120. Intermediate Level (I-Level) Avionics Fundamentals

120. I Level AvionicsPage 1 of 7

120. INTERMEDIATE LEVEL (I-LEVEL) AVIONICS FUNDAMENTALS

References:

[a] Local Directives and Standard Operating Procedures

[b] NAVAIR 17-15BAD-1, Naval Aircraft and Naval Aircraft Support Equipment

StorageBatteries

[c] OPNAVINST 4790.2H, Naval Aviation Maintenance Program (NAMP), Vol. I

[d] OPNAVINST 4790.2H, Naval Aviation Maintenance Program (NAMP), Vol. V

[e] NAVAIR 01-1A-23, Standard Maintenance Practices Miniature/Microminiature

(2M)Electronic Assembly Repair

[f] NAVAIR 17-35QAL-15, Naval Aircraft Carrier METCAL Program Manual

[g] NAVAIR 00-25-100, Naval Air Systems Command Technical Manual Program

.1 Discuss two-person integrity for avionics maintenance. [ref. a]

Self Explanatory

In case of electric shock or any emergency, the other person should be able to rescue the maintainer.

.3 Discuss the facilities requirements for a battery repair shop. [ref. b, app. D]

* AIRCRAFT STORAGE BATTERY SERVICING FACILITIES ASHORE.

1. Dedicated Battery Servicing Facility. The United Facilities Criteria Design Manual for General MaintenanceFacilities UFC 4-229-01N (formerly NAVFAC DM-28.4), shall be followed when establishing and maintaining a shorebased dedicated aircraft storage battery servicing facility (battery shop).

a. A storage battery servicing facility includes the space and necessary equipment for servicing, repairing, charging,discharging, and testing storage batteries used in naval aircraft and naval aircraft support equipment. Thefacilities are typically managed by the Avionics Division (Work Center 600) or by the Support EquipmentDivision (Work Center 900) of an Aircraft Intermediate Maintenance Department or by the Electrical Branch ofa Naval Aviation Depot.

b. Due to the incompatibilities existing between the electrolyte systems in lead-acid and alkaline storage batteries,separate battery shop facilities shall be provided to service vented lead-acid batteries and vented alkalinebatteries. An explosive hazard does not exist but if the electrolytes are mixed, they will neutralize andcontaminate each other. Tools and equipment should be color-coded and battery servicing materials should besegregated to help ensure that they will remain in the designated servicing facility and not be usedinterchangeably between the two battery systems.

2. Non-Dedicated Battery Servicing Facility. Sealed lead-acid storage batteries and sealed alkaline storagebatteries may be serviced together or separately in work spaces other than a dedicated battery servicing facilityprovided the following guidelines are followed:

a. The batteries shall be serviced on automatic type battery chargers and analyzers vice non-automatic type batterychargers and analyzers unless directed by other authority.

b. The workspace air temperature shall be maintained at 77.5°F (±7.5°F).

c. Fire extinguishing equipment shall be available within the work space.

d. Emergency eyewash equipment shall be available within the work space. Portable types are acceptable for use.

e. Splash-proof chemical goggles shall be worn when within an arms length of a battery being charged ordischarged.

f. Some type of a sign reading 'SEALED BATTERY SERVICING AREA' shall be posted where it is highly visibleclose to the charger.

g. Color coding of the walls is not required.

h. A suitable neutralizing agent must be kept in this area.

* AIRCRAFT STORAGE BATTERY SERVICING FACILITIES AFLOAT.

1. Aviation Ships And Amphibious Assault Aviation Ships Battery Servicing Facilities. The storage batteryservicing facilities aboard aviation ships and amphibious assault aviation ships shall be as established by the GeneralSpecifications for Ships of the U.S. Navy and other requirements established by the Naval Air Engineering Center(NAVAIRENGCEN), Lakehurst, New Jersey.

2. Air Capable Ship Alkaline Battery Servicing Facility. The alkaline storage battery servicing facility aboardair capable ships shall be established per the requirements of the General Specifications for Ships of the U.S. Navy andother requirements established by NAVAIRENGCEN Air Capable Ship Aviation Facilities Bulletin Number 1F, orsubsequent bulletins.

a. Intermediate level maintenance performed on alkaline components necessary for electrolyte adjustment (cover,filler caps). Batteries declared beyond the capability of maintenance shall be sent to an alkaline battery servicingfacility aboard an aviation ship, amphibious assault aviation ship, or a shore station for testing and repair orcondemnation as required.

b. The following are the minimum requirements for an alkaline storage battery servicing facility aboard an aircapable ship.

(1) A vented alkaline battery servicing facility shall not be located near any vented lead-acid battery servicingfacility.

(2) Shelves shall be provided to hold the battery charger, the battery analyzer (if separate), and the batteries beingserviced.

(3) One MIL-B-2726/66 electrical receptacle shall be located near the shelves. This receptacle shall provide 1.7kilovolt amperes of 115-volt, single-phase, 60-Hertz, Type 1 power conforming to DOD-STD-1399 (Navy),Section 300.

(4) Stowage space shall be provided to hold one spare battery for each aircraft assigned to the ship.

(5) Ducted ventilation shall be installed as to flow through the battery charging, analyzing, and stowage area(s).

Temperature controlled air is not required.

(6) Fresh water shall be provided to a deep sink.

(7) Permanently installed emergency eyewash equipment shall be available within the work space.

(8) Fire extinguishing equipment shall be available within the work space.

(9) The batteries shall be serviced on automatic type battery chargers and analyzers vice non-automatic typebattery chargers and analyzers unless directed by other authority.

3. Air Capable Ship Lead-Acid Battery Servicing Facility. The lead-acid storage battery servicing facilityaboard air capable ships shall be as established by the General Specifications for Ships of the U.S. Navy and otherrequirements established by NAVAIRENGCEN.

.4 State the purpose of the following test benches and identify which aircraft theysupport: [ref. a]

a. A/E 24T-218

b. A/E 24T 121CRALTS

c. A/E 37T-35OLD – CRALTS REPLACED IT

d. AN/AWM-23OLD(f-14) Weapon control sys intermediate shop TS for (AN/W69) F-14, TA3

e. AN/AWM-90Guide missile launcher TS LAU 114/A, LAU 115A, LAU116/A for AIM missile

f. AN/AWM-94Bomb Rack TS for BRU 32A

g. AN/ALM-88Countermeasure -> AN/ALQ-91

h. AN/ALM-133Obsolete F4AN/ALR-45

i. AN/ALM-139ECM TS

j. AN/APM-376RTBS E2C A/N APS-120 E-2 air

k. AN/APM-446I/ Depot radar test station

l. AN/APM-457/438T/s for S-3, P-3

m. AN/AQM-24BSonar test control H-60

n. AN/ARM-155TacanAN/ARN-84

o. AN/ARM-156Tacan Beacon simulator ARN-84, ARN103

p. AN/ARM-200Base test facility An/ARC-182 (v)

q. AN/ASM-175Elec. Module Test Console (EMTC) E-2C

r. AN/ASM-686IATS hornet

s. AN/SSM-9VTS video test station, S-3

t. AN/AAM-60obsolete IATS

u. AN/USM-403Obsolete Hybrid automated test sation

v. AN/USM-405instrument AV-8

w. AN/USM-429(V)1RADCOM EA-6B

x. AN/USM-449automated TS

x. AN/USM-458NEWTS (ALQ-126) honet classified

y. AN/USM-467WSTS Weapons system TS

z. AN/USM-484Obsolete HTS

aa. AN/USM- 629EOTs

ab. AN/USM-636CASS

ac. AN/USM-641Countermeasure Ts

ad. APR-39Chaff

ae. A/U24T-1(V)Wire TS

af. AVTR/CTVSCVRS TS

ag. EMATSElectrical mechanical automation

ah. GACT/GRADOLD F4, E2 Ts for AE

ai. LK0001 multitester

aj. PRC 2000 microminiature repair stationConsolidated to solder

ak. KA-99

al. KB-35

am. KS-87Old camera for F-4

an. KS-153old camera supports KS-87, F-14

ao. MA-2A/C generator Ts

ap. MXU-810/UOld Catseye NV6s – replace by AN/AVS-9

aq. MU-1107/UOld Memory device loader Ts F-4s

ar. Signal simulatorServo

as. TS-3846/ASM-608(V)IMUTS, HTS – internal navigation unit for F-18

at. TS-3895A/UVNight vision Ts

au. TTU-205G/EPitot station TS obsolete

.5 What is the purpose of the following ATE support assets: [ref. c, apps. A, C]

a. Interface device: Connect specific piece of equip to ATE

b. OTPS(OPERATIONAL TEST PROGRAM SET): The total grouping of test program sets required to test an avionics system on ATE. Operational Test Program set

c. Test program set(TPS): Items needed to test a unit on ATE. These items include electrical, mechanical, instructional, and logical decision elements. The TPS elements are test program, interconnection device, test program instruction, and supplementary data. Pre program series to isolate faults in gear

d. TBI (TEST BENCH INSTALLATION):WRA installed in a test bench harness/test set/test console which is required to simulate in a shipboard or shore-based maintenance shop, system, assembly, or component of the end article for the purpose of accomplishing all necessary operational and maintenance test and repair procedures.

120.6 Discuss the following elements of the Miniature/Microminiature Program:

a. Program manager [ref. d, ch. 23] shall:

(1) Provide 2M Program indoctrination and follow-on training.

(2) Be knowledgeable of NAVAIR SE-004-PQS-000, NAVAIR 01-1A-23, NAVAIR 17-15-99, NAVAIR 17-600-193-6-2, and this instruction.

(3) Ensure a PM program is in effect, and WorkCenter 69B and satellite 2M stations are maintained per NAVAIR 17-15-99 and NAVAIR 17-600-193-6-2 (as applicable).

(4) Ensure only NAVAIR 01-1A-23 authorized materials are used during 2M repair.

(5) Coordinate with the 2M Technician Recertifier to develop local training for certified personnel to practice 2M repair techniques not encountered during routine maintenance. NAVAIR SE-004-PQS-000 identifies tasks required for recertification. These tasks should be used as minimum requirements for training.

(6) Coordinate with the 2M Technician Recertifier to maintain a record of all 2M certified technicians. Forward approved 2M technician recertifications for inclusion in members’ service records.

(7) Ensure the command has adequate QA inspector expertise, for conducting 2M repair inspections, with at least the same skill level as the repair work being inspected. Because a large percentage of 2M repair is at the microminiature level, 2M CDIs should be microminiature certified.

(8) Ensure all 2M CDIs are familiar with specifications and standards, including projects not encountered during normal maintenance. CDIs shall demonstrate knowledge of 2M standards, procedures, and techniques and their relationship to repairs, QA, and reliability.

NOTE: The objective of 2M training is to ensure technicians retain full 2M skills and dexterity necessary to provide quality 2M. Training projects should be performed using non-RFI electronic assemblies. DRMO may be a source for 2M training material.

(9) Maintain a program file to include:

(a) Record of 2M training conducted (to include training and recertification).

(b) Listing of 2M qualified technicians, including name, rate, work center, certification level, next recertification date, and projected rotation date.

(d) Applicable POCs.

(e) Program related correspondence and message traffic.

(f) Applicable references or cross reference locator sheets.

(g) Record of inventoried 2M workstations per NAVAIR SE-004-PQS-000, Appendix F.

(10) Use CSEC information and reports to identify areas of concern and determine corrective action.

b. Certification/recertification requirements [ref. d, ch. 23]

1. Initial miniature certification will be granted upon completion of Miniature Electronics Repair course (Course A-100-0072).

2. Initial microminiature certification will be granted upon completion of Microminiature Electronics Repair course (Course A-100-0073) and the prerequisite Miniature Electronic Repair course (Course A-100- 0072).

3. Skill proficiency of 2M technicians shall be evaluated every 18 months using NAVAIR SE-004- PQS-000.

4. 2M Technician Recertifiers shall be recertified every 18 months per NAVAIR SE-004-PQS-000.

5. Activities without 2M Technician Recertifiers shall request such service from the nearest activity authorized to conduct 2M technician recertifications.

6. ACCs/TYCOMs will be consulted when 2M technician recertifications must be requested from off-station.

c. Special facility requirements and environmental controls [ref. e, WP 003]

* The requirements for 2M Repair Facilities are as follows:

a) ESD: All 2M work areas shall meet the requirements of WP004 00.

b) Cleanliness: Work areas and tools shall be maintained in a clean and orderly condition. There shall beno visible foreign material including dirt, chips, grease, silicones, flux residue, solder splatter, solder balls,insulation residue, and wire clippings at any 2M workstation. Containers of hand creams, ointments,perfumes, cosmetics, and other materials that are not essential to the rework/repair operation, excepthand creams approved and controlled for use in electronic areas, are prohibited at the 2M workstation.

c) Temperature and Humidity: The temperature should be maintained between 65oF (18ºC) and 80oF(27ºC), and the relative humidity should not exceed 70%.

d) Ventilation: Onboard naval ships, local exhaust ventilation (i.e., a fume extracting hood) is not requiredfor any 2M workstation. Questions concerning the adequacy of the ventilation of any specific 2M repairfacility should be directed to a local industrial hygienist or to the NavyEnvironmentalHealthCenter forreview.

e) Noise: The Navy Occupational Exposure Level for occupational exposure to noise is 84 dB(A) for an 8-hour time-weighted average in any 24-hour period when measured with a sound level meter thatconforms, at a minimum, to American National Standards Specification for Sound Level Meters, S1.4A-1985. Personnel are required to wear hearing protection devices where operations generate sound levelsgreater than 84 dB(A).

f) Lighting: Illumination at the surface of 2M workstations shall be 1000 lm/m2 (lumens per meter squared)minimum (93 foot-candles). The surface shall be defined as a circle, 8" in diameter, on the 2Mworkstation where the repair work is actually accomplished. The surface does not include the peripheralareas where the 2M Electronic Rework Power Unit, tool chest, or auxiliary equipment is placed. The lightmeasured can be any combination of ambient (overhead) and supplemental lighting as long as it is atleast the required 1000 lm/m2 minimum (93 foot-candles) at the surface. However, the supplementallighting source may be placed no closer than 8" above the surface to allow for sufficient room to work. Afully functioning fiber optic light source or a fully functioning high intensity light with proper bulbs (one spotand one flood type) will provide the minimum lighting level required.

g) Eyewash Station: Shore facilities shall meet eyewash station requirements in accordance withOPNAVINST 5100.23G, Chapter 1902. Shipboard facilities shall meet eyewash station requirements inaccordance with OPNAVINST 5100.19D, Volume I, Chapter B0508.

h) Habitat: Eating, drinking, use of tobacco products, and use of personal grooming items at a 2Mworkstation is prohibited.

* 2M WORKSTATION: A typical 2M workstation encompasses an area used to perform miniature andmicrominiature repair of electronic assemblies. The repair area is defined as that portion of the work surfacewhere repairs are performed. The requirements for 2M Workstations are as follows:

a) Physical Requirements. The 2M workstation must provide for technician comfort. The technician mustbe able to sit with their legs under the workbench to properly operate footswitches, which are on the deckor on a permanently installed stable platform. The workstation should have an easily cleanable surfacewith a secure and lockable area for tool storage. The repair area of the workstation should be a minimumof 24 inches (609.6 mm) deep by 30 inches (762 mm) wide. The repair area of the workstation should belight colored, burn resistant and must provide for ESD protection. The repair area will not have any itemsstored on it at any time, other than the equipment being repaired.

b) Electrical Requirements. There are no special requirements for the 2M workstation. Standard electricalsafety precautions should be observed. There should be a minimum of four 115 VAC, single phase, 60Hz, 15 amp outlets. Refer to WP 004 00, section 4.3.4 for information on ESD grounding requirements.

* Special Material Requirements: Additional special materials are listed in each work package. Whenstoring consumable materials, consideration shall be given to shelf life, flammability, and contamination of thematerial. All consumables such as flux, solvents, and solders must be labeled with type and expiration date.

.7 Discuss the following elements of a calibration lab:

a. Satellite production control [ref. d, ch. 19]

The FCA shall establish a PME/TAMS Production Control Work Center 67A. When the FCA has been transferred to a RegionalCalibrationCenter, the IMA will retain ProductionControlWorkCenter 67A and perform the same functions previously performed by the FCA.

b. Issue and receipts [ref. d, ch. 19]

The IMA is responsible for inventory control and calibration of equipment held for issue to O-level activities. A Meter card is used for inducting SE for calibration or authorized repairs. All calibration/repair data will be recorded on the METER Card (as appropriate). VIDs/ MAFs not required.

c. Electrical/electronic work center [ref. d, ch. 19]

Ensure proper handling, transportation, and storage of calibratable SE/PME/TAMS to preclude equipment damage. Protective measures shall include:

(a) ESD protective shielding material shall be used on all exposed electrical connectors for equipment requiring special ESD protection.

(b) Use tie down cords and padding, such as horse hair and bubble wrap, in sufficient quantity, to preclude damage during transportation.

(d) Properly trained vehicle drivers.

d. Physical/mechanical work center [ref. d, ch. 19]

Personnel from other ratings/MOS may perform physical/mechanical calibration actions, for example, Phase B and D, if properly trained, qualified, and documented through local professional training/OJT. Calibration work center supervisors, at a minimum, must provide final qualification verification for personnel using OJT as a qualification standard

e. Ship’s support of afloat calibration billets [ref. d, ch. 19]

1. Aircraft carriers have historically operated three separate calibration programs managed by the AIMD Officer, the Operations Officer, and either the Engineering or Reactor Officer. NAVAIR 17-35QAL-15 defines organization and responsibilities for the METCAL Program as they relate to the CV community.

2. Ensure military and civilian personnel performing calibration are graduates of approved calibration training courses. Navy personnel shall be from electronics technical ratings and possess one of the following NECs: 6673, 6718, or 1589. Marine Corps personnel must possess MOS 6492. The following are exceptions to these requirements:

(a) Personnel from other ratings/MOS may perform physical/mechanical calibration actions, for example, Phase B and D, if properly trained, qualified, and documented through local professional training/OJT. Calibration work center supervisors, at a minimum, must provide final qualification verification for personnel using OJT as a qualification standard.

(b) Activities supporting HTS will use NEC 6663 personnel to perform authorized in-place calibration of HTS equipment. NEC 6705 and MOS 6467 personnel support CASS calibration requirements.

f. Support of ship’s CRIS system [ref. f]

g. Repair documentation [ref. d, ch. 19]

Document all calibration and repair actions on a METER Card (OPNAV 4790/58) per OP43P6B. Ensure all aviation 3M elements in block 20 are completed. In addition to MEASURE documentation, document repair and calibration actions as follows:

1) Induct repair actions into NALCOMIS to facilitate parts procurement and aviation 3M reporting.

2) For calibration actions and repairs requiring no parts (Transaction Code 31), ensure all elements in block 20 are entered into aviation 3M via the MDBA/A.

h. Vendor publications [ref. g]

Created by LTJG KyungNho "TACO" Kim9/20/2018