edges). Airplanes 5001 through5045: Located between FS 330 and FS 350 under

center aisle floor; Airplanes 5046 and up, and thoseincorporating Service Bulletin 329-61: Forwardface of FS 570 bulkhead.

g. Check alumina desiccant in cabin window de-misttubes.

h. Check installation of the flight station high limitthermostat and the flight station temperatureanticipator (over right-hand wheel well).

i. Pitch-trim relays.

j. Aileron tension regulator.k. All air-conditioning ducting.

1. Insulation and sound-proofing for moisture.

m. Check forward face of Fuselage Station 570 bulk-head structure.

I t bi i d f k ti i

temperature control box, low limit thermostat

(except on airplanes 5086 through 5092, and 5094

through 5096 not having Service Bulletin 329-234incorporated), cabin high limit thermostat, cabin

temperature anticipator and all of the systemvalves and ducting.

f. Refrigerator unit oil reservoir for need of ser-vicing. Check for corrosion on bottom of refrig-erator core.

g. Visual check of the electric motor-driven hydraulicpump and the hydraulic pressure transmitters.

h. Hydraulic reservoir pressure regulator.

i. Structural check of the underside of the shelf underthe vertical stabilizer between Fuselage Stations690 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 leftand 2 right) for detailed inspection includingstructural check.

b. Check side play in gear.

c. Upper trunnion mount.

d Check clearance of landing gear to overhead floor


A A C S C O S

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5.4.11 (Cont).

b. Landing gear selector valve and gear doors selectorvalve.

c. Fore and aft play in gear through shimmed upperattach bearings. (See paragraph 32.0.4.4.)

d. Uplock adjustment: Check landing gear uplock andlanding gear door (Reference: Section 32.0).

e. Play in side brace actuators.

f. Remove anti-skid generator and check for axle cor-rosion.

g. Wheel well box structure. On aircraft 5001 through5146 not modified by Service Bulletin 329-265, per-form the NDE inspection in paragraph 58.4.2. If de-fects are found, install the kit provided by ServiceBulletin 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 aJL1174 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. Thisinspection is not required on JL1174 cylinders.

j. At each third (3-year intervals) annual inspection,fluorescent penetrant inspect the shock strut internalsurfaces per sections 58.5.4.4 and 58.5.4.5. Refer to figure32-11 for packing instructions withemphasis on step 17.

g. Check all skins in jet blast areas for cracks.

h. Bonding jumpers - all control surfaces.

i. Structural check of empennage pivot fitting (JE24) atlower end of vertical stabilizer rear beam through theaccess panel. (See Figure 52-5, Item 24, C.)

5.4.13 WINGS.

a. Drop L.E. flaps for thorough inspection of wingL.E.

b. Wing front and rear beams for cracks, loose andmissing attachments, and evidence of fuel leakage.

c. All electrical wiring along front beam for evidenceof chafing.

d. L.E. and T.E. flap jackscrew actuators and sup-por t f itt ings.

e. L.E. and T.E. flap torque tubes for clearance tostructure and universal mechanisms for con-dition.

f. Remove wing tip: Check flux valve and end ribfor cracks.

g. Aileron trim tab position transmitter.

h. Aileron counterbalance weights for loose ormissing attachments.

i. Aileron push-pull rods and supports for binding,looseness and need of cleaning.

j Ch ec k fo r ex ce ss iv e pl ay in ai le ro ns an d L E

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5.5.2 (Cont).

d. Inspect the radome rollers, tracks, and latches fordamage.

e. Visually inspect all protruding antennas for dam-age.

f. Inspect the entire exterior surface of the airplanefor pitting, dents, holes and popped rivets.

g. If popped rivets are found in the exterior surface,also inspect the interior structure in the affectedarea for damaged attachments.

h. Inspect all leading edge de-icing boots for pinholes.

i. Inspect the fuel vents, drains and flame arrestorfor damage.

j. Inspect all bonding wires to ensure that they areintact.

k. Inspect all exterior lights for burned bulbs.

5.5.3 SPECIAL INSPECTION-AFTER OVERWEIGHTOR HARD LANDING.

5.5.3.1 Inspect all exterior skin and the areas speci-fied below for cracks, distortion, buckling, loose, da-maged or missing attachments, security of compo-nents, and evidence of fuel leakage. When conditionswarrant, refer to Chapter 58 for more detailed inspec-

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 fordamage. 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 emphasisaround 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 se-vere or if considerable damage is evident, it is recom-mended that all the NDE inspections referenced in pa-ragraphs 5.5.3.1. be accomplished and the followingadditional operations and inspections be performed.

a. Alignment and symmetry check. Refer to Section51.1.

b. Inspect both fuselage lower longerons fromfuselage station 490 to 600.

c. Inspect wing-to-fuselage attach bolts (40 places) perparagraph 58.2.2.

d. External tank forward and aft attach bolts and fit-

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A A C S C O S

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Note

The following inspection in step c is notrequired prior to 20,000 hours.

c. Inspect horizontal stabilizer center section aft lowerattachment in accordance with paragraph 58.3.8.

Note

The following inspection in step d is notrequired prior to 4,000 hours.

d. Inspect wing upper and lower panel to root ribattachment in accordance with paragraph 58.2.15.This inspection should be coordinated with theinspections in paragraph 5.5.8.

5.5.23 6,000 HOUR INSPECTIONS.

Note

The following inspections in steps a, b, c and dare not required prior to 12,000 hours.

a. Inspect wing panel to rear beam lower cap spanwisesplice in accordance with paragraph 58.2.12. Thisinspection should be coordinated with the inspect-tions in paragraph 5.5.8.

c. Inspect wing lower surface spanwise splices in

accordance with paragraph 58.2.11.

d. Inspect frame outer cap at aft engine nacelle mount,F.S. 608, in accordance with paragraph 58.4.11.

Note

The following inspections in steps e, f, gand h are not required prior to 24,000hours.

e. Inspect fuselage main frame to pressure skinattachment in accordance with paragraph 58.4.10.

f. Inspect emergency exit cutout upper corners inaccordance with paragraph 58.4.12.

g. Inspect upper 30-degree longeron attachment, F.S.483 to F.S. 496, in accordance with paragraph58.4.13.

h. Inspect top longeron splice in accordance with par-agraph 58.4.14.

5.5.24 2,500 HOUR, 5 YEARS MAXIMUM,INSPECTIONS.

R l di d d f t t l

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5.6.10 LANDING GEAR

PART NAME MANUFACTURER PART NUMBER T.B.O. NOTES CAT.

Nose Landing GearSteering Actuator

Menasco JL1500-3JL1500-20

JL1501-4

3 Yrs. A

ConsolidatedControls

141V9-8 3 Yrs. ANose Wheel SteeringValve

Bertea 50100-303 6000 Hrs. B

Nose Landing GearShock Strut

Menasco JL 1600-11 13000 Hrs. A

Nose Landing GearRetract Actuator

Menasco JL-1900-3 13000 Hrs. A

Main Landing GearShock Strut

Menasco JL 1100-5JL 1100-7

13000 Hrs.

Rovalco JL 1400-13 10000 Hrs.

Royal

Industries

JL 1400-13 13000 Hrs.

A

A

10000 Hrs.JL1400-9

JL1400-11 13000 Hrs.

13000 Hrs.

Main Landing GearSide Actuator

Menasco

JL1400-7

6000 Hrs.

A

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SECTION 5.7

CONTINUED AIRWORTHINESS

Contents Page

GENERAL........................................................................................... 5-37100/300-HOUR AND ANNUAL INSPECTIONS............................................................. 5-37SPECIAL INSPECTIONS................................................................................ 5-37AIRWORTHINESS DIRECTIVES........................................................................ 5-37INFORMATION ...................................................................................... 5-37LIFE 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 fre-quent inspection of structural components is required.

Inspection programs in this publication have been pre-pared 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

5.7.4 AIRWORTHINESS DIRECTIVES. FAA Air-

worthiness Directives (AD) should be complied with

promptly. Structural improvements are usuallydirected to lowering working stresses, and the sooner

they are made, the better they are to slow the onset ofcumulative damage to the original structure. In some

instances, this publication may require more frequentinspections than are specified in a particular AD. In

such cases, the more frequent inspections are necessary

for continued airworthiness.



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5.7.6 LIFE LIMITED COMPONENTS

FAA Airworthiness Limitations Instructions

Life Limited Components

Part Number Nomenclature Qty (Discard) HOMI Sec Ref

Chapter 32 Landing GearJL1955-3 Cylinder, Nose Landing Gear

Steering1 Discard

Use JL1955-732.4

JL1955-7 Cylinder, Nose Landing GearSteering

1 3600 Flights 32.4

Chapter 55 Stabilizers

JE24-2 Fitting, Empennage Pivot 1 DiscardUse JE24-6

55.1

JE24-4 Fitting, Empennage Pivot 1 Discard

Use JE24-6

55.1

JE24-6 Fitting, Empennage Pivot 1 No Life Limit 55.1

Chapter 57 Wings

MS20008-20 Bolt, Wing Attach, Upper 4 1900 Hrs 57-1



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5.7.6 LIFE LIMITED COMPONENTS (CONT)

FAA Airworthiness Limitations Instructions

Life Limited Components

Part Number Nomenclature Qty (Discard) HOMI Sec Ref

Chapter 57 Wings (Cont)

JW121-8L Fitting Actuator, T.E. InboardFlap

1 4024 Flights 57-1

JW121-8R Fitting Actuator, T.E. InboardFlap

1 4024 Flights 57-1

JW123-6L Fitting Actuator, T.E. OutboardFlap

1 4024 Flights 57-1

JW123-6R Fitting Actuator, T.E. OutboardFlap

1 4024 Flights 57-1

JW123-9L Fitting Actuator, T.E. OutboardFlap

1 4024 Flights 57-1

JW123-9R Fitting Actuator, T.E. OutboardFlap

1 4024 Flights 57-1

NAS630-24 Bolt, Pylon Attach 8 3125 Flights 57.7

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SECTION 9.0TOWING

Contents PageGENERAL................................................................................................... 9-3

NOSE GEAR TOWING........................................................................................... 9-3

MAIN GEAR TOWING ............................................................................................9-3TOWING PRECAUTIONS ...................................................................................... 9-3FIGURES

9-1. Towing Provisions.......................................................................... 9-59.0.1 GENERAL. Towing on a hard level surfaceis best accomplished with a nose gear towbar. Whenthe airplane is on soft ground, deep snow, or whentowing 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 thefront of the nose landing gear (figure 9-1A) provideattachment for a Lockheed 1000-MEU-2 towbar or aLockheed 11013-MEU towbar adapter kit. Alwaysdi t i h t i f th

9.0.4 TOWING PRECAUTIONS.

WARNINGFailure to observe any of these safety pre-cautions may result in damage to the airplaneor injury to personnel.

a Never tow the airplane while any of the engines



9 0 4 (Cont)

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9.0.4 (Cont).

c. When towing, wait until the airplane has started

moving before turning the nose gear. A largeforce is required to overcome the inertia of theairplane when it is standing still. This forcemight place dangerous side loads on the landinggear structure if a start is attempted while thenose wheel is at an angle.

d. Never tow the airplane faster than a slow walk.Avoid quick stops and starts.

e. Never tow the airplane near obstacles withouthaving someone walking at each wing tip and atthe empennage to guard against collision. Makesure an adequate system for relaying signals isunderstood by everyone involved in the operation.Use candle type signal lights at night.

f. Never allow anyone to enter or leave the airplaneor to ride on the outside of the airplane while it

is moving.

g. Never remove the chocks until ready to tow theairplane. Make sure the person in the flight stationis ready to operate the brakes and that brake

pressure is available. The normal (No. 1) hydraulicsystem must be selected by the switch on theinstrument panel.

h. When towing from the nose gear, disconnect

the nose gear scissors. Steering actuatordamage can occur if the nose gear scissors areleft connected and turning angle of 53 degrees isexceeded.

i. Check to see that landing gear downlocks havebeen installed. (See Chapter 32.)

Note

Scissors disconnect pin should be installedon RH side of nose gear as shown in View B,Figure 9-1.

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28.2.3.4 (Cont).

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 incompliance with Service Bulletin 329-168, toa polyurethane sealant topcoat (MIL-C-

83019).

Th b i l t d i th t k i MIL S 8802

b. CLEANING. After the source of the fuel leak isdetermined, clean away the old sealant beforethe new repair material is applied. The surfacesmust be thoroughly cleaned before applying anynew sealant. Oil and dirt from hands, hair, orother foreign substances will prevent the sealantfrom 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 removethe old sealant. Taper the edges of the filletseals back from the cleaned area at about a45-degree angle

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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 wetinstalled fasteners, and in confined areas. MIL-S-

8802 continues to be used for fillets, edge seals,and exposed fasteners. MIL-S-81733 should beused with new parts for fay surfaces and in

injection holes, but MIL-S-8802 is used for leakand sealant repairs for parts in place. The two

sealing materials are very compatible and their

use together or, in an emergency, one in place ofthe other will cause little or no difficulty. MIL-S-

8802 has better fuel resistance and, for thisreason, it is best to use this on all surfaces that are

exposed to fuel. The MIL-C-83019 topcoat is thenapplied over all new sealant to prevent

degradation by the fuel.

45-degree angle.

Do not use metal or plexiglass scrapers.Use only tools fabricated from micarta,wood, or phenolic materials.

2. Remove the corrosion protective coating ofBuna-N or MIL-C-83019, as necessary, soreapplication of sealant will not be madeover the old coating. Buna-N may beremoved with cloths dampened with TT-M-268 Methylisobutylketone (MIBK). Thesoftened Buna-N must be scraped off with a

phenoli c tool. Remove residual Buna-Nwith clean rags dampened with MIBK andwipe dry. MIL-C-83019 topcoat is removed

by scraping and abrading with care not to

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