\lthoughthewords "he," "him," and "his"
are used sparingly in this manual to enhance
communication, they are not intended to be
gender driven nor to affront or discriminate
against anyone reading Aircrew Survival
Equipmentman 3 & 2, Volume 1, NAVEDTRA
10328-1.
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
AIRCREW SURVIVAL
EQUIPMENT/WAN 3 & 2,
VOLUME 1
NAVEDTRA 10328-1
1982 Edition Prepared by
PRC Vernon L. Rising
PREFACE
This Rate Training Manual and Nonresident Career Course (RTM/NRCC)
is the first of two volumes which form a self-study package that enables am-
bitious Aircrew Survival Equipmentmen to help themselves fulfill the re-
quirements of their rating. Designed for individual study and not formal
classroom instruction, the RTM provides subject matter that relates directly
to the occupational standards for the PR3 and PR2. The NRCC provides the
usual method for satisfying the requirement for completing the RTM. The
set of assignments in the NRCC includes learning objectives and supporting
items designed to lead students through the RTM. The occupational standards
used as minimum guidelines in the preparation of this manual are found in
the Manual of Navy Enlisted Manpower and Personnel Classifications and
Occupational Standards, NAVPERS 18068-D.
Volume 1 introduces the aircrew survival equipmentman rating and
describes sewing and fabrication, aviators personal survival clothing and equip-
ment, helo rescue devices and carbon dioxide recharging equipment. Aircrew
Survival Equipmentman 3 & 2, Volume 2, NAVEDTRA 10329 describes ad-
ministration procedures, parachutes and associated components, liferafts and
preservers, the rigid seat survival kit, and aviator's breathing oxygen systems.
When complete, these two volumes will replace Aircrew Survival Equip-
mentman 3 & 2, NAVEDTRA 10358E.
This Rate Training Manual and Nonresident Career Course were prepared
by the Naval Education and Training Program Management Support
Activity, Pensacola, Florida, for the Chief of Naval Education and Training.
Revised 1982
Reprinted 1987
Stock Ordering No.
0502-LP-05 1-6605
Published by
NAVAL EDUCATION AND TRAINING PROGRAM
MANAGEMENT SUPPORT ACTIVITY
UNITED STATES
GOVERNMENT PRINTING OFFICE
WASHINGTON, D.C.: 1982
THE UNITED STATES NAVY
GUARDIAN OF OUR COUNTRY
The United States Navy is responsible for maintaining control of the
sea and is a ready force on watch at home and overseas, capable of
strong action to preserve the peace or of instant offensive action to
win in war.
It is upon the maintenance of this control that our country's glorious
future depends; the United States Navy exists to make it so.
WE SERVE WITH HONOR
Tradition, valor, and victory are the Navy's heritage from the past. To
these may be added dedication, discipline, and vigilance as the
watchwords of the present and the future.
At home or on distant stations we serve with pride, confident in the
respect of our country, our shipmates, and our families.
Our responsibilities sober us; our adversities strengthen us.
Service to God and Country is our special privilege. We serve with
honor.
THE FUTURE OF THE NAVY
The Navy will always employ new weapons, new techniques, and
greater power to protect and defend the United States on the sea,
under the sea, and in the air.
Now and in the future, control of the sea gives the United States her
greatest advantage for the maintenance of peace and for victory in
war.
Mobility, surprise, dispersal, and offensive power are the keynotes of
the new Navy. The roots of the Navy lie in a strong belief in the
future, in continued dedication to our tasks, and in reflection on our
heritage from the past.
Never have our opportunities and our responsibilities been greater.
u
CONTENTS
CHAPTER Page
1 . History of Parachutes 1-1
2. Aircrew Survival Equipmentman (PR) Rating 2-1
3 . Sewing Machines 3-1
4. Fabrication and Manufacture 4-1
5. Flight Clothing 5-1
6. Anti-G Garments 6-1
7. Anti-Exposure Assemblies 7-1
8. Integrated Torso Harnesses 8-1
9. Protective Helmets and Oxygen Masks 9-1
10. Survival Items 10-1
1 1 . Survival Radios and Beacons 11-1
12. Helicopter Rescue Devices 12-1
13. Carbon Dioxide 13-1
INDEX 1-1
Nonresident Career Course follows Index
in
CHAPTER 1
HISTORY OF PARACHUTES
The word "parachute" is, in the modern
sense, derived from the Italian word "parare",
meaning to protect or shield from, and the
French word "chute", meaning a fall or quick
descent literally, "to protect from a fall". As
early as 1300, Chinese experimenters are
reported to have jumped off the Great Wall with
devices resembling umbrellas. In the year 1495,
the great genius, artist, and inventor, Leonardo
da Vinci, sketched a parachute design to be
made of caulked linen that would permit a gentle
descent to earth. About a century later, Fausto
Veranzio described and sketched a parachute
design consisting of a four-poled square frame
covered with fabric which he claimed could be
used to escape from tall, burning buildings.
Since man, not yet airborne, had no use for a
lifesaving device of this nature at that time,
parachutes were considered novelties or items of
amusement, and interest in them gradually
lessened. It was not until the invention of the
first aerial balloon, that interest in the parachute
was renewed. As a result of the balloon, the
parachute became less of a toy and more a
means of escape.
In the late 1700's the Montgolfier brothers
had invented a balloon which would stay aloft.
This balloon was kept in the air by burning
bundles of straw beneath the bag to furnish the
necessary supply of hot air. If the fabric should
catch fire, the flight was abruptly ended thud!
This meant that those who went up on such
flights had to have a means of escape. Those
early days of ballooning saw excursions of
curiosity into the use of parachutes by early
balloonists such as the Montgolfiers, Blanchard,
Martyn, Arnold, Appleby, Hampton and
others. Some parachute drops, using animals as
passengers, were successfully made. The first
human parachute descent was accomplished by
the famous French balloonist Andre- Jacques
Garnerin, on October 22nd, 1797. This historic
event took place over Monceau Park, near
Paris, when Garnerin released himself and his
semi-rigid parachute from the balloon at an
altitude of 6,000 feet.
On July 14th, 1808, a famous Polish
balloonist, Jodaki Kuparento, was the first man
to have his life saved from a flaming bag of hot
air when, over Warsaw, remnants of his burning
balloon blew into the balloon's net structure and
blossomed into a parachute lowering him to the
ground safely. However, the need for a
foolproof parachute whose main role at that
time was its use as an added thrill to balloon
ascensions was not strong enough to stimulate
a great deal of inventive effort until nearly 100
years later. Hence, with the coming of the air
age in 1903, when the Wright brothers made
their spectacular flight at Kitty Hawk, North
Carolina, there came also an era of experimenta-
tion with parachutes designed for this new type
of flying machine.
Albert Berry is credited with being the first
person to successfully jump from an aircraft us-
ing a parachute. This jump was made on March
1st, 1912, from a Benoist Pusher Biplane, at Jef-
ferson Barracks, not far from Kinloch Park
"Aerodrome", St. Louis. The parachute was an
unbleached muslin cotton 'chute, 36 feet in
diameter. Its suspension lines terminated into a
trapeze bar and strap arrangement. The
parachute assembly was packed into a cone at-
tached under the airplane. It was retained within
the metal cone by a series of break-cords. The
weight of Berry's falling body pulled the canopy
and lines from the container. Many others, using
makeshift or experimental parachutes, made
1-1
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
descents before World War I, but parachutes
still were not considered essential equipment for
military aviators. As World War I progressed,
the resultant mortality rate among pilots was
very high. However, the lives of over 800
balloonist observers and artillery fire directors
were saved by parachutes, demonstrating a
desperate need for a foolproof and practical
lifesaving device for aviators. The next step was
to improve parachute reliability and make them
mandatory for military fliers.
Parachute lore tells us that in 1917 a French
pilot attacked a German Fokker and riddled it
with bullets. The plane exploded in flames and
began to plunge to earth. As the Frenchman
circled his kill, he was surprised to see the enemy
pilot jump, immediately followed by a ribbon of
white swing out behind him as he fell through
fVo ^i/MiHc Qtiii amoTpH Vi<a watrhpr^ as a great
opened. The
115 uuujr tMvsvwvi VVJLLAJ. . jerk and began
~,,ajni 5 gently beneath the air-filled blossom.
The adversary waved at the stunned victor and
proceeded to swing into No-Man's land, where
the reception was far from friendly. Twenty-
seven rifle and machine gun bullets were
pumped into the German's legs. He survived and
gained the honor of being the first person to save
his life by an emergency escape from an
airplane.
Official documentation reveals that regular
emergency bail-outs were made during the late
months of 1918 by German aviators. Captured
equipment showed the parachute to be a unique
one designed by Heineke. Gradually, German
fighter pilots began to equip themselves with
parachutes. Soon, whole squadrons were doing
the same. At the end of the war, it was reported
that all fliers in the entire German Air Force
were in the process of wearing parachutes in
flight.
All parachutes, however clever in design,
were still dependent upon a static line attached
to the aircraft to deploy the parachute, and they
were far from perfect. Thus, some emergency
escape attempts continued to take lives.
Towards the end of 1918, with the war coming
to a close, demands by the flying public and
Congress finally resulted in the formation of a
U.S. Air Service Parachute Board at McCook
Field in Dayton, Ohio. Floyd Smith, with a
reputation for his ideas in parachute design, was
put in charge of this new unit of the Engineering
Division. He surrounded himself with Guy M.
Ball, James M. Russel, James J. Higgins, and
Sgt. Ralph W. Bottreil. At the beginning of
1919, energetic Major E. L. Hoffman was
chosen as military head of this parachute
development team.
The * 'crash program" produced results.
Parachutes from all over the world, all attached
(static-line actuated) types, were tested and
found to be unsafe and weak, and otherwise un-
suitable for use in emergency jumps from
airplanes. Initial testing on a new parachute
design devised by Floyd Smith showed potential.
This concept involved the use of a parachute
canopy and lines packed into a container worn
on a body harness, using a manually operated
ripcord, yanked while falling freely through the
air with no attachment to the aircraft, to open
the parachute. Floyd Smith, with Guy Ball
working closely at his side, worked together to
perfect this new revolutionary parachute.
This parachute, ultimately became the U. S.
Air Service Airplane Parachute, Type "A". It
had a 28-foot diameter silk canopy with silk
suspension lines. The canopy was formed of 40
gores, with a novel shock-reducing vent design,
and it was packed into a back pack container
worn on the body of the flyer through being at-
tached to a webbing body harness. A small pilot-
chute was used to deploy the packed canopy and
lines into the air when a pull on the ripcord
opened the flaps on the back container. Being
worn on the body, and not dependent on any at-
tachment to the aircraft for operation, it allowed
the aviator to leave his disabled aircraft
regardless of its position. It was capable of
withstanding an opening shock delivered by 200
pounds falling at a speed of 400 miles per hour.
When it was felt by Major Hoffman that it
was time for the Model "A" parachute to be
live-jumped, he chose a young, enthusiastic
parachutist and designer by the name of Leslie
L. Irvin to do this because of his vast experience
as a parachute jumper. Irvin had responded to
the government's call for a suitable parachute,
and submitted a static-line operated parachute
assembly with a cotton canopy. He was apprised
that the submitted parachute was unsuitable, as
by that time the use of a silk canopy as well as
1-2
Chapter 1 HISTORY OF PARACHUTES
the ripcord-concept was considered preferable.
Irvin continued to cooperate with the board by
supplying parachute items. On April 28th, 1919,
flying in a USD-9 airplane piloted by Floyd
Smith at an altitude of 1 ,500 feet and airspeed of
80 miles per hour, Irvin jumped from its turret
cockpit wearing a prototype Model "A" 'chute.
He pulled the ripcord, the parachute opened in
one and two-fifth seconds, and he became the
first man to make a free-fall parachute jump
from an aircraft.
The new parachute was the first step on the
way to all modern personnel parachutes emer-
gency, military, and sporting. From this basic
design came the seat pack, chest or reserve
chutes, back packs, and any other parachute
which can be attached to a harness.
On October 1922, Lieutenant Harold R.
Harris, U.S. Army, was dramatically saved from
death by using a manually-operated parachute
when his aircraft failed. By March 1924, it
became mandatory for all Army and Navy air-
crew to wear the standard back-type parachute
while in flight. A sign in one of the parachute
lofts read, "Don't forget your parachute. If you
need it and you haven't got it, you'll never need
it again."
With the requirement for all Navy aviators to
wear parachutes, the necessity for trained per-
sonnel to pack and maintain these parachutes
became apparent. In June 1922, the Bureau of
Aeronautics requested volunteers from among
the petty officers attached to the various Naval
Air Stations to take a course of instruction in
parachutes at the Army School at Chanute
Field, Rantoul, Illinois. Thirteen chief petty of-
ficers were selected from throughout the Navy.
They completed the course of instruction and
returned to their duty stations. Three of them
were selected for further training at McCook
Field, Dayton, Ohio, at that time the Army
Equipment Experimental Depot. The three chief
petty officers received advanced training in
parachutes. In August 1923, Chief Alva Starr
and Chief Lyman Ford, two of the three, were
ordered to Lakehurst, New Jersey, to set up a
training course on parachutes. Although the
course was established, the PR Rate was not
established until 1942. In September 1924, Class
No. 1 was convened at the Parachute Material
School at Lakehurst to teach parachute rigging.
Although his name is now lost to history, one
of the farsighted founders of the PR school
decided on a novel means to help combat the air-
man's reluctance to "hit the silk". He reasoned
that if it became known that the men who
packed and repaired the parachutes had enough
confidence in their ability and equipment to
make a deliberate, premeditated jump, the
aviator might be more willing to take a chance
on his parachute than to crash in his airplane. In
the beginning, graduate trainees jumped from
the outer wing tips of a biplane flying high above
the Naval Air Station at Lakehurst. Later, the
students "let go" from short rope ladders
suspended from the sides of the old gondola air-
ships (blimps) and later still, from training and
patrol type lighter-than-air ships. Since the
beginning of the PR school in 1924 there have
been over 60,000 parachute jumps made at
Lakehurst, N.J.
With the coming of the jet age, the emer-
gency use of parachutes has become a highly
technical sequence, i.e., events in time order.
Today's emergency sequence for ejecting from a
disabled aircraft starts with the aircrewman
making a decision to leave his aircraft. After
making that decision everything is done
automatically, as you will see in the ejection se-
quence for the A-6 aircraft shown in figure 1-1.
This is only one of several types of ejection
systems used in modern naval aircraft. For ex-
ample, the ejection sequence of the Mk GRU-7
is:
(1) Initial Ejection
(2) Drogue Gun Fires
(3) Controller Drogue Deploys
(4) Stabilizer Drogue Deploys
(5) Main Parachute Deploys and a normal
parachute descent is made.
From the experimental devices of the early
Chinese through the seat ejection systems of to-
day, we can view the evolution of the parachute.
If we consider this development as a window
through which we can see solutions to the escape
problems of the fliers of the space shuttle or
other advanced craft, then this history is just the
end of the beginning.
1-3
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
219.267
Figure 1-1. Ejection Sequence.
1-4
CHAPTER 2
AIRCREW SURVIVAL EQUIPMENTMAN (PR) RATING
The PR rating was established in 1942 to help
meet World War II parachute survival re-
quirements. The original title of the rating was
Parachute Rigger. The rating title was changed
to its present Aircrew Survival Equipmentman
in December, 1965. The reason for changing the
title from Parachute Rigger to Aircrew Survival
Equipmentman was to provide a more realistic
description of the types of duties performed by
PRs. When founded in 1942, the PR rating con-
sisted only of the general service rating with
career progression from striker status through
PRC.
In February 1956, two emergency service
ratings were established in addition to the PR
general service rating the Parachute Rigger S
(Survivalman) and the Parachute Rigger M
(Maintenance). PR personnel were activated in
these two emergency service ratings at the E-4
level in April 1956. PRM3s were to maintain ox-
ygen systems and related equipment, while
PRS3s were to maintain parachutes, life rafts
and related survival equipment.
The PRS and PRM service ratings were ex-
tended in March 1957 to the E-5 level. This
resulted because advancement to the PR2
general service rate required that all personnel
responsible for packing parachutes complete a
parachute jump in a parachute that they had
packed. While this requirement posed no real
problem for PRS3s, it was not practical for the
PRM3s who did not handle parachutes.
The PRS and PRM service ratings were
disestablished at the E-6 and E-7 levels in June
1957, with the E-5 level being activated. The
qualifications for advancement for PRS2 and
PRM2 were made sufficiently similar so that all
PR personnel could achieve the general service
rate of PR1.
Finally, in November 1957, the PRS and
PRM service ratings were disestablished, with
the duties assigned to the PRM being transferred
to a new service rating of the Aviation Structural
Mechanic rating. This new service rating was
designated as Aviation Structural Mechanic E
(Safety Equipment). With disestablishment of
the PRM and PRS service ratings, there was
again just a single path of advancement from
striker status to PRC.
In March 1958, the Aviation Structural
Mechanic E service rating was established at the
E-4 and E-5 levels to assume the duties of the
PRM rating. The PRS rating simply merged into
the PR general rating. In accordance with the
Flaherty Board recommendations of 1957, the
general service rating of PR was redesignated as
a "general rating".
The PR's primary mission is the business of
saving lives, a mission equally important in
peace and in war. One generally thinks of
aviators as trusting their lives to the aircraft they
are flying. However, if for some reason the air-
craft becomes disabled, the aviator's probability
of survival would be small except for the
equipment that the PR provides for such an
emergency. With this equipment, the aviator
and crew are able to abandon their disabled air-
craft, parachute to safety and survive on land, at
sea, or even in the arctic wastelands.
This training volume presents detailed infor-
mation which is necessary in your preparation
for advancement. The Aircrew Survival Equip-
ment qualifications, which are used as a guide in
2-1
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
should study them for background information
and for a better understanding of the subject.
There are also Naval Air System Command
technical publications covering each piece of
equipment you are required to maintain. You
should always refer to the appropriate publica-
tion when working on survival equipment. You
do not need to know everything that is contained
in these publications, but you should know
where to find the necessary information such as,
the right publication for a specific piece of
equipment.
The NAVAIR 13-1-6 (Series) manual,
prepared by Naval Air Systems Command, pro-
vides detailed inspection and maintenance in-
structions. This manual consists of seven
separately bound volumes as listed below:
1. Inflatable Survival Equipment, NAVAIR
13-1-6.1
2. Parachutes, NAVAIR 13-1-6.2
3. Survival Kits and Items, NAVAIR
13-1-6.3
4. Oxygen Equipment, NAVAIR 13-1-6.4
5. Helicopter Rescue Equipment, NAVAIR
13-1-6.5
6. Ejection Seats, NAVAIR 13-1-6.6, (in
preparation)
7. Aircrew Personal Protective Equipment,
NAVAIR 13-1-6.7.
The purpose of each volume is to provide
technical information on the inspection and
maintenance of a particular category of aircrew
safety and survival equipment. Each volume
contains information intended for organiza-
tional, intermediate, or depot levels of
maintenance as defined within the Naval Avia-
tion Maintenance Program (NAMP). More in-
formation about this manual is covered in more
detail in another chapter of this volume.
WORK AREAS AND CONDITIONS
The parachute loft is the principle work area
designated for the maintenance of parachute
assemblies, systems, and components. Most
parachute lofts are located in a central location
near the operating area of the local organization
serviced. The parachute loft is large enough to
accommodate parachute packing tables 36
inches high, at least 36 inches wide, and long
enough to service the longest parachute
presently in service. Other related parachute
items may be necessary, and room for additional
shops, such as oxygen and survival gear, is
usually made available. Two general types of
parachute lofts currently in use are the shore-
based parachute loft and the shipboard
parachute loft. (See figures 2-2 and 2-3.).
All parachute lofts are equipped to perform
specific levels of maintenance procedures
(depending on equipment and personnel). These
lofts are manned by qualified Aircrew Survival
Equipmentmen.
PARACHUTE LOFT LAYOUT
Wet Locker
The wet locker is used for drying parachutes
after washing. It is separated from the dry locker
and provided with dehumidification and floor
water drains. In all other respects, it is con-
structed to the same requirements as the dry
locker.
Washroom
The washroom is used for cleaning
parachutes. It contains a large tub and a spin
drier. Hoist lines are installed over these units to
allow for parachute handling.
Dry Locker
The dry locker must have controlled en-
vironmental conditions. It is used for airing
parachutes during inspection, and must be high
enough to permit the parachutes to be hung full-
length without touching the walls, floor or other
parachutes. The dry locker must not have win-
dows or skylights. If sufficient height is not
available, the suspension lines are chained to
prevent entanglement. The harness and con-
tainer are to be placed on a smooth table or
suspended above the floor.
2-4
Chapter 1 AIRCREW SURVIVAL EQUIPMENTMAN (PR) RATING
WET LOCKER
EXHAUST FAN
SQUADRON GEAR LOCKER
METAL WORK AREA
RAFTS.SAFETY BELTS &
STOREROOM
CUTTING TABLE
SEWING MACHINES
CUTTING TABLE
OFFICE
FASTENERS & STENCILING AREA
DEEP SINK
WORK BENCH
AIR CONDITIONING UNIT
PACKING TABLES
BUNK ROOM
SINK
STAINLESS STEEL TOP
SINK 7
239.140
Figure 2-2. Typical parachute loft (ashore).
In the dry locker, hoist lines are usually
installed at least 24 inches apart and at least
12 inches from the wall. Hoist lines must be
free of harmful agents, such as tars, oils, and
acid. An adequate number of low-heat, flush-
type incandescent lighting fixtures are in-
stalled in the dry locker walls and ceiling.
Storage Facilities
Bins and other storage facilities are provided
to store packed and unpacked parachutes. They
consist of closed lockers or cupboards divided
into compartments large enough to accom-
modate single parachutes. Open racks or shelves
may be used in place of closed lockers. For
transient activities, cruises boxes are provided.
The shelves are designed to allow storage of
parachutes at least 4 inches from walls and 12
inches from the floor. Storage areas must be
well-ventilated and free of dust and other con-
taminants such as oil, acid, and cleaning fluids.
Parachutes are not stored directly over hot water
pipes, heating apparatus, or in direct sunlight.
Adequate storage facilities are established at the
loft for organizational level use that may not
have proper storage facilities within their com-
mand.
ENVIRONMENTAL CONDITIONS
All parachutes are to be inspected, re-
paired, and packed under regulated temperature
and humidity conditions. Accordingly, these
2-5
AIRCREW SURVIVAL EQUIPMENTMAN * * ^ VOLUME 1
LOCKERSs,
BINS
-SEWING
MACHINES
HAN6EI
DECK
HEAVES FIXED
TO OVERHEAD
DRY
LOCKER
SQUADRON CRUISE BOXES
239.105
Figure 2-3. Typical parachute loft (aboard ship).
conditions must be controlled in all parachute
lofts. In general, the loft must not be excessively
damp or dusty. It must be continuously or fre-
quently ventilated.
Requirements
The temperature and relative humidity in the
packing loft and dry locker shall be maintained
within the limits indicated in figure 2-4. Ideal
conditions are a temperature of 24 degrees
Celsius (75 degrees Fahrenheit) and a relative
humidity of 60 percent.
The shaded area on the temperature-
humidity chart, shown in figure 2-4, outlines the
allowable environmental limits inside the
parachute loft, and illustrates favorable and
2-6
Chapter 2 AIRCREW SURVIVAL EQUIPMENTMAN (PR) RATING
RELATIVE
HUMIDITY
TEMPERATURE C
32 37 43 48
30 40 50 60 70 80 90 100 110 120
TEMPERATURE F
239.4
Figure 2-4. Packing loft and dry locker temperature humidity conditions.
unfavorable conditions. These limits are
affected by two variables: relative humidity and
temperature. Recordings of these variables are
to be taken at least three times daily using the
relative humidity and temperature indicator
shown in figure 2-5 to ensure that favorable con-
ditions are maintained.
Relative humidity is the ratio between the ac-
tual amount of water vapor in the air and the
maximum amount the air could hold at a given
temperature. Relative humidity is usually written
as a percentage. Specific humidity is the weight
of the water vapor found in a given volume of
air. Relative humidity limits must be maintained
to prevent condensation in actuators and other
metal parts. Specific humidity limits must be
maintained to prevent static electricity in canopy
cloth.
Given any two of these variables, it can be
determined, with the chart in figure 2-4, if the
packing loft and dry locker have safe
environmental conditions.
Control
When possible, air conditioning is used to
regulate the temperature and humidity in the
239.5
Figure 2-5. Humidity and temperature indicator.
loft. To get maximum effectiveness from the
air-conditioner, a continuous check of the
temperature (24 C or 75 F) and humidity (60%)
shall be made of the conditions in the
loft.
2-7
Chapter 1 AIRCREW SURVIVAL EQUIPMENTMAN (PR) RATING
Lighting
The nylon material in parachutes is subject
to deterioration by sunlight and some forms of
artificial lighting. Avoid exposure of parachutes
to sunlight; also, avoid prolonged exposure over
inspection lights. Lighting should be adequate
and free of shadows. Fluorescent lights should
not be allowed closer than five feet for long
periods of time. Keep parachutes under cover
except when being inspected and/or worked on.
Parachute Loft Personnel
Only qualified personnel (graduates of the
Aircrew Survival Equipmentman School) are
permitted to service or supervise the servicing of
personnel, drogue, aircraft seat stabilization,
and aircraft deceleration parachute assemblies.
Work Requirements and Administration
The following rules apply to those who work
in parachute lofts.
1 . Smoking and refreshment areas are to be
designated and clearly posted.
2. Brushes used to clean packing table tops
are to be clearly labeled and never used on the
floor.
3. All parachute packing tools are in-
spected for signs of corrosion, rough or sharp
edges, and burrs. This is to be done daily and
prior to use. Tools shall be repaired, polished,
and cleaned if any of these conditions exist.
4. Loft personnel must not work at the
packing tables with objects in their shirt pockets
or on their belt loops.
5. Do not lift or carry parachutes by the
risers or ripcord.
6. Parachutes or any component parts are
not to drag on the deck or floor.
7. Parachute assemblies must not be
stacked on top of each other or on the deck or
floor, unless in suitable shipping containers.
8. No more than one parachute assembly is
to be hung on a single hoist line in the dry
locker.
9. Dry locker lights are to be turned off
when work is not in progress.
10. During any one repack and inspection
cycle, a parachute is not to be exposed to in-
candescent light or indirect sunlight for more
than 36 hours. Exposure to direct sunlight
should be avoided entirely.
11. Do not allow a parachute to come in
contact with lighting fixtures or heat.
12. Do not allow parachutes to become con-
taminated by talc or mica powders. Contamina-
tion of this type weakens the fabric.
13. Every precaution is to be taken to pre-
vent soiling or contaminating parachute
assemblies.
14. Vehicles used to transport parachute
assemblies shall be thoroughly cleaned, checked
for contamination, and provided with suitable
covers during inclement weather.
15. Avoid contaminating the parachute with
hair or body oil. Do not place shroud lines on
your hair, around your neck or your body while
whipping and folding the parachute.
16. Do not make any tackings on a container
with the parachute installed.
LEVELS OF MAINTENANCE
There are three levels of maintenance out-
lined in the OPNAVINST 4790.2 (Series): (1) in-
termediate, (2) organizational, and (3) depot. As
a PR you normally deal with the intermediate
and organizational levels of maintenance. These
three levels are described in Military Re-
quirements for Petty Officer 3 & 2.
ORGANIZATIONAL LEVEL
MAINTENANCE
When removal and replacement of com-
ponents from an aircraft weapon system is
2-8
Chapter 1 AIRCREW SURVIVAL EQUIPMENTMAN (PR) RATING
required, using only organizational test equipment
and hand tools, the maintenance function is con-
sidered organizational level.
Your branch is the Organizational Aviators'
Equipment Branch, and it comes under the Air-
craft Division. The Aircraft Division consists of
the Power Plant, Airframe, Aviator's Equipment
and Inspection Branches. The Aviator's Equip-
ment Division is assigned a work center code of
ISA, and all reports of maintenance actions you
perform use this code.
As an "O" level parachute rigger, you will
find that all of the repacking and testing of
parachutes, seat pans, oxygen regulators, and lox
converters are done by the local Aviation In-
termediate Maintenance Department (AIMD).
These functions are entered on a document
called a VIDS/MAF which is described in Volume
II. You may, however, be involved in aircraft
phase maintenance inspections. Aircraft phase
maintenance is done according to the Naval Avia-
tion Maintenance Program.
The Maintenance Requirement Cards (MRCs)
are used in performing the phase maintenance.
They contain the minimum phased maintenance
requirements. In order to meet these requirements
you inspect the aircraft for any degradation of
material and perform any essential preventive
maintenance. On the MRC, you will find
clearances, pressures, tolerances, illustrations,
equipment required, and manual references to
help you record the information. The cards are
arranged in groups according to the rating re-
quired to perform the tasks. These inspection re-
quirements make up a balanced inspection which
completes a maintenance cycle.
INTERMEDIATE LEVEL
MAINTENANCE
Assigning separate, individual, and distinct
maintenance functions to a maintenance level
allows the maintenance activities to further deter-
mine the specific tasks they are required to per-
form. To determine the amount of repair the
maintenance activity must perform check the ap-
propriate instruction manuals, operating and ser-
vice instruction manuals, or technical directives
which applies.
The Aircraft Intermediate Maintenance
Department (AIMD) parachute loft is assigned to
perform intermediate maintenance on aviators
equipment, inflatable survival equipment, life
preservers, life rafts, survival kits, man-mounted
oxygen equipment, oxygen regulators, helicopter
rescue devices, aircrew personal protective equip-
ment, flight suits, ventilated wet suits, anti-G
suits, torso harness, pressure suits, anti-exposure
suits, helmets, and auxiliary personal equipment
personnel parachutes, automatic parachute ac-
tuators, and survival radios. In addition to the
Aviator's Equipment, the parachute loft also has
a large work load involving manufacturing and
repairing of fabricated items.
To accomplish the maintenance assigned to the
aviator's equipment division, the division is divid-
ed into the following work centers:
800 Aviator's Equipment Division
810 Aviator's Equipment Branch
81 A Parachute Loft
81 B Survival Equipment
8 1C Regulator Shop
As a PR "A" school graduate the PR has a basic
knowledge for assignment to each of these work
centers.
2-9
CHAPTER 3
SEWING MACHINES
Sewing machines are like any other tool you
ise. If you don't have the correct one, the task is
larder or impossible to complete. The same ap-
>lies to sewing machines. You need the right
nachine for the job; whether it be lightweight,
nedium weight, or heavy weight, there is a
nachine designed to perform each task. You
vork with various types of sewing machines in
he process of repairing or fabricating items in
he shop. You need to have all the knowledge
md skill you can possibly acquire about these
nachines to fulfill your duty as a PR. If you
lon't know how to operate and maintain the
ewing machines, they will stand idle, not
operate properly, or not work at all. When you
iave a job to do, you need equipment that is
operational. Without the proper knowledge of
ewing machines, you will not have the con-
idence to perform necessary sewing machine
epairs.
Before you can learn to operate and maintain
sewing machine, you must learn the language
>f the sewing trade. Through your supervisor
nd this text you will hear this language often,
t is very important that you form a habit of re-
erring to the parts of a sewing machine by their
>roper names. It would be difficult to com-
nunicate with other PRs and impossible to pass
rating exam if you do not know the proper
iames of the different parts of a sewing
lachine. Take time to study the illustrations in
his chapter that show the important sewing
lachine parts and their names.
Sewing machines are classified as two types,
)SCILLATING and ROTARY. Both types are
perated by electric motors and are fitted with
heostats and special clutch arrangements which
nable the operator to control the speed.
When it comes to classifying sewing ma-
hines into oscillating and rotary, the important
part is the rotary hook and oscillating shuttle.
This is the device that is out of sight in the base
of the machine, but does the very important job
of forming each stitch after the needle has
passed thread through the fabric.
Oscillating type sewing machines have a sew-
ing hook which rocks back and forth through
half of one revolution to complete one stitch.
Rotary type sewing machines have a hook
which makes two complete revolutions to com-
plete one stitch.
The type of stitch commonly used and made
by sewing machines in repair work is the
lockstitch. The lockstitch makes use of two
separate threads. One comes from the spool
down through the eye of the needle, the other
from the bobbin. In making the lockstitch, these
two threads must become interlocked, as shown
in figure 3-1.
The thread passing through the eye of the
needle is pushed down through the material
being sewn. As the needle travels downward to
the material, a spring pulls tension on the needle
thread to keep it taut to prevent any slack that
might tangle the thread around the needle.
After the needle reaches its lowest position
and starts its upward movement the process
shown in figure 3-1 begins. A small loop of
thread forms alongside the needle beneath the
throat plate. The sewing hook catches this loop
and carries it around the bobbin, which floats in
its track in the bobbin case (B in figure 3-1). By
locking the loop of needle thread around the
bobbin thread, the sewing hook forms the stitch.
As the needle completes its upward move-
ment, the thread tension disks hold the needle
thread firmly. The thread takeup lever, rising
quickly, pulls on the loop that has been formed
and thus tightens the stitch. When the thread
3-1
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
Take-up lever in down position
ok picks up
.edle thread
Bobbin case lug is unseated
by bobbin case opener',
permitting passage of thread
// around bobbin case
BOBBIN CASE OPENER
(C)
(D)
Take-up lever pulls threads
up into center of material
mx Take-up lever at
|\\\ highest point
\\
\ Thread is taut
|\
{ \ Thread advances
{ ;
I
Hook makes 2 revolutions
for each stitch
Figure 3-1. The Lock stitch.
239.261
3-2
Chapter 3 SEWING MACHINES
takeup lever reaches its highest position, the
stitch is completed. (See C and D of figure 3-1.)
Now look at figure 3-2. The standard sewing
machine has four basic parts: bed, uprise, arm,
and face. The BED (1) houses the linkage from
the safety clutch pulley to the sewing hook
assembly; the UPRISE (14) houses the arm shaft
connection belt; the BALANCE WHEEL (12) is
connected to the arm shaft in the ARM (11)
which operates the needle bar mechanism in the
FACE (6) of the machine.
The machine is powered by an electric
motor, which is connected to the motor driving
pulley by a clutch. You connect the motor to the
clutch by pressing the forward part of the foot
treadle. The aft part of the treadle is the brake
which acts upon the clutch.
The material to be sewn is held in position on
the feed dog by the presser foot. The pressure of
the presser foot upon the material enables the
feed dog to push the material forward each time
the needle goes up. The pressure of the presser
foot on the material is released either by a knee
lifter or a hand lifter. The presser foot can be
raised by pushing the knee lifter to the right. The
hand lifter is located behind the face of the
machine. The presser foot may be lifted and
locked into position by raising the hand lifter to
its highest position.
OSCILLATING TYPE
SEWING MACHINES
Two of the most commonly used oscil-
lating type sewing machines are the 31-15
12
14
1. Bed. 5. Needle bar.
2. Throat plate. 6. Face.
3. Feed dog.
4. Presser foot.
8. Thread retainer.
9. Thread takeup lever.
11. Arm.
12. Balance wheel.
7. Upper tension regulating 10. Pressure bar pressure 13. Stitch regulator thumbscrew.
thumb nut. regulating thumbscrew. 14. Uprise. 239.262
Figure 3-2. Sewing machine 31-15.
3-3
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
and 7-33, both of which are discussed in this
chapter.
SINGER SEWING MACHINE 31-15
When starting out as a PR, the 31-15 sewing
machine will probably be the one you'll like to
use. This machine is smaller and lighter than
most of the other machines used in the para-
chute loft. The manufacturer calls the 31-15 a
tailoring machine. It is used to sew and repair
clothing, uniforms, shirts, flying clothing,
jackets, and lightweight protective covers.
The 31-15 is an oscillating type sewing
machine which has a recommended speed of
2,200 stitches per minute and makes a lockstitch.
It is very good for nylon cloth sewing and can be
used for sewing lightweight canvas up to 8
ounces. The number of stitches can be regulated
from 7 to 32 stitches per inch.
When the 31-15 machine is in operation, the
balance wheel turns over toward the operator.
When hand-turning the balance wheel, always
rotate in this direction. The components of the
Singer Sewing Machine 31-15 are shown in
figure 3-2.
The following practices and procedures help
to ensure safe and smooth operation of the sew-
ing machine:
1. The balance wheel must always turn
toward the operator.
2. Do not run the machine with the presser
foot resting on the feed dog without material
being under the presser foot.
Figure 3-3. Oiling points at the front of the machine.
239.263
3-4
Chapter 3 SEWING MACHINES
3. Do not run the machine when both bob-
bin case and needle are threaded unless there is
material under the presser foot.
4. Do not try to help the machine by pull-
ing the material. You may bend or break the
needle. If properly adjusted, the machine feeds
the work without assistance.
5. The slide over the bobbin case should be
kept closed when the machine is in operation.
6. Keep your head away from the thread
takeup lever and needle bar at the top of the sew-
ing machine face.
7. When running the machine do not take
your eyes away from the needle and presser foot.
8. Keep your fingers from under the
needle.
9. When running the machine, keep your
fingers away from the belt and pulley areas.
10. Never attempt threading the needle when
the machine is turned on.
Lubrication
To ensure easy operation and to prevent un-
necessary wear of the moving parts, all sewing
machines need oiling. When a machine is in con-
stant use, it should be oiled twice a day. A new
machine should be oiled more frequently when
in constant use. Use only one drop of oil at each
oiling point. A castor base oil is recommended
since mineral base oil tends to gum the moving
parts.
Oiling points for the 31-15 machine are
shown in figures 3-3, 3-4, and 3-5. Oil should be
applied regularly to the shuttle bearing in the
shuttle race. Occasionally remove the faceplate
239.264
Figure 3-4. Oiling points at the back of the machine.
3-5
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
239.265
Figure 3-5. Oiling points at the base of the machine.
and apply oil to the bearings and points that are
uncovered.
Timing the 31-15
There are two distinct timing operations you
perform: One operation times the needle with
the shuttle. The other timing operation times the
feed dog with the needle. Both the needle with
the shuttle and the feed dog with the needle must
be in proper time for the machine to function
properly. See figure 3-6.
Timing the Needle with the Shuttle
If a class 31 sewing machine does not form
the lockstitch, if it skips stitches, or if it frays or
breaks thread, the needle is not moving in the
proper relationship with the shuttles motion.
First make sure you have the right needle. Check
the needle for the correct class, variety 16 x 87,
and size. Insert the needle in the needle bar (long
groove to the left) as far as it will go (see figure
3-6). Next compare the needle stroke to the
shuttle stroke. To do this, remove the throat
plate. Turn the balance wheel toward you until
the point of the shuttle on its forward stroke
239.443
Figure 3-6. Timing needle with shuttle.
3-6
Chapter 3 SEWING MACHINES
reaches the center of the needle while the needle
is on the upstroke. At this time, the needle bar
should have risen 1/10 inch and the point of the
shuttle should be 1/16 inch above the eye of the
needle, as shown in A of figure 3-6.
NOTE: Prior to making adjustments to the
sewing machine, always follow the trouble
shooting chart in Table 3-1.
If the needle eye is not in this position, the
following steps should be taken:
a. Loosen the needle bar connecting stud
screw, as shown in figure 3-6.
b. Move the needle bar up or down as re-
quired; and then tighten the screw.
c. Rotate the balance wheel through the full
cycle to check the timing.
d. Replace the throat plate.
Timing the Feed Dog with the Needle
The feed driving eccentric is an adjustable
connection between the arm shaft (the shaft in
the head) and the feed rock shaft (first shaft
beneath the bed of the machine). If the feed
mechanism is properly timed, the feed dog
should be on its downstroke and level with the
throat plate when the point of the needle reaches
the material. If there is a twisted knot every one
to two inches on the bottom of your material,
check the timing of the needle before adjusting
the feed mechanism.
To adjust the feed eccentric, first lower the
stitch regulator to the lowest position so the
machine forms its longest stitch. Turn the
balance wheel until the feed dog is on its
downstroke and is flush with the throat plate.
Move to the rear of the machine and take off the
arm side cover. Turn the balance wheel away
from you until the feed eccentric collar setscrew
is visible (figure 3-7). Hold the collar (figure 3-7)
with your left thumb. Loosen the screw and
rotate the balance wheel away from you until the
needle, on its downstroke, reaches the material.
Tighten the setscrew. Rotate the balance wheel
to check the timing. Recheck the timing of the
shuttle point with the needle, because when you
time the feeding mechanism, you may throw the
needle out of time with the shuttle.
SETSCREW
239.444
Figure 3-7. Feed eccentric.
Adjusting the Feed Dog
The height at which the feed dog should be
set depends on the weight and number of plies of
the material being sewn. If the feed dog is set too
low, the material does not feed through the
machine; if i is set too high, it may cut or fray
the material. The recommended height of the
feed dog for sewing lightweight canopy material
is slightly less than 1 tooth above the throat
plate. If you are sewing heavier material, raise
the feed dog to a height which ensures positive
feeding of the material. After you have decided
on the correct height for the project you are
working on, adjust the feed dog accordingly, by
loosening, and then tightening the screw as
pointed out in A of figure 3-7. You must
remember that each time the height of the feed
dog is changed, the feeding mechanism may be
out of time. For this reason, set the feed dog
first and then make the necessary adjustment on
the feeding mechanism. Since most of your
canopy repairs involve material of approxi-
mately the same weight, one-time adjustment of
the feed dog is usually sufficient. Repeated
changing of its height is nqft necessary.
Adjusting the Thread Takeup Spring
To adjust correctly the takeup spring in the
tension assembly (shown in figure 3-8), you
should first understand its normal operation.
The thread takeup lever pulls the thread takeup
3-7
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
Table 3-1. Troubleshooting chart
TROUBLE
PROBABLE CAUSE
REMEDY
Needle breakage.
Incorrect class and variety needle being
used.
Needle loose in clamp.
Needle too small for fabric.
Operator pulling on the material.
Use correct class and variety
needle.
Tighten needle clamp screw.
Use larger needle.
Allow machine to feed material.
Needle thread breakage.
Thread too heavy for needle.
Right twist thread being used.
Damp or defective thread being used.
Machine incorrectly threaded.
Needle incorrectly set.
Needle thread tension too tight.
Thread take-up spring out of adjustment,
Burr on bobbin case, Shuttle point or
tension disks.
Thread rubbing against presser foot.
Needle has burr on eye or point, blunted
or bent.
Use larger needle or smaller
thread.
Use left twist thread.
Use only dry smooth thread.
Check machine for proper
threading.
Set needle with long groove to
the left.
Loosen needle thread tension.
Adjust thread take-up spring.
Smooth with emery cloth.
Adjust presser foot.
Replace needle.
Bobbin thread breakage.
Bobbin tension too tight.
Bobbin incorrectly threaded.
Bobbin wound too full to revolve freely.
Rounds of bobbin thread lapped over one
another.
Bobbin case is dirty.
Adjust bobbin tension.
Thread bobbin to revolve clock-
wise.
Remove some of the bobbin
thread.
Insure bobbin thread is straight
when winding bobbin.
Clean and lubricate bobbin case.
Skipped stitches.
Machine out of time.
Thread controller spring out of
adjustment.
Time needle to shuttle.
Adjust thread controller spring.
Drawing of seam.
Needle and bobbin tension too tight.
Loosen needle and bobbin ten-
sion.
Stitches piled up.
Stitch regulator out of adjustment.
Pressure on presser foot too tight.
Adjust stitch regulator.
Loosen presser foot adjustment
screw.
Feed dog striking throat plate.
Feed dog set too high.
Lower feed dog to correct
height.
3-8
Chapter 3 SEWING MACHINES
TAKEUP SPRING
(BEHIND NUT)
THUMB
NUT
(KNURLED)
STUD
SCREW
SETSCREW
239.445
Figure 3-8. Tension assembly.
spring down about even with the slack thread
regulator while the needle is going up. While
the takeup lever is coming down with the needle,
the thread takeup spring pulls the slack out of
the thread and keeps it from getting under the
needle. If you do not have this adjusted prop-
erly, a loop can form over the needle hole in the
throat plate and the needle can split the thread
as it enters the needle hole. You should set the
spring about 1/4 inch above the slack thread
regulator. The thread takeup spring should be
set so that the spring will have completed its
downward motion and be resting on the stop
when the needle, on its downstroke, reaches the
fabric.
To adjust the spring, loosen the setscrew, B,
as shown in figure 3-8 on right. To put more ten-
sion on the spring, you turn the assembly clock-
wise; to put less tension on the spring, you turn
the assembly counterclockwise.
It may be necessary for you to replace the
thread takeup spring because it can bend and
become weak. Loosen the setscrew and insert a
screwdriver into the slot of the tension screw
stud in figure 3-8. Turn the stud to the left until
it is screwed out of the thread takeup spring
regulator.
Remove thumb nut, A, figure 3-8, the ten-
sion spring, and tension discs. The takeup spring
is now free for removal. After replacing the old
spring with a new one, assemble the parts in
reverse procedure.
Replacing the Needle
While replacing a needle is a relatively simple
job, you must know a few things about needles
in order to decide which needle is required when
a needle must be replaced. It is very important
that the proper needle be used to ensure good
machine operation. The selection of needles by
class, variety, and size for different machines
and materials is necessary in order to elimi-
nate thread breakage, needle breakage, skipped
stitches, and fraying of the thread.
Needles for the various machine classes are
selected and ordered by needle number and size.
The needle numbers consist of a class number
and variety number separated by an "X"; for
example, the class and variety needle 16 x 87 is
used in the 31-15 sewing machine. Cloth point
needles are round, sharp pointed needles used
for sewing cloth, since they do not cut the
strands as they are forced between the woven
threads of the fabric. Many different varieties
of cutting point needles are available, but they
are used only for sewing heavy leather. Figure
3-9 shows the shape of the openings made in
material by the cloth point (A), twist point (B),
and the diamond point (C). Figure 3-9 illustrates
1
A - CLOTH POINT
C DIAMOND POINT
Figure 3-9. Shapes of needle points.
239.446
3-9
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
why it is important that a round-pointed
needle be used in cloth; B and C show how
cutting point needles can cut the warp and
filler threads.
Machine needles have a long groove on one
side, and either a short groove or a scarf on the
opposite side, as shown in figure 3-10. The
purpose of the grooves is to allow the thread
to fall back into the needle when it enters
the material to prevent the thread from
breaking or fraying; therefore, it is important
that the long groove be placed in the machine
properly. On different class machines, the
direction varies with the position of the
bobbin assemblies. On class 31 machines,
eft.
eter or gauge of
The selection of
mined by the size
J used. The thread
inrougn the eye of the
prevent thread fraying or
LENGTH
LONG-
GROOVE
-SHANK (CLASS)
NOTE THE SIZEOF THE
NEEDLE INDICATES THE
GAGE (DIAMETER] OF THE
LOWER HALF OF THE
/'NEEDLE AND THE SIZE
OF THE EYE
(THIS IS CALLED THE
SHAFT)
SHORT GROOVE
EYE
POINT
VARIETY*
239.447
Figure 3-10. Sewing machine needle.
breaking. The sizes of the 16 x 87 needles for
most sewing operations you will do range from
size 18 through size 22. The needle size number
increases with the diameter of the needle;
therefore size 18 needles are used for lighter
weight materials than size 22. Listed below are
some of the needle sizes you will be working with
and their uses:
a. Size 18. For sewing two to four plies of
thin material, such as silk, nylon, or rayon, with
size E thread.
b. Size 20. For sewing five or more plies of
the above.
c. Size 21. For sewing two to four plies of
medium weight materials, such as aircraft cloth >
12-ounce duck, light leather, and artificial
leather.
d. Size 22. For sewing two to four plies of
medium weight material, such as heavy duck,
lightweight and medium weight webbings, and
russet leather.
e. Size 24. For sewing elastic or rubberized
materials.
You should check the condition of the
needle's point before you start to sew. A dull or
rough round needle acts the same as a cutting nee-
dle. It cuts or pulls threads and may weaken the
seam. The condition of a needle may be checked
by sliding the fingernail over the point. If it scrat-
ches or catches the nail, the needle should be
replaced with a new one. A dull needle may be
sharpened by placing it in the chuck of a drill
press, and the drill operated at high speed while
holding a fine grain sharpening stone lightly
against the side of the needle at the
proper angle. The point is then polished with a
piece of russet leather.
Having selected the proper needle, turn the
balance wheel toward you until the needle bar
moves to its highest point. Loosen the needle
clamp screw and put the shank of the needle up
into the groove as far as it will go. Turn the long
groove so that it faces to the left and is directly
in line with the arm of the machine. Then tighten
the clamp screw and check to see that the needle
does not turn or slip. For troubleshooting, refer
to table 3-1.
3-10
Chapter 3 SEWING MACHINES
Threading the Machine
Threading a machine is a very simple job.
The procedure may vary slightly with different
models; but after working with the various
machines in the loft, the task becomes auto-
matic.
The component parts used in threading the
31-15 sewing machine are shown in figure 3-11.
Use this figure in studying the procedures which
follow. Pass the thread from the thread stand to
the thread post on top of the machine, right to
left through the bottom hole, and then right to
left through the top hole. Pass the thread from
right to left through the top hole in the thread re-
tainer (1). Pass the thread from left to right
through the middle hole in the thread retainer
(2). Pass the thread from right to left through
the bottom hole in the thread retainer (3). The
thread is then passed down and under from right
to left between the tension disks (4). Draw the
thread up into the thread takeup spring (5),
drawing the thread up and beyond the spring
end so that it conies out in the center of the
spring. The thread is then placed under the ten-
sion thread guard (6). Pass the thread up and
from right to left through the hole in the thread
takeup lever (7). The thread is now drawn down
through three thread guides (8), (9), and (10).
Pass the thread from left to right through the eye
of the needle (11). Draw about two inches of
thread through the eye of the needle with which
to commence sewing.
Removing the Bobbin Case
Before attempting to remove the bobbin
case, turn the balance wheel toward you until the
needle moves upward to its highest position.
Remove the slide in the bed of the machine
so you can see what you are doing. Reach
under the table with your left hand, and,
using your thumb and forefinger, open the
bobbin case latch (figure 3-12) and lift out the
bobbin case.
While the latch is held open, the bobbin is re-
tained in the bobbin case. Release the latch, turn
the open end of the bobbin case down, and the
bobbin will drop out.
Winding the Bobbin
The bobbin winder is fastened to the
table with its driving pulley in front of the
sewing machine belt. The bobbin winder is so
11
1. Top hole of thread retainer.
2. Middle hole of thread retainer.
3. Bottom hole of thread retainer.
4. Tension disks.
5. Thread takeup spring.
6. Tension thread guard.
7. Thread takeup lever.
8. Thread guide.
9. Thread guide.
10. Thread guide.
11. Needle eye.
239.268
Figure 3-11. -Threading the 31-15 sewing machine.
3-11
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
positioned to allow the pulley to drop away from
the belt when sufficient thread has been wound
on the bobbin.
Figure 3-13 illustrates the bobbin-winding
operation. The procedure is as follows: Place the
bobbin on the bobbin winder and push it on the
shaft as far as it will go. Pass the thread from the
spool down through the thread guide. Loop the
thread around back and through the tension
disks.
The thread is then wound around the bobbin
a few times and the pulley pushed up against
the machine belt. The bobbin can be wound
while the machine is being used for sewing.
If there is no material under the presser foot,
make certain that the presser foot is raised
and not riding on the feed dog while winding the
bobbin.
When sufficient thread has been wound on
the bobbin, the pulley on the bobbin winder
239.269
case.
1. Thread guide.
2. Tension disk.
3. Setscrew.
4. Bobbin winder stop latch screw.
Figure 3-13. Winding the bobbin.
239.270
3-12
Chapter 3 SEWING MACHINES
(B)
(C)
239.271
Figure 3-14. Threading the bobbin case.
drops back from the machine belt automatically.
If the thread does not wind evenly on the bob-
bin, loosen the setscrew in the tension bracket
and move the bracket to the right or left as re-
quired; then tighten the bobbin winder stop
latch screw. The amount of thread wound on the
bobbin is regulated by the bobbin winder stop
latch. To wind more thread on the bobbin, turn
the screw to the right; to wind less thread on the
bobbin, turn this screw to the left.
Threading the Bobbin Case
Hold the fully wound bobbin between the
thumb and forefinger of the right hand with the
thread end running over the top toward the
right, as shown in figure 3-14 (A). With the left
hand, hold the bobbin case as shown, with the
thread slot near the top.
Place the bobbin into the bobbin case and
pull the thread into the slot in the edge of the
bobbin case (B). Draw the thread down under
the tension spring and into the delivery eye at the
end of the tension spring (C). When the free end
of the thread is pulled, the bobbin will rotate
clockwise if the bobbin case has been threaded
properly.
Replacing the Bobbin Case
Hold the latch open on the threaded bobbin
case with the thumb and forefinger of the left
hand, with the latch in a horizontal position.
Place the bobbin case on the center stud of the
shuttle body. Release the latch and press the
bobbin case back until the latch catches the
groove near the end of the stud.
Preparing for Sewing
With the left hand, hold the end of the
needle thread, leaving it slack from the hand to
the needle. Turn the balance wheel toward you
until the needle moves down and catches the
bobbin thread. Continue to turn the balance
wheel forward until the needle comes up and
brings the bobbin thread up with the needle
thread.
With the thread takeup lever at its highest
position, lay both threads back under the presser
foot.
Commencing to Sew
Place the edge of the material beneath the
presser foot, lower the presser foot, turn the
balance wheel by hand until the needle is in the
material, and press lightly on the treadle. To
prevent fouling the needle thread in the bobbin
case, hold the ends of both threads until the first
few stitches are made.
While sewing, hold the work flat, but do not
pull or push on the material. Let the feed dog
carry the work evenly under the presser foot and
needle. If the operator pulls on the material, the
needle bends, strikes the throat plate, and is
either dulled, or more likely, broken. When the
needle is about to cross a seam or other un-
usually thick or uneven place in the work, dis-
engage the clutch, and hand-turn the machine
over the rough place; otherwise, the needle may
be broken or thrown out of time.
Regulating the Tension
The tension on the needle thread should be
regulated only when the presser foot is down. If
the tension of the machine thread is not correct,
it should be adjusted by turning the tension ad-
justing nut, as shown in figure 3-15. To
3-13
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
TENSION ADJUSTING NUT
1. Thread takeup spring. 2. Setscrew.
239.272
Figure 3-15. Adjusting the machine thread tension.
INCREASE THE TENSION, turn the nut
clockwise; to DECREASE THE TENSION,
turn the nut counterclockwise.
The tension on the bobbin thread is regulated
by the small screw in the bobbin case tension
spring. To increase the tension turn the screw
clockwise; to decrease the tension turn the screw
counterclockwise.
This screw is very small and is easily lost if
extreme care is not exercised in backing it out
when the tension is decreased. If the screw is
tightened excessively or is slightly too long, it
will penetrate into the inside of the bobbin case
and prevent removal of the bobbin.
When the tension on the bobbin thread has
once been properly adjusted for a particular size
of thread, it is seldom necessary to change it. A
correct stitch can usually be obtained by varying
the tension on the needle thread, which is an
easier adjustment.
For ordinary stitching, the needle and bob-
bin threads should be locked in the center of the
thickness of the material as shown in figure 3-16
(A). When adjusting the tensions, you will not
have a cross section of the stitch.
If the tension on the needle thread is too
tight, or if the bobbin tension is too loose, the
239.273
Figure 3-16. Properly and improperly adjusted tensions.
thread will lie straight along the upper surface of
the material and appear as small loops (figure
3-16 (B)).
If the tension on the bobbin thread is too
tight, or if that on the needle thread is too loose,
the bobbin thread will lie straight along the
underside of the material (figure 3-16(C)).
Regulating the Length of Stitch
The length of stitch can be checked at the
time the tension of the stitch is checked, as a trial
run of stitches is necessary during both pro-
cedures.
The length of stitch is regulated by the
thumbscrew in the slot on the front of the uprise
of the machine. To LENGTHEN the stitch,
loosen the thumbscrew and move the lever
DOWN. To SHORTEN the stitch, loosen the
thumbscrew and move the lever UP. When the
desired length of stitch has been obtained by test
running the machine on scrap material, tighten
the thumbscrew.
Regulating the Pressure on the Material
Pressure on the material is regulated by the
pressure regulating thumbscrew on top of the
machine face. To increase the pressure, turn the
thumbscrew clockwise. The pressure should be
just heavy enough to enable the feed dog to
move the work along evenly.
Removing Work
Hand-turn the balance wheel toward you
until the thread takeup lever is at its highest
3-14
Chapter 3 SEWING MACHINES
position. Raise the presser foot, either by the
hand lever or by the knee lift, and draw the work
and threads straight behind the presser foot. Cut
the threads close to the material, leaving about 2
free inches of bobbin and machine thread.
Adjusting the Thread Takeup Spring
The thread takeup spring (figure 3-15)
should be set so that when the eye of the needle
reaches the material on the downward stroke of
the needle bar, the spring will be through acting
on the thread, and will rest against the stop of
the thread takeup spring regulator.
If the thread takeup spring is not correctly
set, loosen the setscrew (2) in the arm of
the machine and turn the tension adjusting
stud to the right for more movement of the
spring, or to the left for less movement. When
the spring is correctly set, retighten the set-
screw.
The tension on the thread takeup spring
should be just sufficient to take up the slack of
the needle thread until the eye of the needle
reaches the material on its descent. To increase
the tension on the thread takeup spring, loosen
the tension adjusting stud and move the takeup
spring from the recess in the regulator to the
right between the regulator and the tension
disks. When the required tension is obtained,
securely tighten the tension adjusting stud and
move the spring back into its position in the
regulator recess. To decrease the tension, move
the spring to the left between the regulator and
the tension disks.
SINGER SEWING MACHINE 7-33
The class 7-33 sewing machine is a lockstitch
heavy duty machine and is intended for use in
sewing heavy canvas, webbings, and other
material not adaptable to the lighter duty sewing
machines. The only difference between the 7-31
and the 7-33 is that the 7-33 has the clutch on the
motor, while the 7-31 has the clutch on the
balance wheel. The operation and maintenance
techniques are identical. The procedure for
operating the 7-33 sewing machine is the same as
for the 31-15 sewing machine.
As on any Singer sewing machine, the
balance wheel of the 7-33 should always turn
toward the operator.
Lubrication
The 7-33 machine is oiled at all the oiling
points shown in figures 3-17 and 3-18. The
239.274
Figure 3-17. Oiling points at the front of the 7-33 sewing machine.
3-15
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
Figure 3-18. Oiling points at the back of the 7-33 sewing machine.
Table 3-2. Relative sizes of needles and thread
239.275
Needle class
Needle
Classes
Needle
Cord
Machine
and variety
sizes
of work
size
size
7-31 or 7-33
7x1
19, 21, 22, 23, 24
25, 26, and 27.
Medium to heavy
canvas.
24
3 -cord
7-31 or 7-33
7x5
28, 29, 30, and 31.
Heavy canvas and
webbing.
28
6-cord
machine should be oiled twice daily when it is in
constant use. Use a castor base oil as recom-
mended by the manufacturer.
Needles and Thread
The procedure for ordering needles is the
same for the 7-33 machine as for the 31-15
sewing machine. Refer to table 3-2 for the
relative sizes of needles and thread.
Setting the Needle
The same procedure may be followed
with this machine as for the 31-15 sewing ma-
chines.
3-16
Chapter 3 SEWING MACHINES
Thread guide.
Thread guide.
Retainer disks.
Tension disks.
5. Thread takeup spring.
6. Wire loop.
7. Thread takeup lever.
8. Thread guide.
9. Slot in the vibrating presser bar.
10. Thread guide on the needle clamp.
11. Eye of the needle.
12. Hole in the lifting presser foot.
13. Lubricating cup.
239.276
Figure 3-19. Threading the 7-33 sewing machine.
Threading the Machine
Turn the balance wheel toward you until the
thread takeup lever (7) moves up to its highest
position (figure 3-19). Pass the thread from the
thread stand to the thread post, right to left
through the bottom hole then right to left
through the top hole. Pass the thread through
the two thread guides (1) and (2). Continue the
passage of thread between the retainer disks (3),
down and under the tension disks (4). Pass the
thread into the loop of the thread takeup spring
(5), under the wire loop (6), up, and from back
to front through the hole in the thread takeup
lever (7). Now pass the thread down through the
thread guide (8), into the slot in the vibrating
presser bar (9), and on down through the thread
guide (10) which is located on the needle clamp.
The needle is now threaded from left to right
through the eye of the needle (11). After the
needle is threaded as shown in figure 3-19, pass
the thread down through the hole in the lifting
presser foot (12). Draw about 4 inches of thread
through the hole in the lifting presser foot with
which to commence sewing.
Notice that the lubricating cup has been
bypassed. No lubricant is used on the threads
and cords used in the manufacture or repair of
parachutes.
Removing the Bobbin
Turn the balance wheel forward to bring the
needle bar and thread takeup lever to its lowest
position. With the aid of the shuttle opening tool
or a small screwdriver, insert the blade end in the
slot in the spring latch beneath the shuttle
cylinder (figure 3-20). Press the latch away from
the cylinder and it will swing out. The bobbin
will then slide out of the shuttle cylinder.
3-17
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
239.277
Figure 3-20. Removing the bobbin from the shuttle
cylinder.
1. Thread slot in the cylinder.
2. Delivery eye and tension spring.
Figure 3-21. Replace the bobbin.
239.278
Winding the Bobbin
Place the bobbin on the bobbin winder
spindle and push it up closely against the
shoulder. The small pin in the shoulder must
enter the slot in the bobbin.
Pass the thread from the thread stand
through the hole in the left side of the bobbin
from the inside. Push the bobbin winder pulley
up against the balance wheel and place the bob-
bin winder latch in position. Raise the presser
foot and start the machine. The end of the
thread should be held until a few turns are
wound on the bobbin to prevent slipping. When
sufficient thread has been wound on the bobbin,
the bobbin winder will stop automatically.
Replacing the Bobbin and
Threading the Shuttle
Take the bobbin between the thumb and
forefinger of the left hand as shown in figure
3-21 . The free end of the thread should be drawn
off from the underside toward the right. Place
the bobbin in the shuttle cylinder as far as it will
go. Draw the thread into the slot in the cylinder
and under the tension spring into the delivery
eye. Push the shuttle cylinder in until it is locked
by the spring latch. There should be about three
inches of thread hanging free from the shuttle
with which to commence sewing.
Regulating the Tension
The tension on the needle thread is regulated
by the thumb nut at the front of the thread re-
tainer disks. The tension on the thread retainer
disks should be just enough to cause the tension
wheel to turn when the thread is taken from the
spool.
The tension on the bobbin thread is regulated
by the small screw which holds the tension
spring to the shuttle cylinder. To increase the
tension, turn the screw clockwise. To decrease
the tension, turn the screw counterclockwise.
The tension on the machine and bobbin
threads should be checked by test-running a row
of stitches on scrap material. The lockstitch
should lock in the center of the material as
described for the 31-15. When sewing webbings
with the 7-33 sewing machine, the specifica-
tions for webbing sewing should be checked to
3-18
Chapter 3 SEWING MACHINES
determine at what ply of the webbing the stitch
should lock.
Regulating the Length of Stitch
The procedure for regulating the stitch on
the 7-33 sewing machine is the same as for the
31-15.
Regulating the Pressure on the Material
The pressure on the material is regulated by
means of the hexagon head screw (1). (See figure
3-22.) Loosen the hexagon head locknut (2) and
turn the adjusting screw clockwise to increase
the pressure or counterclockwise to decrease the
pressure on the spring (3). When the desired
pressure has been obtained, hold the adjusting
screw with a wrench to keep it from turning
while the locknut is being tightened against the
bracket (4).
The pressure should be just heavy enough to
enable the feed dog to move the work along
evenly, and to prevent the work from rising with
the needle.
Preparing the Sewing
The same sewing preparatory procedures are
used for the 7-33 as for the 31-15 sewing
1. Hexagon head adjusting screw. 3. Spring.
2. Hexagon head locknut. 4. Bracket.
239.279
Figure 3-22. Regulating the pressure on the material.
machine except there is no knee lifting device.
The hand presser bar lifter is the only device pro-
vided for lifting the presser foot on the class 7-33
sewing machine.
Removing the Work
Stop the machine and raise the thread takeup
lever to its highest position. Draw about three
inches of thread through the thread retaining
disks. Raise the presser foot and draw the work
back, cutting the threads close to the material.
Leave the ends of the threads under the presser
foot.
Modification of Presser Foot for
Webbing Sewing
The modification of a presser foot is il-
lustrated in figure 3-23. The presser foot should
be cut along the dotted line, removing the right
portion of the foot. After cutting, the edges
should be filed down to a smooth round finish.
239.280
Figure 3-23. Modification of presser foot for webbing
sewing.
3-19
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
Parachute harness and webbing sewing is
classified as a major repair. However, there are
various other sewing projects requiring webbing
sewing.
ROTARY TYPE
SEWING MACHINES
CLASS 111 SEWING MACHINES
The class 111 sewing machines are one line
(single needle) lockstitch machines designed to
sew medium weight and heavyweight material.
They are capable of sewing at a speed of approx-
imately 3,000 stitches per minute (spm). The
lockstitch is formed in the bobbin assembly by
the rotary hook on the 111 machines. The class
111 machine is most commonly used for sewing
aircraft protective covers, upholstery, and
soundproofing.
Functional Features
The oiling parts for class 111 sewing ma-
chine are shown in figure 3-24A. Figure 3-24B
II'
10
1. Vibrating presser bar thumbscrew.
2. Tension thumb nut.
3. Thread controller stud thumb nut
4. Presser bar spring regulating screw,
5. Stitch indicator disk view hole.
6. Model number.
7. Hook driving shaft lock stud.
8. Feed regulating stud (plunger).
9. Bed slide.
10. Throat plate.
11. Presser foot.
12. Needle bar.
239.281
Figure 3-24A. Class 111 sewing machine, front view showing oiling points.
3-20
Chapter 3 SEWING MACHINES
LIFTING PRESSER-BAR
TENSION REGULATING SCREW
FEED DOG
FEED INDICATOR
PLUNGER
BOBBIN
BOBBIN. CASE-RETAINER
HOOK GIB
NEEDLE-DEFLECTING
HOOK WASHER
THROAT PLATE
BED SLIDES
ROTARY HOOK
ASSEMBLY
ROTARY HOOK
SADDLE COMPLETE
ARM CAP
FEED INDICATING DISC
BALANCE WHEEL
BED SLIDE
BOBBIN CASE OPENER
ARM-AND-HOOK
DRIVING-SHAFT
CONNECTION BELT
SAFETY-CLUTCH LOCK STUD
ROTARY-HOOK AND
CONNECTION BELT TIMING
PLATE AND ARROWS
239.448
Figure 3-24B. Class 111 sewing machine, front view showing components and parts.
identifies the component parts. The primary
feature of each component is explained in the
following listing:
Lifting Presser Bar Tension
Regulating Screw
Regulates the pressure on the alternating
presser foot.
Feed Indicating Disc
Indicates the number of stitches per inch
which are being made by the machine.
Balance Wheel
Provides a connection between the driving
unit and the sewing machine head.
Arm-and-Hook Driving Shaft
Connection Belt
Connects the upper arm shaft with the hook
driving shaft.
Feed Dog
Feeds the material from the under side.
Rotary Hook Assembly
Contains the mechanism which forms the
lockstitch by using the needle and bobbin
threads.
Bobbin
Contains the lower thread used in forming
the lockstitch.
Bobbin Case Retainer Hook Gib
Holds the bobbin case in the bobbin race.
Needle-deflecting Hook Washer
Deflects the needle so the rotary hook will
not strike the needle.
3-21
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
Throat Plate
Surrounds the feed dog and keeps the
material from slipping after the feed dog has
been adjusted to the proper height.
Bed Slides
Covers the feed eccentric and rotary hook
assembly on each side of the throat plate.
Feed Indicator Plunger
Used in connection with the feed indicator to
regulate the number of stitches per inch desired.
Safety-clutch Lock Stud
Reengages the needle with the hook driving
assembly after clearing a thread jam.
Bobbin Case Opener
Prevents thread from jamming underneath
the throat plate on the bobbin case base.
Rotary Hook Saddle Complete
The rotary hook is operated by the spiral
driving pinion gear which, in turn, is operated
by the hook driving gear located on the hook
driving shaft.
Rotary Hook and Connection Belt
Timing Plate and Arrows
Used to time the arm shaft with the hook
driving shaft.
The following parts are shown in the side
view of the Class 111 sewing machine (figure
3-25A and 25B).
Thread Takeup Lever
Pulls the needle thread against the tension
disc after the lockstitch is formed at the rotary
hook and pulls sufficient thread from the spool
to make the next stitch.
VIBRATING PRESSER-BAR
TENSIONS REGULATING SCREW
THREAD
TAKE-UP
LEVER
NEEDLE THREAD
TENSION
NEEDLE THREAD
CONTROLLER
SPRING ASSEMBLY
LIFTING
PRESSER-FOOT
NEEDLE BAR
VIBRATING PRESSER-FOOT
239.449
Figure 3-25A. Class 111 sewing machine, side view.
Vibrating Presser Bar Tension
Regulating Screw
Regulates the pressure on the presser foot.
Only sufficient pressure to hold the material
securely is needed.
Face Plate
Covers and protects the mechanism of the
two presser feet and needle bar.
Needle Thread Lubricator
Lubrication of the thread when sewing
leather. Lubrication of the thread prevents it
3-22
Chapter 3 SEWING MACHINES
FOR Illwl53,
AND Illwl54
FOR lllwlSS 21
PR.282
1. Hand lift for presser foot.
2. Vibrating presser bar thumbscrew.
3. Needle bar.
4. Vibrating presser bar.
5. Presser bar.
6. Presser foot.
239.282
Figure 3-25B. Class 111 sewing machine, side view show-
ing oiling points.
from fraying and prevents the needle from
becoming hot when sewing at high speed.
Needle Thread Tension
Regulates the tension on the needle thread so
that the lockstitch may be adjusted properly.
Needle Thread Controller Spring Assembly
Removes sufficient slack from the needle
thread when the needle is descending to prevent
the needle from splitting the thread.
Needle Bar
Holds the needle and carries the thread to the
rotary hook where the lockstitch is formed.
Vibrating Presser Foot
Holds the material in place while the alter-
nating presser foot rises to make another stitch.
Lifting Presser Foot
Holds the material in place while the
vibrating presser foot and feed dog go forward
to get material for the next stitch.
The class 111 machine is a compound feed
machine. This means that the feed dog, vi-
brating presser foot, and needle move together
to feed the material. Some class 111 machines
are equipped with a compound feed alone, such
as the 111W151; and others are equipped with a
combination of the compound feed and alter-
nating presser foot that holds the material
while the needle and vibrating presser foot are
moving into position for the next stitch such as
the 111 W 155.
Perhaps the description of the feed
mechanism gave you a hint that the class 111
sewing machine is a more complicated machine
than the class 31. It is indeed.
Timing the 111 W Class Sewing Machines
The first step in timing the 111 W is to set
the feed driving eccentric on zero stitches per
inch (0 spi). Set the needle bar. With the needle
bar in its lowest position (needle bar crank in
the horizontal position, the rounded portion on
the top and driving stud at the bottom), the con-
necting link will be vertical. Set the needle bar
with the upper timing mark just visible at the
base of the needle bar rock frame and tighten the
needle bar pinch screw. The needle bar is then
properly set.
To set a needle bar which has no mark, set
the feed eccentric for eight stitches to the inch.
Then set the needle bar so that when it rises 3/32
inch from its lowest position and the point of the
3-23
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
sewing hook is at the center of the needle, the
needle eye will be about 1/16 inch below the
hook point.
The next step is to time the arm shaft with
the hook drive shaft. With the connection belt
removed, rotate the balance wheel toward the
operator until the thread takeup lever is at its
highest point, then aline the arrow on the hook
drive shaft collar with the timing plate arrow,
and replace the connection belt. Rotate the
balance wheel and check. The next step is to
center the feeding action. For this step the feed
driving eccentric must be set on spi. With the
needle entering the feed dog, center the needle in
the hole in the feed dog with a distance of 17/32
inch between the needle bar and the presser bar.
In centering the feeding action the following
sequence should be followed:
Hold the needle centered in the feed dog with
a 17/32-inch space between the needle bar and
presser bar. Tighten the feed driving crank and
feed driving rockshaft crank pinch screws, being
sure that the crank is flush with the end of the
feed driving rockshaft and parallel with the bed.
Next, tighten the needle bar rock frame rock-
shaft crank pinch screw in the back of the
uprise. NOTE: The shank of the presser foot is
17/32 inch wide and may be used for measuring
the space.
The next step is to set the sewing hook to or
from the needle. This is done by moving the
hook saddle left or right as necessary, the hook
should pass the needle as closely as possible
without touching. When this is done, retighten
the hook saddle screws. Next, set the sewing
hook with the needle. With the needle bar on the
upstroke, the lower timing mark on the needle
bar should be just visible at the base of the
needle bar rock frame. Set the point of the sew-
ing hook in the center of the needle 1/16 inch
above the eye. To advance the sewing hook,
move the hook drive gear to the right; and to
retard, move the hook drive gear to the left.
NOTE: The first screw in the hook pinion
gear and the second screw in the hook drive gear
are splined screws. The hook drive gear must be
centered in relation to the sewing hook shaft at
the bottom of the hook saddle.
Ill W 150 Sewing Machine
The 111 W 150 sewing machine is a high-
speed, single-needle, lockstitch, compound feed
machine employing a gear driven rotary hook
with a vertical axis. It is designed for sewing
medium weight fabrics such as flight clothing,
nylon, twills, and lightweight canvas.
Ill W 151 Sewing Machine
The 111 W 151 sewing machine is also a
single-needle, lockstitch, rotary hook machine,
intended for high-speed straight stitching of
medium heavy materials.
The 111 W 151 sewing machine differs from
other models of the class 111 machines in that it
has a single presser foot instead of the alter-
nating presser foot.
Ill W 152 Sewing Machine
The 111 W 152 sewing machine is a single-
needle, lockstitch, compound feed machine with
a vertical axis sewing hook. This machine has
alternating pressers with a 3/8-inch lift. It has
a safety clutch which prevents the hook from
being damaged or getting out of time due to ac-
cidental strain.
Ill W 153 Sewing Machine
The 111 W 153 sewing machine is similar to
the 111 W 152, but it is used for sewing heavy
work such as automobile and truck upholstery,
tents, awnings, and leather flight jackets.
Ill W 154 Sewing Machine
The 1 1 1 W 154 sewing machine is also similar
to the 111 W 152, but its alternating pressers
have a lift of 1/2 inch and the machine is de-
signed for stitching upholstery work and leather
coats and binding heavy materials such as felt
padding.
Ill W 155 Sewing Machine
The 111 W 155 sewing machine is similar to
the 111 W 154 except that its minimum stitches
per inch is 3 1/2, and it has an adjustable lifting
eccentric for instantly setting the alternating
3-24
Chapter 3 SEWING MACHINES
pressers to the minimum amount of lift required
for the work to be sewn.
Lubrication of The Class 111
Sewing Machines
Figures 3-24A, 3-25B, and 3-26 show the
various lubrication points on class 111 sewing
machines. Oiling points are indicated by the un-
numbered arrows. Familiarization with the
nomenclature of the machines may also be ac-
complished by studying these illustrations.
To lubricate the class 111 machine, swing
back the top cover and oil the bearings, then
replace the cover.
Loosen the thumbscrew in the upper end of
the faceplate, turn the faceplate upward, and oil
the wick and bearings as shown in figure 3-25B.
After oiling, turn down the faceplate and tighten
the thumbscrew.
Turn the machine back on its hinges and
apply oil at the places designated by the
arrows in figure 3-27. All contacting parts on the
bottomside of the machine should also be oiled.
To lubricate the hook, remove the bed slide
and place oil in the oil well (figure 3-26). This
lubricates the upper hook bearing and the
mechanical opener mechanism.
The small' green felt pad on the side of the
bobbin case should be kept wet with oil to
lubricate the hook race. When this pad is wet, it
appears nearly black; when it appears light
green, it indicates that it is dry. When a machine
is new, oil should be applied to this felt pad
EACH TIME A BOBBIN IS REPLACED.
Needles and Thread
The thread used on rotary type sewing
machines is left twist. To determine the twist of
thread, refer to figure 3-28.
239.283
Figure 3-26. Rear of machine, showing oiling points.
3-25
_VOLUMEI
Table 3-3._Data for Qass , sewing
machine
-
are 225
type sewing
239.284
Sewing Machine
-
111 W 150
111 W 151
HI W 152
HI W 153
111 W 154
"I W 155
Stitches per
minute
1 ~-
3,500
3,500
2,900
2,900
2,900
O cnn
T == ====^ ~ ____
Stitches per
inch
.
5 to 32
5 to 32
5 to 32
5 to 32
5 to 32
Needle class
and variety
1 '
135x7
135x17
135x17
135x17
126x11
T =======:=
Needle
size range
t ~
7 to 24
14 to 26
12 to 24
12 to 24
- - 1 gyjjyu
3 1/2 to 32
1 QR v 1 n
22 to 27
| w A J. /
_
12 to 24
sewi ^ -achines
* th 8C fOr OSCillatin g
than the needles for
The additional part is the
small
K ne more Prt
8 T chines -
which is a
3-26
Chapter 3 SEWING MACHINES
239.267
Figure 3-28. How to determine the twist of thread.
point of the sewing hook to come close enough
to pick up the needle thread without striking the
needle.
Operation
Operation of the rotary type sewing ma-
chines is the same as for the oscillating sewing
machines.
Setting the Needle
Turn the balance wheel toward you until the
needle bar moves up to its highest position.
Loosen the setscrew in the needle bar and slip
the needle up into the bar as far as it will go. The
needle must be inserted with its long thread
groove toward the left; the eye of the needle
being directly in line with the machine bed.
Retighten the setscrew.
Threading the Machine
Pass the thread from the thread stand from
back to front (figure 3-29) through the lower
hole (1) in the thread post on top of the machine,
then from right to left through the upper hole (2)
in the post. Pass the thread down through hole
(3), up through hole (4), and down through hole
(5) in the thread guide on the front of the
machine. Continue the thread over from right to
left between the tension disks (6), and down,
from right to left around the thread controller
(7). Then the thread should go up into the fork
(8) in the thread controller disk against the
pressure of the wire controller. The thread is
9&11
1 . Lower hole in thread post.
2. Upper hole in thread post.
3. Hole in thread guide.
4. Hole in thread guide.
5. Hole in thread guide.
6. Tension disks.
7. Thread controller
8. Fork in the thread controller.
9. Thread guide.
10. Thread takeup lever.
11. Thread guide.
12. Felt pad and retainer finger.
13. Thread guide.
14. Thread guide.
15. Eye of needle.
16. Free end of thread.
239.285
Figure 3-29. Threading the Class 111 sewing machine.
then passed up through the thread guide (9), and
from right to left through the hole in the thread
takeup lever (10).
Pass the thread down through the thread
guide (11), and between the felt pad and the felt
pad retainer finger (12). (If the machine you are
threading does not have the felt pad and retainer
finger installed, bypass this component.) Finish
the threading by passing the thread down
through the thread guide (13), through the
3-27
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
thread guide (14) at the bottom of the needle
bar, and from left 10 right through the eye of the
needle (15). Always thread a needle toward the
bobbin.
Removing the Bobbin
To remove the bobbin draw out the right-
hand slide plate in the bed of the machine. Insert
the fingernail of the forefinger under the latch,
raise the latch, and lift the bobbin out. (See
figure 3-30).
Winding the Bobbin
To wind the bobbin and adjust the bobbin
winder, follow the procedure given for the 31-15
sewing machine.
Replacing the Bobbin and Threading the
Bobbin Case
Hold the bobbin between the thumb and
forefinger of your right hand with the thread
,/ 7
1. Slot in the bobbin case.
2. Projection on the bobbin case.
3. Bobbin case latch.
4. End of bobbin thread.
5. Bobbin.
6. Tension adjusting setscrew.
Figure 3-30. Bobbin case threaded.
239.286
drawn out on the bottom from left to right.
Place the bobbin on the center stud of the bob-
bin case; then push down the latch.
Draw the thread into the slot (1), and under
the back of the projection (2). Leave a loose end
of thread about 2 inches long above the slide.
When closing the slide plate, leave just enough
space for the thread to pass through when it is
first picked up by the needle.
Regulating the Tension
The tension on the needle thread is regulated /
by the tension thumb nut located at the front of/
the tension disks on the front of the machine. To
increase the tension, turn this thumb nut clock-
wise. To decrease the tension, turn the thumb
nut counterclockwise.
The tension on the bottom (bobbin) thread is
regulated by means of the small screw nearest
the center of the tension spring in the outside of
the bobbin case (1), as shown in figure 3-30. To
increase the tension, turn this screw clockwise.
To decrease the tension, turn the screw counter-
clockwise.
Regulating the Length of Stitch
The number of stitches per inch is stamped
on the stitch indicating disk, which can be seen
through the hole on the uprise.
To change the length of stitch, press down
the feed regulating stud (plunger), located in the
bed of the machine. At the same time turn the
balance wheel slowly until the plunger enters a
notch in the adjustable feed eccentric disk. Con-
tinue to hold the plunger and turn the balance
wheel forward or backward until the number of
stitches per inch desired can be seen through the
hole in the front of the uprise. Disengage the
plunger by releasing it.
Regulating the Pressure on the Material
The pressure on the material is regulated by
the presser bar regulating screw at the back
of the sewing machine. The screw acts on a flat
spring. To increase the pressure, turn this screw
downward. To decrease pressure, turn this
screw upward. The pressure should be only
heavy enough to enable the feed to move evenly
3-28
Chapter 3 SEWING MACHINES
along whatever thickness of material you are
using.
Preparing for Sewing
With the left hand, hold the end of the
needle (machine) thread, leaving it slack from
the hand to the needle. Turn the balance wheel
over toward you until the needle moves down
and up again to its highest position. If the sew-
ing machine is properly timed, this will bring
the bobbin thread up with the machine thread
through the hole in the feed dog. Lay the threads
back under the presser foot and close the slide.
Place the material under the presser foot.
Lower the presser foot either by hand or by the
knee lift, and commence to sew. Start the sewing
by turning the balance wheel over toward you as
you depress the treadle.
Removing the Work
After the machine has stopped, move the
thread takeup lever to its highest position. Raise
the presser foot, draw the work back, and cut
the threads close to the material. Lay the ends of
the threads back under the presser foot.
SINGER SEWING MACHINE 211 W 151
This machine performs the same functions as
the 111 W 151. It is a newer model, more
streamlined and modern in appearance, and has
some design features not found in the 1 1 1 W 151
machine. (See figure 3-31.) These features
include a new lubrication system, a thread
takeup lever guard, a thread lubricator, and a
new stitch indicator.
TAKE UP LEVER
GUARD
OIL SIGHT GAGE
240.80
Figure 3-31. The 211W151 sewing machine.
3-29
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
The 211 W 151 sewing machine is a high-
speed (4,000 rpm maximum), single-needle,
lockstitch-type machine, designated for sewing
medium to heavy weight fabrics. It is belt-driven
and has a rotary hook on a vertical axis, which
makes two revolutions for each stitch.
It has a safety clutch (figure 3-32) which is
adjustable to suit the sewing conditions; this
protects the sewing hook from damage. If the
hook is obstructed by foreign matter, the clutch
will disengage and reengage only after the area
has been cleared. The feeding mechanism is a
compound drop and needle feed with the longest
stitch at five stitches per inch.
Other features of the machine include a
hinged presser foot, a presser bar lift of 1/4
inch, a needle bar stroke of 1 5/16 inches, a bed
which is 20 3/8 inches long by 7 inches wide, and
a space of 10 1/2 inches to the right of the
needle.
Needles
The needles used in this machine vary ac-
cording to the clearance under the presser foot.
Use 135 x 7 needles with machines set with
1/4-inch clearance under the presser foot, and
135 x 17 needles with those set with 3/8-inch
clearance (lift).
Adjustments
SETTING THE NEEDLE BAR. Place the
needle bar up into the needle bar holder as far
as possible. Hold in this position and turn
the balance wheel toward the operator until the
needle bar is at its lowest position. When in this
position, set the bar so the upper timing mark is
just visible below the needle bar frame and
tighten the needle bar connecting stud pinch
screw.
In case the needle bar does not have timing
marks, set the machine to stitches per inch and
place the needle bar up in the holder as far as
possible. Turn the balance wheel by hand until
the bar is at its lowest position. After reaching
the lowest position of the needle bar, continue
turning the balance wheel toward the operator
until it reaches 3/32 inch above its lowest point,
then set the eye of the needle 1/16 inch below the
point of the sewing hook.
SETTING THE NEEDLE. To set the
needle, insert the needle shank as far as possible
into the needle bar with the long groove of the
needle to the left and tighten the screw. (See
figure 3-33.)
TIMING MARKS
MOVE NEEDLE BAR
TO HIGHEST POINT
LOOSEN SCREW
INSERT NEEDLE UP AS
FAR AS POSSIBLE AND
TIGHTEN SCREW
LONG GROOVE
TO LEFT
HINGED
PRESSER FOOT
240.81
Figure 3-32. Safety clutch and lower belt pulley.
240.82
Figure 3-33. Setting the needle.
3-30
Chapter 3 SEWING MACHINES
RELATIVE POSITION OF NEEDLE BAR
AND PRESSER BAR. To set the relative posi-
tion of the needle bar to the presser bar,
loosen the needle bar rock frame rockshaft
clamp screw which is located behind the cover
plate on the front upright position of the arm
(figure 3-34). Set the needle bar so the distance
between the needle bar and presser bar is 17/32
inch. Retighten the clamp screw. NOTE: A
handy tool for this adjustment can be manufac-
tured locally from a thin piece of metal stock
filed to exactly 17/32-inch width. This gage
should be placed between the two bars while the
clamp screw is being tightened. This enables the
operator to keep pressure on the loose needle
bar.
ADJUSTMENT HEIGHT OF SEWING
HOOK. Before attempting to adjust the
height of the sewing hook, it is necessary to
make a feeler gage for testing the height.
This gage can be made of 0.032-inch shim stock,
or a regular feeler gage can be cut or trimmed
down so it will fit in the small groove in the
throat plate which retains the bobbin case stop
finger.
If, after testing, the hook height is un-
satisfactory, turn the balance wheel so the
two setscrews in the bottom of the hook
are accessible; loosen them with an Allen
wrench. Remove the cloth washer from the
bobbin case and turn the hook until the
height adjusting screw is directly under the
hole in the bobbin case. (See figure 3-35.) Turn
the screw in to raise the hook, and out (while
pressing down on the hook) to lower it. The
gage should barely pass between the throat
plate and bobbin case stop finger. Retighten the
Allen setscrews and turn the adjusting screw
in so that a slight tension is left on the
screw.
SETTING SEWING HOOK TO OR FROM
NEEDLE. To set the relative position of the
hook saddle to the needle, loosen the hook sad-
dle adjusting screws (figure 3-36) and slide the
hook saddle to the right or left, as necessary, in
order to set the point of the hook as close to the
needle as possible (without actually touching).
After setting the hook saddle, check the clear-
ance between the hook drive gear and the face of
the hook saddle. This clearance should be 0.008
inch; if it is not, reset it by loosening the
screw and setscrew in the hook drive gear and
NEEDLE BAR VRAM^SHAFT
CLAMP SCREW
240.83
Figure 3-34. Needle bar rock frame rockshaft clamp
screw.
239.450
Figure 3-35. Timing the sewing hook.
3-31
AIRCREW SURVIVAL EQUIPMENTMAN 3 & ^VOLUME 1
FEED LIFTING CAM FORK
CAM FORK ADJUSTING SCREW
FEED ECCENTRIC
HOOK SADDLE
ADJUSTING SCREWS
Figure 3-36. Hook Saddle assembly showing bobbin case raceway oil reservoir.
240.85
move the gear to the right or left to get the
proper clearance.
TIMING BOBBIN CASE OPENER. To
set the bobbin case opener, turn the balance
wheel toward the operator until the lower timing
mark on the needle bar is barely visible below
the needle bar frame on its upward stroke. Tip
the machine back and loosen the two Allen
screws in the bobbin case opener drive gear; then
line up the timing marks by turning the opener
shaft with a screwdriver. The timing marks are
located as follows: one on the flange of the
opener, and the other on the hook saddle (figure
3-35). Adjust the opener so it lightly touches
the bobbin case and turns it enough to make a
sufficient opening for a free passage of thread
between the bobbin case stop finger and the
throat plate. Tighten the screws in the bobbin
case opener drive gear.
RAISING OR LOWERING THE FEED
DOG. To raise or lower the feed dog, remove
the throat plate and clean all lint and dirt from
between the grooves and teeth of the feed dog.
Tip the machine back and turn the balance wheel
toward the operator until the feed dog is in its
highest position. Loosen the screw in the feed
lifting cam fork and raise or lower the dog as
desired; then retighten the screw. NOTE: A
properly set feed dog will show a full tooth
above the throat plate when at its highest posi-
tion.
After adjusting the feed dog, check to see
that the needle is properly set in the hole in the
feed dog. If adjustment is needed, loosen the
pinch screws in the feed driving rock frame and
set the needle so that when it is all the way down
it will be slightly forward of center in the hole.
Retighten the pinch screws. The feed adjustment
points are illustrated in figure 3-37.
ADJUSTING FEED ECCENTRIC. The
feed eccentric (figure 3-38) may occasionally
need adjustment to remove play caused by wear
of the gib, or by looseness between the feed ec-
centric and the eccentric body. To adjust the gib,
loosen the two locking screws, then turn inward
3-32
Chapter 3 SEWING MACHINES
I SCREWS
FEED DRIVING ROCK SHAFT
CK FRAME
240.86
3-37. Feed adjustment for the 211W151 sewing
machine.
iCKING
:REWS
ADJUSTING
SCREWS
240.87
Figure 3-38. The feed eccentric.
on the adjusting screws until all play is elim-
inated and the eccentric fits in the slot properly.
CAUTION: LOCKING SCREWS MUST
BE LOOSENED BEFORE ATTEMPTING TO
LOOSEN ADJUSTING SCREWS. RE-
TIGHTEN THE LOCKING SCREWS AFTER
ADJUSTMENT IS MADE.
The feed eccentric collar may be moved to
the right or left to change spring tension, but it
is ordinarily set flush with the hub of the eccen-
tric body.
CHANGING THE LENGTH OF THE
STITCH. To change the length of stitch, stop
the machine. Turn the balance wheel, by hand,
toward the operator until the button drops
(clicks), then turn the machine pulley until the
number representing the desired stitches per inch
is lined up properly and then release the button.
CAUTION: DISENGAGE THE BUTTON
BEFORE ATTEMPTING TO SEW. DO NOT
ENGAGE THE BUTTON WHILE THE
MACHINE IS IN OPERATION.
Removing Components
To remove the hook, take off the presser
foot, throat plate, and feed dog; then loosen the
two Allen screws in the hub of the hook and lift
the hook off the hook shaft. To remove the bob-
bin case from the hook assembly, loosen the
hook gib screws, lift off the gib, and then lift out
the bobbin case.
Removing the Arm Shaft Connection Belt
When the arm shaft connection belt is
disconnected for any reason, the machine will be
completely out of time. Therefore, the needle
should be removed before removing the belt to
prevent damage. To remove the belt, slide it off
the lower belt pulley, loosen the screws in the
machine pulley, and remove the pulley and ball
bearing, which come out through the end of the
arm.
Replace the belt by reversing this procedure.
Remove the end play from the shaft by lightly
setting the setscrews and tapping the balance
3-33
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
wheel into position with the palm of the hand
and then securely setting the setscrews. Place the
belt over the upper belt pulley and line up the
timing marks on the lower belt pulley and on the
bed of the machine. While holding the lower belt
pulley in position, turn the balance wheel toward
the operator's position until the thread takeup
lever is at its highest position, then slide the belt
onto the lower belt pulley. The arm shaft con-
nection belt and the lower belt pulley are il-
lustrated with the safety clutch in figure 3-32.
CAUTION: DO NOT TAMPER WITH THE
SAFETY CLUTCH. ITS TORQUE IS PRESET
AT THE FACTORY.
Lubrication
The hook saddle is equipped with an oil
reservoir (fig. 3-36) which contains oil to be
pumped to the bobbin case raceway. The flow of
this oil is controlled by a control valve screw
located just aft of the bobbin case opener in
the hook saddle. For more oil, turn the valve
screw clockwise; counterclockwise for less oil.
CAUTION: DO NOT ADJUST FLOW OF OIL
WITHOUT FIRST LOOSENING THE LOCK-
ING SCREW LOCATED ON THE SIDE OF
THE HOOK SADDLE JUST ABOVE THE
CAM SHAFT GEAR. AFTER ADJUST-
ING THE CONTROL VALVE SCREW FOR
PROPER FLOW, RETIGHTEN THE LOCK-
ING SCREW.
SINGER SEWING MACHINE
143 W 2 AND 3
This type of machine is not as common as
those previously described, but it has unlimited
uses in the repair and maintenance of parachutes
and survival equipment.
The 143 W 2 is a high-speed sewing machine
which has an aluminum alloy vibrating needle
bar frame and a rotary hook. It is intended for
overseaming and zigzag stitching on fine and
general fabrics and lightweight leather. It has
ball bearings on the rear end of the arm shaft
and hook driving shaft. The needle bar has a
maximum throw of 3/16 inch, vibrating both
sides of a centerline.
The 143 W 3 sewing machine is similar to the
143 W 2 except that the needle has a maximum
throw of 5/16 inch.
The maximum speed recommended for ma-
chine 143 W 2 is 3,500 stitches per minute, and
for machine 143 W 3, 3,000 stitches per minute,
the speeds depending on the material being
sewn.
Needle and Thread
The needles for the 143 W 2 and 3 sewing
machines are of class and variety 135 x 7; the
sizes from 7 to 24.
Left twist thread should be used on these
machines. To make a smooth even stitch with
the sewing machine, use good, firmly twisted
and smoothly finished thread. The thread
should pass freely through the eye of the needle.
Setting the Needle
Push the needle up in the needle bar as far as
it will go, with the LONG THREAD GROOVE
TO THE FRONT, and secure it firmly with the
setscrew. It may be necessary to turn the needle
slightly to the right or left for some threads if
stitches are missed.
Bobbin and Bobbin Case
The procedure for removing the bobbin case,
winding the bobbin, threading the bobbin case,
and replacing the bobbin case is the same as for
the 31-15 sewing machine. The only exception to
this is that when the bobbin case is threaded, the
thread should be drawn from the BOTTOM
from left to right, instead of from the top as
given for the 31-15.
Threading the Needle
These machines are threaded in the same way
as the 111 series machines, described earlier in
the chapter. When threaded up to the needle,
thread the needle from the front through the eye
to the back. The long thread groove should be in
front when the needle is properly set in the
needle bar.
3-34
Chapter 3 SEWING MACHINES
Regulating the Length of Stitch
To adjust the length of stitch, depress the
stitch regulator lever (figure 3-39) on the uprise
and, at the same time, turn the balance wheel
forward until the lever engages in the notch in
the stitch regulator flange. Hold the lever in the
notch and turn the balance wheel backward or
forward (as necessary) until the desired number
of stitches per inch is shown opposite the arrow
on the stitch regulator.
Regulating the Width of the Zigzag
The extreme width of the zigzag (needle
throw) on the 143 W 2 is 3/16 inch; it is 5/16
inch on the 143 W 3. The width of bight is
regulated by turning the knurled knob on the
needle vibrator regulating spindle head (figure
3-39) at the front of the machine. To increase the
width of the stitch, turn the regulating spindle
head to the left, and to the right to decrease.
Setting the Needle Bar
The two adjustment marks on the needle bar
are 3/32 inch apart. To set, insert the needle bar
up into the needle bar frame so the upper mark
is just visible at the lower end of the needle bar
frame with the bar at its lowest position. The eye
of the needle should be 1/16 inch below the
BALANCE
WHEEL
iSTITCH
REGULATOR
LEVER
VIBRATOR REGULATING
SPINDLE HEAD (KNURLED)
239.293
Figure 3-39. Oiling points at the front of the 143W2.
3-35
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
1. Eccentric stud.
2. Vibrator pinion gear.
3. Stitch regulator.
4. Stitch regulator lever.
5. Regulating spindle head.
6. Lower belt pulley.
7. Hook drive gear.
8. Hook spindle screw.
9. Hook pinion gear.
10. Feed driving rocks haft.
11. Hook drive shaft.
12. Arm shaft.
Figure 3-40. X-ray view of zigzag sewing machine.
240.92
point of the hook, and the long thread groove
toward the operator.
Setting and Timing the Needle Bar Frame
Turn the regulating spindle head all the way
to the right. This will cause the machine to sew a
straight stitch. The needle should be centered in
the hole in the throat plate. If not, loosen the
setscrew which holds the eccentric stud (1) and
turn the stud until it is centered (figure 3-40.)
Turn the needle regulating spindle head (5) to
the extreme left for the widest throw. Turn the
balance wheel forward until the needle is at its
lowest position. The needle bar should start to
move in a sideward movement as the needle
starts to rise. If it does not, you must advance or
retard the vibrator jpinion gear (2) shown in
figure 3-40.
3-36
Chapter 3 SEWING MACHINES
1. Hook spindle screw.
2. Feed dog adjusting screw.
3. Hook drive gear.
4. Feed dog eccentric stud setscrews.
5. Feed dog eccentric stud.
6. Bobbin case stop.
7. Hook pinion gear setscrews.
8. Hook shaft retaining screws.
9. Feed driving arm connection pinch screw.
10. Lower belt pulley setscrews.
240.93
Figure 3-41. Adjustments in the bed of the machine.
Timing Sewing Hook
Turn the balance wheel toward the
operator's side until the needle bar is all the way
down and has risen until the lower timing mark
is just visible below the needle bar frame.
Loosen the setscrews (10) in the lower belt pulley
(figure 3-41) and set the hook point to the center
of the needle eye. Retighten the setscrews.
Setting the Hook Distance
To or From Needle
Loosen the two hook shaft retaining screws
(figure 3-41 (8)) and the two screws in the hook
pinion gear (figure 3-41 (7)), and slide the hook
to the correct position. Retighten the hook shaft
retaining screws. Set the gear in the proper place
on the shaft gear aligned with hook drive
gear and retighten the two setscrews to hold
the hook in position.
Raising or Lowering the Feed Dog
The feed dog should show a full tooth above
the throat plate when at its highest position. To
adjust the dog, remove the throat plate and
make sure all lint, dirt, or other obstruction is
removed, then replace the throat plate. Turn the
balance wheel forward until the feed dog is at its
highest position; then loosen the feed dog ad-
justing screw (figure 3-41 (2)), and raise or lower
the feed dog as required. Retighten the adjusting
screw to hold the feed dog in position.
To prevent the feed dog from striking either
end of the slots in the throat plate, loosen the
pinch screw (figure 3-41 (9)) and move the feed
dogs forward or backward (as necessary) until
3-37
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
the longest stitch can be taken without striking
the throat plate.
Sewing Techniques
In this chapter we pointed out the need to let
the machine feed the material being sewn, and
other techniques to obtain a good seam. At first
you will find it very difficult to turn comers
when using a sewing machine. If you will follow
these instructions you will find it very easy to
make a turn and not lose your stitch.
Stop the machine while the needle is rising,
but before it is out of the material raise the
presser foot and turn the work. This method
uses the needle as a pivot. When the material lies
in the new position, lower the foot and continue
sewing.
Removing the Work
Raise the presser lifter and turn the machine
by the balance wheel until the takeup lever is at
its highest position. Draw the work out away
from you. If the threads do not draw out easily,
the takeup lever is not in the right position. If
the machine is stopped as directed, the needle
will not be unthreaded when you start to sew,
even if only a short end is left through the eye of
the needle.
CONSEW 99R and 99R-3 SEWING
MACHINE (Figure 3-42)
The Navy has recently acquired new model
zigzag sewing machines capable of the rope sew-
ing needed to install the four-line release system.
Two models are available the 99R and the
99R-3. Both models are rotary hook type ma-
chines. They are fairly conventional machines
and the operation of both is very similar to that
of the machines we have already discussed.
Threading the 99R and 99R-3 Machines
Follow the instructions below when thread-
ing the needle and bobbin on the 99R and 99R-3
sewing machines:
1. Turn the balance wheel toward you until
you are able to position the needle so you can
place the thread through its eye. Remember,
always thread the needle toward the bobbin. In
this case you run the thread from front to back.
2. Hold the loose end of the needle thread in
your left hand, turn the hand wheel toward you
with your right hand until the needle moves
down and up again to its highest position.
3. Pull the needle thread gently and the bob-
bin thread will come up with it through the hole
in the needle plate.
4. Place both ends of the thread beneath and
in back of the presser foot.
5. With the needle at its highest point, place
the material to be sewn beneath the presser foot
and fully lower the presser foot lifter lever.
6. Start sewing.
Regulating the Tension
Tension is the key word to good sewing. For
perfect stitching, the tension of the upper and
lower threads should be balanced and just suffi-
ciently tight to lock both threads in the center of
the material (look again at figure 3-16).
The machine is correctly adjusted to make a
perfect stitch before leaving the factory. When
adjustments do become necessary, the problem
is more likely to be caused by the upper thread
tension, so always begin there. To adjust the
upper thread tension proceed as follows:
1. Lower the presser foot. Remember upper
thread tension adjustments must be made with
the presser foot down.
2. Check the upper thread tension. If it is
loose, turn the tension nut (A in figure 3-43)
clockwise to increase the tension; if the upper
thread tension is tight, turn the tension nut
counterclockwise to loosen it.
Adjusting the Bobbin Thread Tension
When you find it necessary to adjust the bob-
bin thread tension, turn the tension screw
(T of figure 3-44) on the bobbin case clockwise
to increase the tension and turn the screw
counterclockwise to decrease the tension.
3-38
Chapter 3 SEWING MACHINES
11
8
1. Spool pin
2. Thread guide
3. Pressure regulator
4. Take-up lever
5. Tension regulator
6. Needle bar
1. Presser foot
8. Slide plate
9. Needle Plate
10. Stitch length regulator
11. Feed direction lever (for tacking)
12. Zigzag width regulator
Figure 3-42. Consew 99R and 99R-3.
239.451
B
DECREASE
Figure 3-43. Upper thread tension.
239.452
DECREASE
Figure 3-44. Bobbin thread tension.
239.453
Regulating the Pressure of the Presser Foot
The pressure of the presser foot should be
adjusted according to the type of material being
sewn. The heavier the material, the heavier the
3-39
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
pressure. The lighter the material, the lighter the
pressure. The pressure should be only heavy
enough to prevent the material from rising with
the needle and to enable the feeder mechanism
to move the work along evenly. The pressure
becomes tighter as the regulating thumb screw is
turned clockwise, and looser as the thumb screw
is turned counterclockwise (figure 3-45).
Stitch Regulator and Reverse Sewing
and Tacking
1 . When the number (1) on dial (A) of figure
3-46 is set uppermost on a vertical line, the
feeder does not move the material.
2. When the dial (A) is turned counter-
clockwise and lever (B) is raised as far as it will
go, the machine makes forward stitches, increas-
ing in size as the dial knob is turned toward the
larger numbers.
3. For reverse sewing, lower the lever (B) as
far as it will go.
4. By moving the lever up and down during
sewing, you can easily make forward or reverse
stitches continuously and at will. You can make
use of this feature for locking the thread at the
start or end of seams.
B
239.455
Figure 3-46. Stitch Regulator.
STRAIGHT AND ZIGZAG SEWING
TURN
239.454
Figure 3-45. Adjusting the Presser foot pressure.
Be sure that stops (SI) and (S2) are set at the
extreme ends of their slot. If not, use a
screwdriver to loosen them about one turn and
then tighten them in their extreme positions.
Turning the zigzag regulating knob (Z) clock-
wise as far as it will go causes the machine to sew
with a straight stitch. Turning this knob
counterclockwise produces a zigzag stitch. The
zigzag becomes wider the more this knob is
turned in a counterclockwise direction. The
widest zigzag stitch is sewn when knob (Z) can-
not be turned any further. This occurs when the
pointer at the underside of knob Z points at the
largest number on the dial and is stopped by stop
(S2).
When you want to control the width of the
zigzag between certain minimum and maximum
limits between the numbers on the dial, use a
3-40
Chapter 3 SEWING MACHINES
screwdriver to set stops (SI) and (S2) to the
selected widths. Be sure to set stop (SI) as far to
the left as possible when a straight stitch is
desired.
NOTE: The zigzag regulating knob can be
moved into any desired position while the
machine is operating. Do not turn the zigzag
regulating knob when the machine is at rest and
the needle is in the material. If you do you may
bend or break the needle. Turn the handwheel
toward you to raise the needle out of the
material before operating the regulating knob.
Preparing the Machine for Rope
Stitching (Model 99R-3 only)
For rope stitching, the standard combination
of presser foot, feed dog, and (throat) needle
plate is replaced with a special set of components
designed specifically for this purpose. To do
this, move slide plate (S of figure 3-47) as far to
the left as it will go. Using a screwdriver, remove
the two screws holding the needle plate (N) to
the bed of the machine. Remove presser foot (P)
from the presser bar and lift the needle plate off
the bed. Now the feed dog becomes exposed.
Loosen the two screws which attach the feed dog
to its carrier, and remove the feed dog.
Proceeding in reverse order, first install the
special rope-sewing feed dog on the feed dog
carrier, making certain that the two screws are
tightened well. Next, put in place the special
(throat) needle plate, and then the special presser
foot, tightening all their screws securely, and
close the slide plate.
Adjust the stitch length and the width of
zigzag to suit the rope to be sewn.
SETTING THE NEEDLE BAR
AT THE CORRECT HEIGHT
Before adjusting the height of the needle bar,
make sure that the needle is pushed up into the
needle bar as far as it will go. Now, remove the
face plate from the machine. Set the zigzag con-
trol knob for straight sewing and turn the hand
wheel toward you until the needle reaches the
lowest point of its downward stroke. See that
the needle enters the needle slot in the throat
(needle) plate at the very center. If it does not,
239.456
Figure 3-47. Rope Stitching.
center the needle as described in the paragraphs
entitled * 'Centering. . . ". When the needle is
centered, proceed in the following manner:
Remove the slide plate, needle (throat) A late
and feed dog. Continue turning the handwheel
toward you until the needle bar has risen ap-
proximately 3/32" above its lowest position. The
point of the sewing hook should now be at the
center of the needle at a distance approximately
3/32 " above the eye.
If adjustment should be required, loosen the
set screw (B of figure 3-48) in the needle bar con-
necting stud to raise or lower the needle bar as
may be necessary. Be sure to tighten the set
screw after making this adjustment.
CENTERING THE NEEDLE IN THE
THROAT (NEEDLE) PLATE
If the needle needs centering within the
needle slot in the needle (throat) plate, set the
3-41
3 & 2, VOLUME 1
239.457
Figure 3-48. Setting needle bar.
machine for straight sewing and turn the hand-
wheel toward you until the needle bar reaches
the lowest point of its downward stroke. Loosen
set screw (C of figure 3-48) and turn eccentric
stud (A of figure 3-48) until the needle is
centered correctly. Retighten set screw (C).
Set the zigzag knob to the widest stitch posi-
tion and turn the handwheel toward you.
Observe the passage of the needle through the
needle (throat) plate. It should pass at about an
equal distance from either end of the needle slot
when making the left and right zigzag stitch. If
necessary, readjust the eccentric stud (A 'of
figure 3-48) as described before.
TIMING THE SEWING HOOK
Remove the presser foot, slide plate, throat
(needle) plate and bobbin case. Also remove the
feed dog. With a new needle in the machine turn
the handwheel toward you until the needle bar
reaches its lowest point. Continue turning and
allow the needle bar to rise about 3/32" while on
its upward stroke. With needle bar in this posi-
tion, the point of the sewing hook should be at
the center of the needle (figure 3-49).
If the sewing hook should not be timed cor-
rectly, loosen the three set screws in its hub,
Turn the hook on its shaft to align the point with
the center of the needle as shown in figure 3-50,
Tighten the three set screws.
23V. 458
Figure 3-49. Timing sewing hook.
Figure 3-50. Sewing hook.
239.45S
3-42
Chapter 3 SEWING MACHINES
TO REMOVE AND REPLACE THE
SEWING HOOK
Remove the needle, slide plate, and bobbin
case. Take out screw (D of figure 3-51) and
remove hook retainer (E of figure 3-51). Loosen
the three set screws in the hub. Turn the hand-
wheel until the thread guard (widest part) of the
hook is at the bottom, then remove the sewing
hook from its shaft (figure 3-51).
When installing a new sewing hook, have the
thread guard at the bottom. Now turn the bob-
bin case holder until the notch (F) is at the top.
Replace the hook retainer (E) watching that the
projection (G) near its end (figure 3-51) enters
notch (F) in the bobbin case holder. Fasten the
hook retainer to the underside of the bed by
means of its screw. Replace the needle and time
the sewing hook as described in the preceding
paragraph. Reinstall the bobbin case, throat
plate, and slide plate.
TIMING THE FEEDING MECHANISM
The feeding mechanism is timed at the
factory for average stitching performance. Nor-
mal timing is such that the feed dog teeth, rising
from their lowest position, should be just flush
with the surface of the throat (needle) plate after
the needle point has traveled about 5/16" above
the plate while on its upstroke.
239.460
Figure 3-51. Removing sewing hook.
To adjust the feeding mechanism, remove
the top cover from the machine. Turn the hand-
wheel toward you until the two set screws which
lock the feed eccentric into the main shaft come
into view (figure 3-51). Loosen both set screws;
lightly tap the feed eccentric toward you to ad-
vance the feed timing. To retard the feed timing,
tap the eccentric to rotate it toward the rear of
the machine.
NOTE: Rotate the eccentric no more than
about 1/16", then tighten its set screws and
check for results.
TIMING THE MOVEMENT OF THE
NEEDLE BAR FRAME
Set the zigzag knob for straight stitch. Turn
the handwheel and observe the travel of the
needle into and out of the needle slot in the
throat (needle) plate. If the needle is not
centered in the slot, make the adjustments which
have been described.
Now adjust the needle to produce the widest
zigzag stitch. Turn the handwheel toward you
and observe vibration (sidewise movement) of
the needle bar. The needle bar, on its upward
movement, should begin to vibrate when the
point of the needle is no less than about 3/32"
above the throat plate and should stop vibrating
when the needle has reached approximately the
same position on its downward movement. To
adjust the vibration of the needle bar on model
99R, loosen the set screws (H of figure 3-51) in
the vibrator cam and slightly turn this cam on its
shaft. Tighten the set screws and check for
results.
On model 99R3 the vibration of the needle
bar is produced by a plate cam located at
(R) on figure 3-51. Loosen its set screws
and slightly turn the cam on its shaft follow-
ing the same procedure as outlined in the preced-
ing paragraph. Be sure to retighten the set
screws.
TO RAISE OR LOWER THE
FEED DOG
When at its highest position, the feed dog
should usually rise above the throat (needle)
plate the full depth of the teeth.
3-43
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
To adjust the position of the feed dog,
loosen screw (J of figure 3-50) and raise or lower
the feed dog; then tighten the screw. When rais-
ing or lowering the feed dog, be careful that its
underside does not drop so low that it strikes the
hook.
ADJUSTMENT OF THE THREAD
TAKE-UP SPRING
The thread takeup spring (X of figure 3-52)
should be set so that when the eye of the
needle reaches the material on the downward
stroke the spring has completed its action and
rests against the top of the thread takeup spring
regulator.
If the thread takeup spring is not correct,
i^/>r. AY i cot c/> r pw n nf ficriirp VS2"i and turn the
Juced move-
ght for more
p spring is set cor-
Regulation of the tension of the thread
takeup spring (K) is done by turning the tension
stud (M) to the right to increase tension or to the
left to decrease it. Tension of the spring should
just be enough to take up the slack of the needle
thread until the eye of the needle reaches the
material on its downward movement.
239.461
Figure 3-52. Adjusting Thread Take-up spring.
3-44
CHAPTER 4
FABRICATION AND MANUFACTURE
You, as an Aircrew Survival Equipmentman
need to know what materials are best suited for
the job at hand if you are to be considered a
master craftsman of your trade. Therefore, to
lay the groundwork for your becoming a skilled
PR, this chapter discusses the textile materials,
tapes, webbing, thread, cards, knots, and seams
you will use.
Many of the repairs you come across can be
accomplished by replacing missing or worn
hardware. There are occasions when minor
repairs require hand sewing because machine
sewing is impractical or impossible. For in-
stance, it might be advisable to make minor
repairs to aircraft upholstery by hand sewing the
repair in the aircraft rather than by bringing the
item to the shop. On the other hand, most sew-
ing is done by a sewing machine. A seam is
usually constructed faster, and is more durable,
when a sewing machine is used. The use of a
sewing machine gives the seam a better ap-
pearance. To do your job right, you must know
the types of hand and machine-made seams and
how to make them.
TEXTILE MATERIALS TERMS
AND MEANINGS
When a PR talks about warp, he doesn't
mean something's out of shape; and when he
talks about filling, he isn't referring to teeth.
He's using terms textile manufacturers use,
terms which are standard throughout the textile
industry. The Navy uses these standardized tex-
tile terms to identify and classify materials on
Navy stock lists. Aircrew Survival Equipment
Changes and Bulletins also contain some of
these terms. In order to comply with these repair
instructions, you must first understand the terms
used in them.
FIBER AND FILAMENT
Fiber is the basic unit used in the fabrication
of textile yarns and fabrics. Vegetable, animal,
and mineral fibers are natural fibers; nylon,
dacron, and rayon are synthetic fibers. A fila-
ment is an individual strand of material, and can
be any length. Filament is also another word for
fiber, usually used when indicating or referring
to synthetic fibers. A fiber, or filament, is the
smallest unit in any type of cloth. An example is
a silk filament, which may vary in length from
300 to 1,000 yards. Synthetic filaments may be
several miles long.
Staple
The staple is the smallest unit of a naturally
occurring fiber, or a synthetic filament cut in
short lengths to be combined with other fibers in
the manufacture of a variety of materials. When
used in reference to the naturally occurring
fibers, it denotes quality or fineness, such as
"long staple" cotton.
Yarn
Yarns are continuous strands of textile fibers
or filaments, in a form suitable for manufactur-
ing textile materials. The strength of the yarn is
influenced by fiber strength, size, and length;
size of the yarn; and tightness of twist. The
strength of textile fabrics is determined by yarn
strength and weight. You may form yarn by any
of the following processes: a number of fibers
twisted together, a number of filaments laid
4-1
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
together without twisting, or a number of
filaments twisted together. Yarns formed by
twisting a number of filaments together are
referred to as multifilament (many-filament)
yarns. Ply yarn is two or more single yarns
twisted together.
Selvage and Raw Edges
The selvage edges of material, as shown in
figure 4-1, are the edges of cloth, tape, or
webbing that are woven to prevent raveling.
When the material is cut, the resulting edge at
the cut is referred to as a raw edge.
Warp
These are threads that run lengthwise of the
cloth parallel to the selvage edge. If there is a
difference in the strength of the warp and filling
threads, the warp threads are usually stronger,
because they form the framework for the ma-
terial and support most of the strain during
the weaving process. Figure 4-1 illustrates both
warp and filling threads.
Filling
Filling is also referred to as a woof, weft, or
pick. It is the threads that run crosswise to the
FILLING
SELVAGE
EDGE
239.367A
Figure 4-1. Textile terms.
cloth as it comes from the loom. This term is not
to be confused with " filling* ' in the sense of siz-
ing, which means the addition of substances that
give body or decrease porosity of the material.
Warp and filling threads must be determined in
pattern layout, for patterns (unless otherwise
stated) are always cut with the warp and filling.
Weave
The weave is an interlacing of two sets of
threads (warp and filling) to form a specific pat-
tern. The manner in which the material is woven
or constructed affects many of the cloth proper-
ties, such as tensile strength, air permeability,
and elongation.
Bias
A bias is a diagonal line of a cut, a fold, or a
seam across a piece of textile material at an angle
of 45 degrees to the direction of the filling
threads in the material. Bias construction is used
to save material, prevent tearing between sec-
tions, and provide elasticity where it is a re-
quirement for a satisfactory performance of the
article. The bias direction of the fabric has a
greater stretching quality than the straight direc-
tion. A bias cut is illustrated in figure 4-1.
Tensile Strength
The force required to break a material is
called tensile strength. The tensile strength of a
fabric is stated in pound-per-inch width for warp
and filling. The tensile strength of webbings and
tapes is stated for the full width.
Cloth Weight
The cloth weight is the weight of a cloth, or
fabric, in ounces per square yard. All fabrics
have a designated cloth weight. For instance, a
square yard of cotton duck may weigh 8 ounces;
therefore, it is called 8-ounce duck.
CONSTRUCTION FEATURES AND
USES OF VARIOUS TEXTILE
MATERIALS
If a cigar ash burns a hole in your tweed
jacket, you will not patch it with a piece of velvet
4-2
Chapter 4 FABRICATION AND MANUFACTURE
material. If a life raft needs repair, you will not
use tweed fabric to repair it. Or, if an NES 12
canopy needs repair, you won't use 7.25-ounce
nylon duck. If a repair is to make an item
usable, you must use like material.
In the not too distant past we were limited to
natural fibers as a source for our fabrics and
associated materials; but today, with the advent
of synthetic fibers, we can enjoy their im-
provements in some respects over the natural
fiber. Currently the natural and synthetic fibers
have their respective advantages and disadvan-
tages. You cannot use synthetics or natural fiber
materials exclusively, but must decide instead
which best serves your purpose. There are many,
many different types of fabrics, or cloth. When
we say cloth, we mean any textile material over
12 inches wide from selvage to selvage.
The construction of cloth is determined by
many factors, such as tightness of yarn twist,
number of threads per inch, porosity of the
yarns, and the type of weave used in its forma-
tion. The weave is one of the most important
factors. The two basic weaves are plain and twill
(as illustrated in figure 4-2). The plain weave is
the simplest method of weaving and gives the
smoothest surface of the fabric. It consists of the
filling threads passing over one warp thread and
under the next warp thread. The twill weave is a
PLAIN
"WEAVE
more complicated weave in which the filling
threads pass over and under more than one warp
thread, thereby producing a surface on the
fabric which is generally recognized as a
diagonal pattern.
Cotton
Cotton is a natural plant fiber, usually white.
The fibers or "staples" are between 3/8 and 2
inches in length. Chemically, it is almost pure
cellulose. Cotton fabrics, webbing, and tapes
absorb water readily unless treated. They dry
more slowly than the synthetic fabrics and are
more susceptible to mildew and fungus growth.
One should never ignore the presence of mildew
because it seriously affects the tensile strength of
cotton and other fabrics. Heat is less damaging
to cotton than to the synthetics. Insect damage
should, however, always be considered because
cotton is a food for certain cellulose-eating in-
sects, and cotton makes good nesting or cocoon-
spinning material for rodents and insects.
Nylon
This is a synthetic fiber of extreme toughness
and elasticity. It absorbs very little water, dries
quickly, is mildewproof, and is not affected by
most ordinary oils, greases, or cleaning fluids. It
is also mothproof. It is sensitive to some
chemical fumes, excessive heat, and direct rays
of sunlight. Nylon melts and drips when it is
subjected to fire. This characteristic requires
that precautions be taken when nylon is worn
where there is a risk of fire. Melted nylon on the
skin can cause the most serious of burns.
NOMEX Fabric
TWILL _
WEAVE
239.367B
Figure 4-2. Basic weaves.
NOMEX is the trade name for a fabric that is
used in the construction of flight suits. NOMEX
fabric is a high temperature resistant and in-
herently flame retardant synthetic fabric. This
fabric has no melt point or drip characteristics
when it is subjected to fire. NOMEX material is
light in weight, does not support combustion,
but begins to char at 700 degrees to 800 de-
grees F. The fabric, similar to nylon, is abrasion
resistant, and is also nonabsorbent.
4-3
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
Duck
This is a comparatively firm, coarse, plain-
weave, cotton or nylon fabric with weight per
square yard from 6 to 50 ounces. Cotton duck is
frequently called canvas. It is primarily used in
the construction of protective covers because of
its durability and wearing characteristics.
Rubber
Rubber and rubberized fabrics are used in
the manufacture of exposure suits and flotation
equipment, because they are watertight. Rub-
berized materials are susceptible to deterioration
if subjected to heat and mildew. Foam rubber is
thick and resilient and is used for padding in
upholstery and aircraft crash pads.
Leather
Cowhide or horsehide may be used for rein-
forcing patches where heavy wear occurs. It is
used for reinforcing patches for grommets and
chafing strips on seat belts. Artificial leather has
replaced the natural product and is used to a
large extent for seat pad, crash pad, and up-
holstery covering.
Vinyl
Vinyl is a plastic material and is used in many
instances in the fabric shop. Vinyl is available in
various thicknesses depending on its intended
use. It may be used for seat covers or ventilating
clothing. The type used for ventilating clothing
consists of two layers of flexible vinyl film. Vinyl
is vaportight and has a smooth surface. Soap
and water can be used to clean it. Do not use
ammonia detergents for cleaning because this
bleaches the vinyl.
WEBBINGS AND TAPES
You have already read that cloth is fabric
wider than 12 inches. Any fabric less than 12
inches, from selvage to selvage edge, is called
webbing or tape. The dividing line between web-
bing and tape is determined by the respective
weight.
Webbings
The heavier of the two is webbing. Webbing
weighs over 15 ounces per square yard and is
less than 12 inches wide. As you would expect,
webbings are used for the toughest holding and
reinforcing jobs. Slings, harnesses, safety belts,
reinforcing and securing straps are made of
nylon, with a wide variety of tensile strength.
The personnel parachute harness, which is the
main support of man's weight, has a tensile
strength range of 6,000 to 8,700 pounds. Some
nylon webbings are of tubular construction
which makes them very strong. Tubular web-
bings are 1/2 to 1 inch wide, with tensile
strengths ranging from 1,000 to 4,000 pounds.
Tapes
In addition to webbings, there are the
lightweight tapes of a twill weave construction.
You can use tapes for reinforcement on many
types of fabric covers. Tapes can weigh up to 15
ounces per square yard. Cloth tapes are woven
in the same manner as fabric. Some are bias
which, because of the bias cut or construction,
facilitates the binding of curved edges where
stretching qualities are desired. These bias tapes
are sometimes referred to as binding tapes.
Velcro tape is commonly used in many shops
as a fastening or closing device. Velcro tape con-
sists of two parts the hook, and the pile or loop
tape. The hook tape is made of nylon consisting
of a series of small hooks. The nylon pile or loop
tape has many small loops. When the two parts
of the tape are joined, the hooks engage with the
loops holding the two tapes together.
DIFFERENCE BETWEEN THREADS
AND CORDS
Threads
Filaments (nylon) or staples (cotton) are
twisted together to form yarns, and two or more
yarns are twisted together to form a thread or
ply yarns, as the yarn by itself is too small for
practical use. The strength of a thread depends
upon the size and number of yarns used to make
4-4
Chapter 4 FABRICATION AND MANUFACTURE
up the thread. The thread numbers on spools in-
dicate the size of the yarn and the number of
yarns that are piled (or twisted) together to
give the necessary strength to the thread. For ex-
ample, a 16-4 thread indicates that the thread
was made from a single yarn, size 16, and that
four of these single yarns were twisted together
to make a thread. The finer the yarn used, the
higher its size number. Silk and nylon thread
sizes, however, are indicated by letters, such as
A, B, etc.; A is finer than B; the farther down
the alphabet, the coarser the thread.
Thread is twisted to the left or twisted to the
right, depending on its use. Left-twist thread is
always used in the sewing machine because the
action of the stitch-forming mechanism tends to
ravel or break right-twist thread. Left- or right-
twist thread may be used for hand sewing. The
terms that designate left-twist threads are
machine, machine twist, left twist, and Z twist.
A cord or thread has left (or Z) twist if, when
held in a vertical position, the twist of the yarn
follows the slope of the central portion of the
letter Z; and right (or S) twist, if it follows the
slope of the central portion of the letter S, as
shown in figure 4-3.
Cords
UNBRAIDED CORDS. Unbraided cord is
twisted together in the same manner as thread,
as shown in figure 4-3. The difference between
threads and cords is that cords are stronger and
larger in diameter than threads.
Nylon cords play an important part in the
repairing of life support items. To identify ny-
lon cord you must remember the larger the
number, the larger and stronger the cord.
BRAIDED CORDS. You know what a
braid is three or more strands of material en-
twined together. Cords also come braided, and
in two types: a solid woven cord or a cord with a
hollow channel center, as shown in figure 4-4.
Solid woven cords are flat. Hollow channel
cords sometimes contain several straight, in-
dividual threads, known as a core. This core
increases the strength of the cord and keeps the
outer braided cover round. Parachute suspen-
sion lines are made from this type cord.
LEFT TWIST FOR ALL
MACHINE THREADS AND
CORDS AND HAND SEWING
RIGHT TWIST FOR
HAND SEWING ONLY
239.368
Figure 4-3. Thread twist.
SOLID
HOLLOW CHANNEL
239.369
Figure 4-4. Braided cords.
4-5
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
STORAGE OF TEXTILE MATERIALS
It is necessary to know the general principles
of care and storage of materials because they dif-
fer greatly in their resistance to damage such as
moisture, heat, mildew, fungus, insects, and
rodents. There are certain insects, however, that
will eat almost anything; mice build nests in
almost any kind of stored fabric material; and
there are hundreds of fungus growths that thrive
under moist tropical atmospheric conditions.
Conditions in various parts of the world vary
widely in regard to humidity, heat, or cold, and
the presence of insects. Such conditions must be
taken into account when you are storing and
protecting materials. The following ideal storage
conditions should be attained as nearly as possi-
ble: a dry room with temperature of 70 degrees
Fahrenheit, absence of direct sunlight, a storage
room construction that affords protection
against insects and mice, wooden shelves for
storage, and air conditioning or some other
method of humidity control.
Now let's consider some of the character-
istics of materials which you should know if you
are to be responsible for keeping them in
storage. Nylon absorbs very little water, dries
quickly, is mildewproof, and is not affected by
most ordinary oils, greases, or cleaning fluids. It
is mothproof, and because it is not an animal
fiber like wool or silk, does not offer food to
hungry insects. However, if insect larvae develop
from eggs laid inside the folds of stored fabrics,
they may eat their way out. Soiled or greasy
spots in a fabric attracts insects.
Soot and certain chemical fumes are highly
injurious to nylon, and direct heat and exposure
to the sun's rays seriously weaken it.
Rayon has many of the characteristics of
nylon. It is more easily damaged by direct heat
or the sun's rays and is more combustible than
nylon. Rayon fabrics "take a set" (form a
crease) more easily than other fabrics, and if left
stored in folds for too long, they will form per-
manent creases.
Cotton fabrics, webbings, and tapes, unless
treated, absorb water readily. They dry more
slowly than synthetic fabrics and are more
susceptible to mildew and fungus growth.
Mildew should never be ignored because it
seriously weakens cotton or other fabrics. Heat
is less damaging to cotton than to the synthetics.
Bugs or their larvae will eat cotton or use it to
make cocoons or nests.
In all cases, fire is a constant threat to
fabrics. Smoking should not be permitted where
fabrics are handled or stored. The rayons are
almost explosive when set afire. Nylon, although
harder to ignite, will burn, but does not explode
in the process. You should be careful to learn the
storage problems peculiar to any specific locality
or climatic conditions in order to ensure safe
storage of these materials.
The construction and characteristics of
various fabric products has been explained to
give you some basis for the intelligent use and
storage of these materials. Besides textile
materials, you are required to use dopes,
cements, and solvents in the daily performance
of your duties as a fabrication and parachute
specialist.
ENGINEERING REQUIREMENTS
FOR FABRICS
If a parachute is to serve its purpose, it must
be reliable. To be reliable, parachutes must meet
certain engineering requirements.
At this point you may be wondering why you
should be concerned with engineering re-
quirementsafter all, you are not designing
parachutes. You service parachutes. Here is
where the difference shows up between just a
parachute packer, and a good parachute rigger.
Almost anyone can learn to pack a parachute.
But a good parachute rigger needs to understand
the "why" that determines maintenance pro-
cedures. When you have learned the engineering
and aerodynamic principles which affect
parachute reliability, you will know why it is so
important to be a conscientious and precise
worker. And, you will see to it that those who
work for you do their job exactly right. First, the
engineering requirements for parachutes are
listed and explained below. Then you will learn
why the textile most often used in parachute
construction is nylon.
Chapter 4 FABRICATION AND MANUFACTURE
Air Permeability
This term refers to the measured volume of
air in cubic feet that flows through one square
foot of cloth in one minute at a given pressure.
If a material gets wet and shrinks, it has less air
permeability, because the weave draws together
and less air gets through. This is the reason for
that very important rule: DO NOT, FOR ANY
REASON, PACK A WET PARACHUTE.
Also, a wet parachute assembly can freeze at
high altitudes. Air permeability affects the
reliability, opening time, opening force, canopy
drag, and stability of the parachute assembly.
The proper ratio of air entering a parachute
canopy to air passing over the canopy gives a
parachute good performance. The greater the
airflow through a canopy the slower the opening
time. This is why canopy designs differ. A quick
opening time is required for personnel para-
chutes, but a slower opening time is desired for
deceleration and cargo parachutes. The braking
force in deceleration and cargo parachutes is
built up over a longer period of time, which
enables the parachute assembly to withstand and
decelerate greater loads.
Strength
This term refers to a fabric's ability to resist
strain or rupture by external forces. Strength is
expressed as tensile strength (a term you already
know) and is measured in pounds per square
inch. The strength of the fabric determines the
strength of the parachute. Remember the old
saying about the chain being only as strong as its
weakest link. Strength is a very important re-
quirement for a safe, reliable parachute. Refer
to table 4-1 for tensile strengths of fabrics, web-
bings and tapes.
Elongation
This term describes the deformation,
lengthening, or stretching caused by a tensile
force. It's what you do when you stretch a rub-
ber band. The ability to elongate gives stretch
to a fabric. Elongation is expressed as the per-
centage of stretch over the original length. For
instance, if a tape has 10 percent elongation, a
10-inch piece will stretch to 11 inches before it
breaks. Parachute specifications call for 20-25
percent elongation.
Elasticity (or Elastic Recovery)
This term describes the ability of a fabric to
elongate (or stretch) when tension is applied,
and to recover its original shape when the ten-
sion is released. If you stretch a rubber band,
then let it go, it comes back to its original size.
Tc test the elasticity of a material, stretch it 4
percent and then measure to see how closely it
returns to its original length. A fabric that
returns to within 75 to 95 percent of its original
length after being stretched is said to have
satisfactory elasticity. A parachute made from
fabric with good elasticity is stronger and gives
less opening shock.
Weight
Lightweight fabric is an absolute necessity
for all parachute canopies. A canopy of light-
weight material opens faster. Can you imagine a
pilot walking around wearing anything as heavy
as a canvas beach umbrella? Lightweight crrw
and deceleration parachutes enable the aircraft
to carry more weight in cargo and fuel.
Resistance to Abrasion
This refers to a fabric's ability to withsicuid
wear and rubbing. A parachute in its lifetime is
subjected to a great deal of abrasion. When you
pack a parachute you pull the canopy down the
table. A deceleration parachute slides along the
runway. For this reason, deceleration parachute
riser webbings and personnel parachute har-
nesses and risers are treated with Merlon (brand
name) to make them more resistant to abrasion
damage.
Resistance to Mildew and Insects
Moths and other insects love to feast on
fabrics; mildew and other fungi thrive on them
in warm, damp climates. Parachutes damaged
4-7
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
Table 4-1. Tensile strengths
Threads
Tensile Strength
Textile
A
2.75 Ibs
Nylon
B
5.50 Ibs
Nylon
E
8.50 Ibs
Nylon
F
11. 00 Ibs
Nylon
FF
16.00 Ibs
Nylon
Cords
3
24 Ibs
Nylon
6
50 Ibs
Nylon
Tubular Webbing
1/2"
1000 Ibs
Nylon
9/16"
1500 Ibs
Nylon
3/4"
2300 Ibs
Nylon
1"
4000 Ibs
Nylon
Webbing
I 9/16"
525 Ibs
Nylon
II 1"
600 Ibs
Nylon
III 1 1/4"
800 Ibs
Nylon
IV 3"
1800 Ibs
Nylon
V 5"
3000 Ibs
Nylon
VI 1 3/4"
1800 Ibo
Nylon
VIII 1 3/4"
3600 lb a
Nylon
X 1 3/4"
8700 Ibs
Nylon
XII 1 3/4"
1200 Ibs
Nylon
XIII 1 3/4"
6000 Ibs
Nylon
XIX 1 3/4"
10000 Ibs
Nylon
Tapes
II 3/8"
18 Ibs
Nylon
II 1"
900 Ibs
Nylon
II 2"
1700 Ibs
Nylon
III 3/8"
200 Ibs
Nylon
III 1/2"
250 Ibs
Nylon
III 3/4"
400 Ibs
Nylon
III 1"
525 Ibs
Nylon
IV 1"
1000 Ibs
Nylon
IV 1 1/8"
1100 Ibs
Nylon
IV 1 1/2"
1500 Ibs
Nylon
VI 3/4"
425 Ibs
Nylon
Shroud Lin
I
100 Ibs
III
550 Ibs
4-8
Chapter 4 FABRICATION AND MANUFACTURE
by mildew or insects would be unsuitable for
Navy use. Therefore, it is necessary that
parachute fabric be as resistant as possible to
this type of damage.
Moisture Regain
This term refers to the percentage of
moisture that a bone-dry fiber absorbs from the
air under standard conditions of temperature
and humidity (65 percent relative humidity and
70 degrees F). Less than 5 percent moisture
regain means that the fibers build up static elec-
tric charges when rubbed. If static electricity
builds up, the parachute assembly is more dif-
ficult to service. Static electricity also adversely
affects the opening time of a parachute
assembly.
The ability to take on dye (color) is another
important consideration when selecting para-
chute fabrics. The percentage of moisture regain
possible in a fabric determines whether it can be
successfully dyed. Dying gives the fabric color,
which is important for a parachute canopy.
Rescue teams can easily spot multicolored
canopies from the air. Pickup crews can quickly
identify colored deceleration canopies on run-
ways. Also, yellow dye in a canopy makes it
more resistant to ultraviolet damage from
sunlight, which relates to the next engineering
requirement on this list.
Resistance to Sunlight
Ultraviolet light, which is found in sunlight,
reduces the strength of fabrics. Ultraviolet rays
give you a painful sunburn when you're out on
the beach too long. All parachutes are exposed
to some sunlight. Military specifications for
parachute materials state fabrics should not lose
more than 25 percent of their original strength
after 50 hours exposure to sunlight. Investiga-
tions into causes of deceleration parachute
failures have shown strength loss of more than
50 percent after 50 hours of exposure to sun-
light.
Resistance to Heat
In addition to sunlight, heat and friction are
natural enemies of a parachute. In case of fire
on an aircraft, personnel and deceleration para-
chutes may be exposed to great amounts of heat.
Friction and heat are generated when the
deceleration parachute comes in contact with the
runway. Line-overs cause friction and burn
holes in parachute canopies. Line-overs happen
when an improperly stowed suspension line is
drawn over the canopy during deployment.
Resistance to Chemicals
Because parachute assemblies are exposed to
various chemicals, it is important to know which
chemicals are harmful and which are not. Most
damaging are mineral type acids, such as the
type used in batteries.
You have studied a long list of engineering
requirements which are important to know when
you service parachutes. You already know that
nylon is the most widely used fabric in the
parachute shop. In the next section, we examine
the good and bad characteristics of nylon in
parachute construction.
There is no fabric known to man that
measures up perfectly to all the engineering re-
quirements for parachute construction. But
nylon comes closer, by far, than any other
fabric. Nylon, when properly handled by the
parachute rigger, has more good than poor
qualities. First, we will review the good
characteristics of nylon:
a. Strength. Nylon is one of the strongest
synthetics made.
b. Elongation. Nylon stretches from 18 to 40
percent, which is well above military specifica-
tions of 20 to 25 percent.
c. Elasticity. Nylon returns to 100 percent of
its original length.
d. Weight. Nylon fibers are very strong for
their weight; theiefore, the fabrics manufac-
tured of nylon fibers are lightweight fabrics.
e. Resistance to abrasion. Nylon doesn't
have enough resistance to last forever under all
the rugged use parachutes get, but it is better
than any other material tested for parachute use.
f. Resistance to mildew and insects. Nylon
has no food value. This makes it unappetizing to
moths and other insects. It cannot support the
growth of mildew. This isn't true, however,
4-9
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
when a cup of coffee is accidentally spilled on a
parachute assembly, or other edible foreign mat-
ter comes in contact with it. What we really
mean is clean nylon has no food value.
We warned you that nylon is not the perfect
fabric. Where possible, improvements have been
made in manufacturing nylon. The limitations
you must keep in mind when handling nylon are
as follows:
a. Moisture regain. Remember, we said that
if the percentage of moisture a fiber absorbs
from the air is less than 5 percent, the fiber is dif-
ficult to dye and builds up static electricity when
rubbed. The moisture regain of nylon is only 4.2
percent, so you can expect static electricity to
develop as you service the assembly.
b. Resistance to sunlight. We mentioned
earlier that yellow dye improves resistance to
ultraviolet light damage. That is why yellow dye
is added to deceleration canopy material. In ad-
dition, a chemical known as Chemstrand "R"
has been developed, which, when added to nylon
fiber as the yarns are manufactured, makes
nylon more resistant to ultraviolet light.
c. Heat resistance. Nylon has a relatively
low melting point, 482 degrees F, which makes it
very susceptible to damage from heat. This is
why it is so important that suspension lines
be stowed properly. In the rapid deployment
sequence, lines crossing each other will break
from the friction heat generated.
In short, there are several natural enemies to
be aware of when you handle parachute textiles
of any type. These are the hazards of sunlight,
abrasion, heat, chemicals, insects, and fungi on
parachute components.
Keep in mind the natural enemies of textiles
you have learned. Then it is easy to see which
elements are to be avoided when you store
parachute fabrics.
SPECIAL HAND TOOLS
You find that when working in the fabric
shop you have a need for tools that are not com-
monly stocked in the average tool room. There-
fore, we must discuss some of the specific tools
used in the fabric shop. The tools used for fabric
and rubber maintenance are not highly compli-
cated, but are designed for a specific purpose.
In your hands these tools can help produce a fin-
ished product of which you can be proud.
SHEARS
A scissors type tool that you often use for
fabric work is known as shears, as shown in
figure 4-5. A pair of shears consists of two
CUTTING JAW
Figure 4-5. Shears.
4-10
239.370
Chapter 4 FABRICATION AND MANUFACTURE
utting edges so hinged that, when closed, the
utting edges cross each other in close contact,
'his shearing action is used for cutting fabrics,
'he large loop in the handle is for two or three
ingers and the small loop is for the thumb. The
lades are not straight but slightly curved toward
ach other so that, in closing, the two cutting
dges are held firmly together by the spring ae-
on of the blades.
Always keep the shears sharp. If the shears
re not sharp enough to effectively cut the
laterial, they must be sharpened. A more effec-
ve job can be done by disassembling the shears
nd sharpening one shear at a time. The bottom
hear has a more blunt angle than the upper, so
xercise care in the cutback or angle of sharpen-
ig. Also in sharpening, start at the point or toe
f the shear and move toward the heel of the
lear. This drives the heat, generated in grind-
ig, to the heel of the shear where there is more
letal to radiate the heat. To grind toward the
:>e or point drives the heat to the lesser metal
nd can result in burning the metal and drawing
le temper out. After grinding the shear, re-
ssemble it loosely at first so that, on the first
losing, the wire edge resulting from the grinding
. removed.
Another type of shears you will use is known
s pinking shears. This tool is used for cutting a
>ries of Vs along fabric edges to prevent fray-
ig. If pinking shears become dull, they should
e returned to the manufacturer for sharpening.
Remember, always keep the shears sharp.
on't drop your shears, as this springs the
lades and reduces their cutting ability. DON'T
se them to puncture metal objects or to pry
lings open. DON'T use shears as a knife to
>move stitching; you may injure yourself or
amage the stitches you are cutting. (For this
)b, use an upholsterer's knife or a stitch cutting
>ol.) When shears are beyond shop mainte-
ance capabilities, return them to supply for a
^placement.
OOT-OPERATED GROMMET PRESS
With the foot-operated grommet press, as
lown in figure 4-6 you can install grommets by
lass production. The press itself stores the two
arts of the grommet, leaving your hands free to
ADJUSTABLE SCREW
STOP NUT
CHUCK
DIE
239.371
Figure 4-6. Foot-operated press.
position material while your foot applies the
needed pressure. The important parts of this
press are the chuck and die. For each type and
size of grommet, there is a corresponding chuck
and die. The chuck is the upper tool; the die is
the lower tool. Use the adjustment screw,
located either at the top or bottom of the foot-
operated press to prevent pressure damage to the
4-11
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
chuck and die. When set correctly, this adjust-
ment screw will set the clearance of the chuck
and die to 1/32 inch, about the thickness of
bond typing paper, which is adequate for most
grommets. Some foot-operated presses have
been in service for as many as 25 years and still
require only the replacement of the chuck and
die. The foot press may also be used in the shop
to install glove fasteners. However, if a portable
glove fastener installation tool is needed, you
can use the hand press.
HAND PRESS
The Durable Fastener hand press, as shown
in figure 4-7 mates the two female portions of
the fastener (socket and button) and the two
female portions (stud and eyelet). You will use
this often as you replace Durable Fasteners on
soundproofing, cushions, or other related items
where a portable installations tool is required.
KNIVES
- -
or a pry to open can lids. Always cut away from
you, and keep your hands out of the way of the
blade.
To sharpen a knife, use an oilstone and apply
the same basic principle as that used for
sharpening shears. Do NOT sharpen a knife
blade on a grinding wheel, because the metal is
too thin. Too much heat is generated for the
thickness of the metal. To sharpen a knife, clean
the oilstone of all gum and dirt accumulation.
Put 2 or 3 drops of medium-light oil on the
stone. Lay the knife on the stone with the back
of the knife slightly raised. Draw the knife
toward you with a diagonal stroke from heel to
toe with the cutting edge advancing. Turn the
knife over and move the blade away from you,
cutting edge advancing, moving from heel to
toe. Repeat these steps several times. The edge is
sharp if you feel a decided drag when passing it
lightly over a wet thumbnail. No drag indicates
the edge is not sharp.
MEASURING DEVICES
A knife, because of its familiarity, can be
one of the most abused tools. At its best, a knife
has a well-sharpened blade and a secure handle.
DON'T use any knife as a screwdriver, a punch,
239.372
Figure 4-7. Hand press.
The ruler, tape measure, as shown in figure
4-8, and "carpenter's" square, are used often
during the repair of fabric and rubber articles.
These may become special tools by adding a
special mark to show a commonly used scale or
measurement. To comply with technical direc-
tive specifications, be sure to exactly measure
items such as the patch overlaps, length of lines
on life rafts, and every other job you do that re-
quires special measurements.
The 12-inch, plain steel rule is used for laying
out and measuring small work. One side of the
rule, shown in A, figure 4-8, has one edge
graduated in sixteenths of an inch and the other
edge graduated in eighths of an inch. This is in-
dicated on the rule by the numbers 16 and 8,
which are stamped into the metal. The opposite
side of the same rule may have one edge
graduated in sixty- fourths of an inch and the
other edge graduated in thirty-seconds of an
inch as shown in B, figure 4-8.
The "carpenter's" square is a steel tool in
the form of a right angle. One arm is 24 inches
long, and the other is 18 inches long. It is used
by the carpenters to lay out the framework of
4-12
Chapter 4 FABRICATION AND MANUFACTURE
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239.373
SADLMAKER'S PALM
The sailmaker's palm has a small metal disk
insert set in rawhide and stitched into a leather
glove type device. It is designed to be worn in the
palm of the hand and is used to aid in pushing a
sail needle through the material being sewn or
tacked. (See figure 4-9).
AWL
The awl is another instrument used as an aid
in sewing heavy material where pushing the sail
or hand sewing needle through the material
becomes difficult. It is a sharp pointed instru-
ment, with a handle attached, and is used for
punching holes in a heavy fabric or material
prior to inserting the needle. Never use a hot
needle or iron as a substitute for the awl.
STAR PUNCH
The star punch or leather punch is a very
useful tool for punching holes through material
to be fastened with snap fasteners or speedy
rivets.
HARDWARE
Looking back through the first two sections
of this chapter, you see that we have discussed
textile materials and tools. This section is also
concerned with a different type of material often
used in the fabric shop. We call it hardware.
Grommets, glove fasteners, and interlocking
fasteners are pieces of hardware you used during
Figure 4-8. Measuring devices.
buildings and to square off wood materials. The
fabrication and parachute worker uses it for
layout work and measuring.
The tape measure is a convenient tool. It is
used to measure large objects, yet it is portable
and can be carried in a pocket. The tape measure
is flexible and allows you to measure curved ob-
jects. These measuring devices, ruler, tape
measure, and "carpenter's" square, are used by
a person who wants to achieve accurate and pro-
fessional results.
Figure 4-9. Sailmaker's palm.
4-13
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
your daily work. You must install pieces of hard-
ware to covers, bags, and clothing to strengthen
or to secure these items. Not only do you have to
be able to identify this hardware, you also have
to know how to install it properly.
GROMMETS
You use grommets whenever it is necessary
to reinforce holes for lacings in covers, bags,
panels, and upholstery. There are two parts to a
grommet: the grommet itself or collar and the
washer. The two types of grommets used are
plain and spur grommets, as shown in figure
4-10.
The plain grommet uses a plain washer,
whereas the spur grommet uses a toothed washer
that bites into the material to form a grip. The
spur grommet, because of its strength, is used
where the pull will be particularly strong; or it
may be used in large covers. Leather is some-
times used at corners to reinforce the area where
grommets are to be installed. Grommets are
made of aluminum, brass, or chrome plated
brass. They are available in several sizes; 00, 1,
2, 3, 4, etc., the smaller the number the smaller
the size of the grommet.
To install grommets, you must proceed
through a series of operations. Locate and mark
where a grommet installation is needed. Be sure
you set the grommet far enough from the edge
of material to prevent it from tearing. Select the
GROMMET
SPUR GROMMET
WASHER
SPUR WASHER
ill
,1,'
ill
, 1,
^
3/8" INSIDE MEASUREMENT
239.304A
Figure 4-10. Grommets plain and spur.
3/8" CUTTING PUNCH
239.374
Figure 4-11. -Inside diameter measurements.
correct punch by matching its size to the size of
the grommet collar, as shown in figure 4-11.
After you have used the leather cutting
punch to cut a hole in the fabric, you must mate
the parts of the grommet. Place the grommet on
the finished side of the material and the washer
underneath. Determine the correct size chuck
and die. Assemble the grommet, washer, punch,
and die, as illustrated in figure 4-12. Now you
are ready to flatten the collar. This operation
can be accomplished in a variety of ways, de-
pending upon the availability of tools.
Grommet Press Installation
You may have a foot-operated grommet
press or a hand press, as illustrated in figures 4-6
and 4-7. To use either type of press, you need an
assortment of chucks and dies. Install the die in
the bottom of the press and the chuck in the top
of the press. Set the foot press and check for a
clearance of 1/32 of an inch between the chuck
and die. This prevents damage by striking the
chuck and die together. By depressing the foot
pedal or handle, you securely flatten the grom-
met.
Grommet Set Installation
A grommet set, consisting of a punch and
die, is used to install grommets in material.
Figure 4-12 illustrates a grommet set. The
4-14
INSIDE
OUTSIDE
CLOTH
DIE
239.375
Figure 4-12. Grommet collar, cloth and washer in groin-
met set.
grommet set has to be the same size as the grom-
met for a proper grommet installation. Use a
rawhide mallet to strike the punch. This action
flattens the grommet. The grommet set installa-
tion is used because of its simplicity and porta-
bility.
FIGURE 4-13 HAS BEEN DELETED DUE
TO OBSOLETE MATERIAL.
GLOVE FASTENERS
The most common type of fastener used on
clothing and other items made of fabric and
rubber is the glove fastener. In many instances,
the glove fastener has replaced the conventional
button. Glove fasteners are dependable and are
used for their holding and firm gripping ability.
Figure 4-14 shows the three different types of
glove fasteners most commonly used. The main
difference between the three fasteners is size. The
Segma Dot is the smallest; the Durable Dot is the
largest type of glove fastener. Each fastener is
made of four parts: button, socket, stud, and
eyelet, as illustrated in figure 4-14. The socket
and button are matched to form the snap.
4-15
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME
BUTTON SOCKET STUD EYELET
ANZO DOT
BUTTON SOCKET STUD EYELET
2 DURABLE DOT
BUTTON SOCKET STUD EYELET
3 SEGMA DOT
Figure 4-14. Glove fasteners.
239.377
The stud and eyelet form the part to which the
socket and button snap.
Press Installation
Cut a hole the size of the collar of the button
and insert the button in the material. Place the
correct chuck and die into either a foot- or hand-
operated press, as shown in figures 4-6 and 4-7.
The die is the lower and the chuck is the upper
tool, as shown in figure 4-15. Fit the socket to
the chuck, as shown in figure 4-15. Lay the but-
ton in the die and complete the attachment by
depressing the handle or foot pedal. Cut the
proper size hole in the material to receive the
eyelet. Place the correct chuck and die in the
press. Insert the collar of the eyelets through the
hole from the back of the material. Fit the stud
into the chuck. Lay the eyelet on the die and
complete the attachment.
Hand Installation
Cut a hole the proper size for the collar of
the glove fastener button. Insert the button in
CHUCK
CLOTH
CHUCK
STUD
CLOTH
EYELET
239.303A
Figure 4-15. Durable dot fastener installation.
BUTTON
INDENTURE
WOODEN BLOCK
239.378
Figure 4-16. Flaring button collar.
the material and place the socket over the collar
of the button. Make an indentation in a wooden
block for holding the head of the button. Flare
the collar of the button slightly with a center
punch, as shown in figure 4-16. Flatten the col-
lar of the button with a solid drive pin punch.
Assemble and install the stud and eyelet on the
other pieces of material so the base of the eyelet
is on the backside of the material. Flare and
4-16
Chapter 4 FABRICATION AND MANUFACTURE
flatten the collar of the eyelet in a manner
similar to the installation of the button and
socket.
THREE-WAY LOCKING FASTENERS
There are times when you need to use a snap
fastener that you do not want to come apart ac-
cidentally. When you must have this type of
fastener, you should use either the three-way
locking snap or the curtain fastener.
THREE-WAY LOCKING SNAPS
The three-way locking snap is stocked in one
size only regular. It is used on flight clothing,
parachute containers, and back pads. (See figure
4-17). This fastener opens only when lifted from
the side with the dot located on the top of the
button. When installing this snap fastener, you
should ensure that you install the three-way
locking snap in the position that you want to be
opened. This type snap should never be used
where any quick opening devices or quick releas-
ing action is required.
CURTAIN FASTENER
The curtain type fastener (lift-the-dot) is
stocked in two sizes large and small. (See
figure 4-18). These fasteners have many uses,
SOCKET
239.298
Figure 4-17. Three-way locking snap type fastener.
especially for truck and boat covers. The small
lift-the-dot is the same as the large one, and
designed on a smaller scale for use on lighter
work where the bulkiness and weight of the large
lift-the-dot are not desired.
INTERLOCKING SLIDE FASTENERS
Tasks are accomplished more easily and
quickly through the use of interlocking
fasteners. For example, they save precious
seconds for an aircrewman when he is donning
his flight clothing or exposure suit. These
fasteners also provide the repairman with a
means of easy access to items that require in-
spections.
The types of interlocking slide fasteners
(zippers) used on flight clothing and other items
of aviation equipment are shown in figure 4-19.
Figure 4-20 shows the parts of an interlocking
fastener.
Interlocking Slide Fastener
Construction
An interlocking slide fastener consists of two
chains of teeth (hollow cones or scoops) facing
each other. When brought together at the proper
angle, each tooth fits within the scoop of the
tooth opposite it.
When closed, the interlocking slide fastener
teeth cannot be parted except through use of the
slider which, when moved, displaces teeth at the
proper angle for meshing and unmeshing. The
small clips (stops) at the top and bottom of the
interlocking slide fastener are designed to pre-
vent the slider from running off the track.
Separating type slide fasteners do not have a
bottom stop, but are equipped with a pin on one
side and retainer arrangement on the other to
allow the two parts of the slide fastener to
separate.
Interlocking Slide Fastener
Operation
Ordinary interlocking slide fasteners are
designed for flat, smooth operation. Both hands
are required for proper functioning. The chains
4-17
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
CLINCH PLATE
CLINCH PLATE
SOCKET
MACHINE SCREW
HEX BASE STUD
WOOD SCREW STUD
239.299
Figure 4-18. Large curtain type fastener (lift-the-dot).
should be stretched taut with one hand and the
slider worked (without force) with the other.
When operating an interlocking slide
fastener installed in a garment of soft nappy
material, or lined with wool or fur, do so with
care to prevent the nap or wool from jamming
the slider.
Very often grease or oil deposits lodge be-
tween the tiny hollow parts of the teeth and
accumulate dirt and lint. This causes stiff
operation of the slider. A dirty or gummed
chain should be cleaned with an old tooth-
brush or a pipe cleaner saturated with
Stoddard solvent or other similarly approved
cleaning solvent. After each cleaning, the chain
should be lubricated by applying one drop
of oil or a small amount of graphite between
your thumb and forefinger and running the
chain up and down between your fingers several
times.
4-18
Chapter 4 FABRICATION AND MANUFACTURE
TAPE ALLOWANCE
li^
LENGTH
(NOM.)
TYPE A
TYPE B
TYPE C
LENGTH r I
(NOM.) L
1.
LENGTH
(NOM.)
1
LENGTH
(NOM.)
TYPE E
TYPE F
TYPE G
TYPE A - NON-SEPARATING, SINGLE ACTION.
TYPE B - SEPARATING, SINGLE ACTION.
TYPE C - NON-SEPARATING, SINGLE ACTION WITH BRIDGE STOP.
TYPE D - SEPARATING, SINGLE ACTION, QUICK DETACHING.
TYPE E - NON-SEPARATING, DOUBLE ACTION, CENTER OPENING.
TYPE F - NON-SEPARATING, DOUBLE ACTION WITH BRIDGE STOP.
TYPE G- SEPARATING, DOUBLE ACTION, END OPENING.
SIZE - LIGHT SERVICE.
SIZE 1 - LIGHT-MEDIUM SERVICE.
SIZE 2 - MEDIUM SERVICE.
SIZE 3 - MEDIUM HEAVY SERVICE.
SIZE 4 - HEAVY SERVICE .
STYLE S - STANDARD NON-LOCKING.
STYLE L - LOCKING.
Figure 4-19. Slide fasteners.
239.307
REGULAR
TOP STOP
TEETH
PI ii i TAR
> )
H
L"t!f
rULL IMU
V
u
C
r
.(fid
*
THAIN
C
t
e
*c
TAPF
x:
e
c
c
iHl L
c
T;
c
BOTTOM STOP
*c
_x
1
239.308
Figure 4-20. Slide fastener parts.
A brief inspection will determine whether
a slider (or pull tab) is the locking or non-
locking type. Always be certain that the pull
tab is lifted at right angles to the slider before
attempting to remove the locking type. The
relative positions of the pull tabs are shown in
figure 4-21.
Interlocking Slide Fastener Tools
In addition to common tools such as
screwdrivers, pliers, awls, knives, scissors, and
needles, a well-equipped slide fastener kit should
be included in the parachute loft equipment.
The interlocking slide fastener kit (zipper
repair kit) contains all the parts necessary to
repair any size or type interlocking slide
fastener, plus the following special tools: end
cutters, or nippers, used for removing stops and
teeth; stop-closing pliers, specially designed to
span over the slider and clamp the stops in posi-
tion; and pull-up pliers, designed to close the
slider without a pull tab. Another handy tool in
slide fastener repair is an awl with a bent tip.
This tool may be used to close the chain by
hand.
Interlocking Slide Fastener Repair
A torn or ripped interlocking slide fastener
bead cannot be repaired, but should be replaced
with a complete new interlocking slide fastener.
If the bead is damaged near the top or bottom of
the interlocking slide fastener, and the damaged
ends can be cut off to shorten the interlocking
4-19
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
SLOT FOR CAM
CAM
\
SLIDER WITH CAM TYPE LOCK
PIN IN LOCK POSITION
SLIDER WITH PIN TYPE LOCK
239.309
Figure 4-21. Slide fastener pull tabs.
slide fastener without hampering the usefulness
of the garment, an effective repair can be made.
Loose or missing teeth and stops can cause
trouble. If teeth or stops are not tightened, they
will eventually be lost and tear the bead. In
repairing such damage, see that the loose stop is
in position (almost touching teeth), then set
tightly with stop-closing pliers. Set any loose
teeth parallel with the other teeth in the chain,
then apply pressure with the stop-closing pliers.
Set any loose teeth parallel with the other teeth
in the chain, then apply pressure with the stop-
closing pliers. If a replacement stop is not
available in the repair kit, a soft wire or heavy
thread may be used as a temporary stop.
A missing tooth should be repaired by
replacing the entire interlocking slide fastener.
However, in the event that there are no spare
fasteners available, a missing tooth may be
replaced. This is done by carefully removing the
stop from the top of the chain, taking off the top
tooth, replacing the stop, and setting the tooth
in place. (Use caution; do not damage the bead
of the chain when resetting the tooth.)
You may run into trouble in moving the
slider on the chain. This is caused by the jaws of
the slider being too tight, or a dirty chain may be
the trouble. To loosen the slider, insert a
screwdriver between the jaws, and very gently
pry them apart until they operate freely. A dirty
chain is cleaned in the manner described in a
preceding paragraph.
Should the slider become jammed with fur,
wool, or other material, carefully remove such
matter with a pin or needle while gently pulling
the slider until it is released. If it is so badly
jammed that it resists all efforts, remove the
slider by carefully bending the jaws apart and
returning the jaws to their original position.
Then replace the slider on the chain as described
later.
Most pull tabs have two small projections fit-
ting into slots on each side of the slider. To
remove the pull tab, use two pairs of pliers, one
on each side, and twist in opposite directions. In
replacing pull tabs, this procedure is reversed.
Pull tabs furnished as replacements need only to
be squeezed onto the slider.
To repair a damaged slider, you must first
remove it. The proper procedure for removing
and replacing a slider on the chain following
repairs is explained in the following paragraphs.
To remove the slider from the regular type
interlocking slide fastener (nonseparating),
carefully rip the stitches from the BOTTOM of
the interlocking slide fastener to expose the ends
of the tape. Then remove the bottom stop, and
slip the slider off the bottom of the chain and
entirely off the beads and tape, as shown in
figure 4-22.
To replace the slider on a regular type in-
terlocking slide fastener, thread the two bottom
beads into the wide end of the slider. Hold the
4-20
Chapter 4 FABRICATION AND MANUFACTURE
239.310
Figure 4-22. Removing the slider.
tape so that the bottom teeth are correctly
matched, then draw the slider upward until the
teeth mesh for several inches. Without allowing
the teeth to separate, clamp the bottom stop
close to the teeth and over both beads. Replace
the tape ends and ripped stitches by hand or by
machine.
To remove a damaged slider on a separating
type slide fastener, carefully rip the stitches at
the TOP of the slide fastener, on the retainer
side only, thus exposing the end of the tape.
Remove the top stop, slip the slider off the top
of the chain, and completely remove it from the
bead and tape. Repair or replace the slider.
To replace the slider on a separating type in-
terlocking slide fastener, thread the bead on the
retainer side into the narrow end of the slider,
and allow the slider to slip down the chain.
Replace the tape end and ripped stitches by hand
or machine.
To replace the slider on the top of a regular,
nonseparating type interlocking slide fastener
with the aid of pull-up pliers, slip the tool over
the bottom stop, clamp together, and pull up-
ward. Close the entire chain in this manner.
Thread the two top beads into the narrow end of
the slider, holding the teeth meshed until they
enter the slider. Replace the top stops, tape ends,
and ripped stitches.
Shortening an Interlocking Slide Fastener
To shorten an interlocking slide fastener,
first determine the length required. The chain
should be about 1/2 inch shorter than the open-
ing in the material or garment. Mark the desired
length, measuring from the bottom stop up-
ward. Open the chain to any point below this
mark and cut directly across the tape about 1
inch above the mark. Cut the excess teeth from
the marking point to the end of the tape, and
replace the two stops, crimping them firmly.
Installing an Interlocking Slide Fastener
The installation of an interlocking slide
fastener varies with the type of job. Some are
curved, some have rounded corners, and some
are hidden. The installation of a straight slide
fastener is described in the following para-
graphs.
Slide Fastener Presser Foot
In order to install a slide fastener neatly and
easily you should use a slide fastener presser
foot on the sewing machine. The slide fastener
presser foot serves not only as a guide for a neat
row of stitches, but also prevents the foot from
riding up on the chain.
The sewing machine manufacturer can sup-
ply a regular slide fastener presser foot (right or
left) for any sewing machine, or one can be
made locally. File or grind the left side of an old
presser foot to permit sewing to within 1/8 inch
of the chain.
Fabrication
When sewing, always stretch the slide
fastener and not the material, as this makes a
flatter and neater job.
When making a bag or cover with two closed
ends, a simple method of installing a slide
fastener follows: Lay the piece of material right
side down, and place the slide fastener right side
down on top of the material where the opening is
to be located. Sew a row of stitches completely
4-21
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
"'^-ALIGN MARK
rf" %. '
W'" \
SPECIAL PRESSER FOOT
239.311
Figure 4-23. Installation of a slide fastener. Step 1.
around the outer edge of the tape, as shown in
figure 4-23.
Turn the material over. Then by feeling with
the points of a pair of scissors, cut the material
directly down the center of the chain and cut a V
at each end, as shown in figure 4-24.
Turn the edges of the material under, thus
exposing the chain. Allow sufficient space be-
tween the chain and the folded edge of the
material, to prevent the slider from rubbing the
edge of the hems. Cutting the V at each end of
the chain permits the sewing of neat, square cor-
ners. (See figure 4-25.)
239.312
Figure 4-24. Installation of a slide fastener. Step 2.
Procurement of Slide Fasteners
When requisitioning slide fasteners or slide
fastener parts through the supply system, certain
specific information is necessary: type, size,
grade, color, style of slider, and unit of issue are
all part of this information.
There are two types of slide fasteners-
separating and nonseparating. A nonseparating,
Type A, slide fastener is used where only a small
area needs to be opened; for example, the open-
ing in a parachute bag. A separating slide
fastener, Type B, is used in areas where it is
necessary to spread the opening for easy access,
such as on a jacket or the legs and waist of an
anti-g coverall.
4-22
Chapter 4 FABRICATION AND MANUFACTURE
EDGES UNDER
AND SEW
239.313
Figure 4-25. Installation of a slide fastener. Step 3.
To determine the size or service weight of a
slide fastener to be installed on a fabric
assembly, consider the weight of the material
and the stress that will be applied. The size range
and services of slide fasteners are as follows:
1. Size Light service.
2. Size 1 Light to medium service.
3. Size 2 Medium service.
4. Size 3 Medium to heavy service.
5. Size 4 Heavy service.
Materials used in slide fastener construction
vary from plastic and nylon to cotton, rubber,
and metal. There are two common grades of
slide fastener chains. Grade I is of brass con-
struction and Grade II is made of other metal
alloys or synthetic materials.
In most instances, however, you will be
concerned with fasteners which have been con-
structed from cotton fabric and metal parts.
A closely woven cotton fabric is commonly
used for the tape of a slide fastener; match the
color of this tape to the main fabric color when
installing a slide fastener.
On certain items of survival equipment using
slide fasteners, it is mandatory that the slider re-
main stationary where it is positioned on the
chain. An accidental opening in flight of an
equipment container or item of flight clothing
could cause a lot of trouble for the aircrewman.
Unintentional opening of a slide fastener
which requires positive security is prevented by
using a locking Style L slider.
Illustrated in figure 4-21 are two common
types of locking Style L sliders: the pin type and
the cam type. The pin type is designed to lock
when the pull tab is pressed flat onto the chain,
thereby inserting its pin between two teeth on
one side of the chain.
The cam type is also designed to lock when
the pull tab is pressed flat onto the chain,
thereby causing friction between the chain and
the cam. This action prevents any movement of
the slider.
Slide fasteners installed where the movement
of the slider is not critical may be equipped with
a Style S, standard nonlocking slider. The Style
S slider is normally used on slide fasteners where
accidental openings do not create a problem.
The length of a slide fastener is determined
by the amount of closure required. When order-
ing slide fasteners from Class 5325 of the Federal
Stock Catalog, you need to refer to the dimen-
sion column which lists both the length of the
chain and the width of the tape. The size of a
slide fastener is referred to as its service weight.
Activities should specify the brand of chain
for which stops and sliders are required (Talon,
Crown, or any other make.)
Slide fasteners in stock are supplied in the
nearest length ordered. When received, you can
cut the chain to the desired length; stops can be
salvaged and reused on the cut chain.
4-23
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2, VOLUME 1
SEAMS AND KNOTS
HAND-SEWN SEAMS
This is the age of great technological ad-
vancements and man has come to rely heavily on
the conveniences that technology provides. As
you know, almost everything you do involves
the use of a machine. From the housewife with
her automatic dishwasher and the computer that
pays you regularly twice each month to the sew-
ing machine you use to repair articles made from
fabric technology is involved. Yet, in spite of
all the benefits of technology, there are disad-
vantages. The biggest disadvantage is the lack of
pride that you can feel by accomplishing things
skillfully with your own hands. Very few people
in our society have the opportunity to use hand
skills; therefore, they search for hobbies, such as
model aircraft building, carpentry, and leather
crafts to satisfy this desire.
You are fortunate because your job involves
using both hand and machine skills. Very few
people get the opportunity to work with raw and
finished materials and have creating, fabri-
cating, and repairing as part of their job. In your
particular situation, not only do you use your
hands for tying knots and packing life rafts, but
you also use your hands to take the place of a
sewing machine. By now you have seen that sew-
ing is perhaps the most useful skill the fabrica-
tion and parachute specialist should develop.
Few fabric maintenance jobs are performed
without some kind of sewing. Although, from
your experience you know that most sewing is
done with a machine, you also know there are
occasions when machine sewing is impractical or
impossible. The design of the article may be such
that using a machine would not meet the seam
specification. Not only may some jobs be better
done with hand sewing than with a machine, but
also hand sewing is specified by technical order
for certain jobs.
Some of the hand stitches you will use are
basting stitch, running stitch, hidden stitch,
overthrow stitch, and baseball stitch. You
should use the one that best suits the particular
job. In order to use these stitches properly, you
should first become acquainted with the ap-
plicable definitions and general procedures.
A stitch is a unit of thread formation. A
seam consists of a series of stitches hand- or
machine-sewn, joining two or more pieces of
material. All seams should possess strength,
elasticity, durability, and a good appearance.
The strength of a seam depends upon the type
of stitch used, type of thread used, number of
stitches per inch, tightness of seam, construction
of seam, and size and type of needle used. The
appearance of a seam depends on how the seam
is made. Even though you desire a good ap-
pearance, your first considerations should be
elasticity, durability, and strength.
The elasticity desired in a seam is determined
by the material being sewn. If the material
possesses an elastic quality, thte seam should also
possess this same quality. If the seam does not
possess the same elastic quality as the material,
the stitches may break when stress is applied. A
seam should be as durable as the material it
joins. Tightly woven fabrics are more durable
and have a smoother finish; therefore, they tend
to slide on one another. To prevent this sliding,
set the stitches tight and deep enough into the
material to reduce wear caused by their rubbing
on other surfaces.
When hand sewing cloth, turn under one-
half inch of the material as reinforcement and
insert the needle through both plies. When hand
sewing thick materials, such as leather and felt,
do not turn the edges under.
To hand sew any seam, you must know how
to prepare for the job. Select the proper needle
and thread. Choose a thread that matches the
thread of the material as nearly as possible. Use
the smallest size needle which allows the thread
to pass easily through the eye of the needle. To
thread the needle, pass one end of the thread
through the eye and continue to pull it through
until the ends meet. The resulting double thread
should be no longer than an arm's length. Tie a
binder's knot at the end of the doubled thread.
For sewing seams which require only one thread,
pull only about 6 inches of thread through the
eye and then tie an overhand knot in the other
end of the thread. Again, use no more than an
arm's length of thread.
The overhand knot is the simplest knot
made. It is important because it forms a part of
4-24
Chapter 4 FABRICATION AND MANUFACTURE
the many other knots. To practice making this
knot, get a short piece of cord and make a loop
in it. Then pass the end through the loop and
pull the loop tight. If two pieces of thread side
by side are formed in a loop, the resulting knot is
called a binder's knot. This knot is identical to
the overhand knot except that two threads are
used.
Most permanent hand-sewn seams in fabrics
should be locked with two half hitches at inter-
vals of six inches. These half hitches prevent any
break in the seam from going past an interval.
Lock all seams at the end with two half hitches,
a square knot, or a surgeon's knot. A half hitch
is simply an overhand knot whose loop passes
around another item, such as a thread or an edge
of material. To tie the square knot, tie a simple
overhand knot. You then tie another overhand
knot in the opposite direction, locking the first
knot. The surgeon's knot is a modified form of
the square knot. It is the same as the square knot
with the exception of the first overhand knot
which is a double turn. This double turn keeps
the cord from slipping while the last overhand
knot is made.
Yellow beeswax is applied to hand sewing
thread to prevent fraying and untwisting. Use
only pure beeswax, since the impurities in other
waxes may cause oil or grease spots which
deteriorate the thread. Beeswax preserves cotton
thread; be sure to use it.
Other wax used in the survival equipment
shop is made up of one part beeswax and one
part paraffin. It is blended in a wax melting pot.
If you are required to perform the task of wax-
ing an entire spool of thread, place the wax pot
on a wide, level surface. Place the electric cord
of the wax pot so that you or other personnel in
your section will not walk into it. Gently lower
the thread into the hot, molten wax; don't let the
thread rest on the bottom of the pot. How long
you keep the thread in the wax pot is determined
by the size and type of thread you are using.
Follow these directions carefully to prevent the
thread from burning or weakening because of
overcooking.
When sewing, hold the needle between your
thumb, index, and middle fingers. Push it for-
ward with the thimble on your fourth finger.
Keep your fourth finger about two-thirds bent.
Three fingers are needed to guide the needle ac-
curately and swiftly from right to left. Hold the
material in such a manner that you do not tire
easily; crossing your legs and resting the material
on them is helpful. Never point the needle out-
ward at arm's length, because you may injure a
passerby.
Purposes and Characteristics
of the Basting Stitch
The basting stitch is used only for holding
plies of material together temporarily, before
machine sewing. This stitch is particularly
helpful when you install a patch to a flight suit
or a cover. Basting stitches are removed after
making the machine seam.
Two types of needles can be used for
basting either the straight or the curved. Use
the curved needle for hard-to-get-at areas, such
as basting a patch on a cover; otherwise, the job
can be done with a straight needle. Make the
basting stitch as follows. Thread the needle with
a sufficient length of 16-4 thread, single or
waxed. Tie an overhand knot in the end of the
single thread. Turn under the material edge 1/2
inch, unless specified otherwise in the technical
order. Make each stitch 1/4 inch in length and
1/8 inch from the folded edge of the material.
At the end of the row of basting stitches, lock
the last stitch with two half hitches. Cut the
thread 1/4 inch from the knot. Figure 4-26 il-
lustrates the formation of the basting stitch.
Hand sewing the Running Stitch
You can use a running stitch as a substitute
for a machine-sewn seam. It is designed to be a
permanent stitch, when a sewing machine is not
available. Use a straight needle threaded with
single or doubled waxed cord or thread. Tie a
knot at the end of the cord. The material should
be turned under 1/2 inch. Insert the needle in-
side the 1/2 inch fold of one ply and plush it
through the three remaining plies so the starting
knot will be hidden. Continue sewing the pieces
together by using the basting stitch. When you
come to the end of the row, turn the material
around and go back in the opposite direction,
4-25
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
Figure 4-26. Basting stitch.
Figure 4-27. Running stitch.
filling in the empty spaces as you sew, as shown
in figure 4-27. These two rows together become
the running stitch. Use four stitches per inch
(each stitch 1/4 inch long) and 1/8 inch from the
folded edge. Lock the seam every 6 inches.
Keep enough tension on the thread to form
firm, well-set stitches. When you make the last
stitch, insert the needle through two plies and
bring it out in the center of the plies. Make two
half hitches around the stitch extending from the
second layer to the third layer of material.
Hand-sewn Overthrow Stitch
You use the overthrow stitch to attach metal
parts, such as cones and eyelet. For this type of
attachment, a sewing machine is not practical.
The overthrow stitch is also used for harness
tackings. A curved needle is used when the stitch
can only be sewn from one side of the fabric.
Fold the material under 1/2 inch for reinforce-
ment. Insert the needle in such a manner that the
knot will be between the two pieces of material.
Form the overthrow stitch by inserting the
needle 1/8 inch from the folded edge and at right
angles to the material, as shown in figure 4-28.
Make each stitch by inserting the needle from
the same side as the previous stitch. For best
results, make six stitches per inch. At the end of
the row, tie off the thread with two half hitches.
Sewing the Baseball Stitch
The baseball stitch is a useful, permanent
stitch, because it is very flexible and very elastic.
It pulls the edges of material (cloth or leather)
evenly together forming a flat surface and is
used for repair or closing an opening. The
thread lies on both the top and bottom edges of
the material. Like lacing, it can be pulled as
tightly as desired. Usually a curved needle is used
to sew the baseball stitch.
Thread the needle with the required type of
cord, waxed and tied with a knot at the end. If it
Figure 4-28. -Overthrow stitch.
4-26
Chapter 4 FABRICATION AND MANUFACTURE
KNOT
FORMING
OVERTHROW
B
COMPLETED
OVERTHROW
239.379
Figure 4-29. Baseball stitch.
is fabric to be sewn, rather than leather, turn the
edges under 1/2 inch. Insert the needle through
the fold of one ply of material to hide the knot,
as shown in figure 4-29. Insert the needle from
the outside of the lower ply and bring it out the
center of the plies, forming a straight overthrow
stitch at the beginning of the seam, as shown in
B of figure 4-29. Start the baseball stitch by in-
serting the needle in the center of the plies
toward the outside of the opposite piece of
material, as shown in C of figure 4-29. Proceed
with the baseball stitch along the folded edges
of the fabric (or the edges of the leather), as
shown in figure 4-30. Insert the needle from the
inside of the folded edges, only 1/6 inch from
the folded edge, as shown in D, E, and F of
figure 4-29. Keep enough tension on the thread
to remove all loops and slack thread. Do not ap-
ply too much tension, however, because this
tends to pucker or draw the seam out of line.
Every time you sew 6 inches of the baseball
stitch, make a lock knot, as shown in figure
4-31. After the last two stitches of the baseball
stitch, finish with a straight overthrow stitch and
two half hitches.
Use of the Hand-sewn Hidden Stitch
and the Needle Used
The hidden stitch is usually used to make
repairs on upholstery and on clothing where
good appearance is important. To make this
4-27
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
OVERTHROW KNOT UNDERNEATH
\ /
239.256A
TEMPORARY WRAPPING
LOOP
Figure 4-30. Baseball stitch (top view).
239.256B
Figure 4-31. Forming a lock knot for the baseball stitch.
stitch, select a 2 1/2-inch curved needle and a
length of suitable thread. Thread the needle to
sew with a single thread and tie a knot in the
long end. Fold under 1/2 inch of material and
place it on the other piece of material, as shown
in figure 4-32. Start the stitch by pushing the
needle through the back of the fold, about 1/8
inch from the end. Pull the needle through the
bottom material at a point directly below where
the needle came out of the fold. Guide the
needle so that the point comes out again about
1/4 inch along the line of the seam. The point
should come out directly below the creased edge,
as shown in A of figure 4-32. Pull the needle and
thread out to draw the stitch tight. Push the
needle into the front edge of the fold directly
above the point where the needle came out of the
bottom material. Guide the needle point along
the inside of the fold so that it again comes out
the creased edge about 1/4 inch from where
it entered, as shown in B of figure 4-32. Pull
the stitch tight and repeat the previous steps
until the end is reached. Finish the seam off by
coming back one stitch (through the opposite
material) so that the needle reappears alongside
the exposed thread of the next-to-the-last stitch.
Tie two half hitches around the exposed thread.
MACHINE-SEWN SEAMS
Chances are, you have been accomplishing
sewing projects since you arrived at your new
assignment. Then again, you may have done no
sewing at all. The amount of sewing done in
your shop depends upon the mission of your
base. If your unit does much fabrication, then
you probably will do quite a lot of machine sew-
ing. In this section, we discuss techniques con-
cerning machine-sewn seams. While there is
generally no option in choosing a hand-sewn
seam, there are many options in choosing a
machine seam.
Advantages and Characteristics
of a Machine-Sewn Seam
Machine seams or stitchings have the follow-
ing advantages over hand-sewn seams: (1) speed,
4-28
Chapter 4 FABRICATION AND MANUFACTURE
B
239.380
Figure 4-32. Hidden stitch.
(2) appearance, and (3) uniformity of tension.
Their desirable characteristics are as follows:
STRENGTH. Strength of a seam of stitch-
ing depends on the type of thread, stitch type,
number of stitches per inch, the construction
and tightness of the seam, and the size and type
of needle point used. The strength of the seam
should equal that of the material it joins. Use
only the material specified for the assembly in
the applicable technical order.
ELASTICITY AND FLEXIBILITY. Elas-
ticity and flexibility depend on the stretching
qualities of the material used, the quality and
tension of the thread, the length of the stitch,
and type of seam or stitch used.
DURABILITY. Durability is determined
by the wearing qualities of the material, the
quality of the thread used, and proper tension to
set stitches well into the material to reduce abra-
sions. Relationship between the elasticity of the
seam and the elasticity of the material is very
important in determining durability.
SECURITY. The security of a seam or
stitching depends chiefly on the stitch type and
its ability to resist unraveling. The stitch must be
well set in the material to prevent snagging which
can cause thread breakage and unravel some
types of stitches. Seam "run offs" weaken a
seam. All seam ends should be backstitched or
anchored (backstitched and overstitched) to pre-
vent the seams from unraveling, as illustrated in
figure 4-33.
APPEARANCE. The appearance of a
seam is controlled by its construction and
neatness of workmanship; however, appearance
is of less importance than any of the four factors
explained previously strength, elasticity,
durability, and security. Size and type of thread
and length of stitch may also affect appearance.
'/2 1 '
1 II
1 1 II
OVERSTITCHED
(OVER THE
EDGE] 3 TIMES
BACKSTITCHED ft 11 '
^"N^^.^^rf^^^V^.iWfc yv .^-^ /Y^**^ ^ >_
SEAM STARTS AT "A" AND ENDS AT "B"
NO BREAK IN THE THREAD
Figure 4-33. Properly anchored machine seam.
4-29
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
Meanings and Symbols of
Machine-Sewn Basic Stitches
STITCH. A stitch is one unit of thread for-
mation resulting from passing a thread through
material at uniformly spaced intervals. The class
of stitch is indicated by a specification
number for example, 301, which specifies a
United States Standard Lockstitch (one lock
knot for each stitch). The class 31 and 111 sew-
ing machines sew a United States Standard
Lockstitch 301.
SEAM. A seam is a joint consisting of a
sequence of stitches uniting two or more pieces
of material.
STITCHING. A stitching consists of a
sequence of stitches for finishing an edge, for
ornamental purposes, or both in preparing parts
for assembling.
The seam or stitch formation is indicated by
a symbol consisting of three parts:
NOTE: The three parts follow the three-digit
number showing the type stitch the machine
makes.
(1) The first part denotes the class and con-
sists of two uppercase letters; for example, SS.
(2) The second part denotes the type or the
class of the seam or stitch formation and consists
of one or more lowercase letters; for example, a.
(3) The third part denotes the number of
rows of stitches used and consists of one or
more Arabic numerals preceded by a dash; for
example, -1.
The complete seam specification for the ex-
amples given becomes 301 -SSa-1. (Remember
that the "301" is the machine class of stitch.)
There are places where one seam will be
better than others. Experience has shown certain
seams are best to serve a certain purpose. These
seams have been standardized so that people
who do sewing can turn out the same type of
work. Standardization makes it possible to make
drawings and blueprints that can specify a
desired seam. This way, no matter who does the
job, the finished article turns out to be as strong
and durable as the designer wanted it.
Uses of Varying Classes of
Machine-sewn Seams and Stitchings
CLASSES OF SEAMS. The three classes
of seams are SS (superimposed seams), LS
(lapped seams), and BS (bound seams).
Class SS, Superimposed Seams. These are
formed by placing one ply of material above
another with the edges together and the seam
along one side. Superimposed seams are usually
made with two plies of material, although more
than two plies can be used for special projects.
The edges may be folded under, but they are
never overlapped when the stitching is made.
Types of superimposed seams are SSa-1 and
SSc-2, as shown in figure 4-34.
(1) The SSa-1 seam is the simplest method of
joining two or more pieces of material. It is also
used as the first step in the formation of other
seams, such as the LSak-2 seam.
(2) The SSc-2 seam is used for making many
different types of covers. It is also used in
making channels for sash cord when making
handles on carrying bags and cases.
Class LS, Lapped Seams. You form the
class LS seam by overlapping the material a suf-
ficient distance and stitching with one or more
rows of sewing, as shown in the cross-sectional
views in figure 4-35. Types of lapped seams are
LSc-2, LSc-4, LSd-1, and LSak-2.
(1) The LSc-2 seam is used for the sectional
seams and the LSc-4 for the channel seams of
parachute canopy. The interlocking of the folds
makes the LSc seams the strongest of the seam
formations.
(2) The LSd-1 seam, as shown in figure 4-35,
is used in sewing pockets or patches. Also, use
the seam to patch small holes.
(3) The LSak-2 seam, as shown in figure
4-35, is used for finishing seams of covers for
shop equipment.
Class BS, Bound Seams. BSa-2 seams are
made by folding binding strips or tapes over the
edges of the material to reinforce and finish the
4-30
Chapter 4 FABRICATION AND MANUFACTURE
Figure 4-34. Superimposed seam.
edges. Use the BSa-2 seam, as shown in
figure 4-36, to bind the edges of tool aprons,
reinforcment panels, etc. Most soundproofing
is bound with 3/4-inch tape using the BSa-2
seam.
Figure 4-36. Bound seam.
CLASS OF STITCHING. You form class
EF (edge finishing) stitching by using the edge of
a single ply of material to make the hem. The
EFb-4 stitching, as shown in figure 4-37, is made
by folding the edge back twice, thus turning the
cut edge inside the second fold to prevent fray-
ing and to reinforce the hem. The hem may also
include a piece of reinforcing tape, plain or
tubular webbing for adding strength. All seams
and stitches pictured are used in the survival
equipment shop for modification and repair
Figure 4-35. Lapped seam.
4-31
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
TUBULAR WEBBING
REINFORCEMENT
Figure 4-37. Edge finishing stitching.
work on the parachute canopy, pack, seat, and
back pads, or for making covers and bags for
aircraft, shop equipment, and tools.
Appropriate Spacing of
Machine-sewn Seams
The following rules will help you to space
correctly more than one line of stitching and to
place a seam the correct distance from the edge:
(1) Sew regular binding tape 1/16" from
the selvage edge of the tape.
(2) Sew heavier tapes from 1/16" to 1/8"
from the edge. Sew the raw ends of the tapes
1/4" from the raw edge.
(3) Sew horsehide and thin leathers 1/8"
from the edge in patching, trimming, etc.
(4) Sew the raw edges of 8 to 15 oz duck
1/2 "from the edge.
(5) Fold the material no less than 1/2" for
reinforcement.
(6) Sew the folded edges of 8 to 15 ounce
duck 1/8" from the folded edge.
(7) Make the second and succeeding rows
of stitches 1/4" apart. In heavier material, it is
sometimes desirable to separate the rows as
much as 3/8".
(8) Heavy duck, heavy fabric, or the
heavier leathers may be sewn approximately
1/4" from folded edges for best results, while the
raw edges of such heavy fabrics need at least
1/2" to 3/4" seams for security.
(9) Sew light nylon or aircraft fabric 1/16"
from the folded edge. Raw edges of these light
materials are seldom sewn together except as the
first step of another seam.
(10) When you are sewing a row of stitches
and the thread breaks, start sewing again 1/2"
behind the break and sew on top of the existing
stitches. This is called backstitching.
The stitches that form the various classes of
seams should be tight, even, and well-set into the
material. An understanding of how the machine
functions to form the stitch and feed the
material provides the basis for you to sew high-
quality seams consistently.
KNOTS
A Boy Scout's first achievement is to learn to
tie knots. Knots are necessary to many activi-
tiescamping, boating, mountain climbing, and
parachute rigging. Different knots serve dif-
ferent purposes. For instance, a hangman would
be out of a job if he forgot how to make a slip
knot. A doctor would have trouble sewing his
patient up after an appendectomy if he didn't
make a proper surgeon's knot. Also, you could
never pack a parachute correctly without a
working knowledge of several different types of
knots.
Some specialists have a tendency not to be as
concerned about knots as they are about other
items involved in servicing parachutes. Think of
knots as the treads (and the depth of the treads)
on your automobile tires. Sure, the tire can per-
form without treads. But, if the tires are going to
grip the road surface and stop the automobile in
the shortest time and distance possible, they re-
quire good tread depth. Tire treads are designed
to meet many performance requirements. The
same principles apply to knots used in parachute
rigging.
Make sure that all knots and tackings are
changed as often as possible. Their "tread"
deteriorates and becomes loose. Parachutes are
designed to perform under the most unpredict-
able situations, at speeds and configurations
4-32
Chapter 4 FABRICATION AND MANUFACTURE
too great to imagine. One poorly made knot and
tacking could cause burned suspension lines, ex-
cessive opening shock, or oscillation all of
which could result in the failure of the
parachute. Remember, no matter how small the
task is, treat each area of the parachute with the
greatest care and concern.
The type of knot used in assembling compo-
nent parts of parachutes depends on the purpose
for which the knot is intended, the strength re-
quired, and the kind of thread, rope, or cord
that is to be used. Remember, knots, hitches,
and turns decrease the tensile strength of rope,
cord, or thread, as shown in figure 4-38. Some
knots are tied for the purpose of breaking during
parachute deployment, and other knots are tied
so as not to break. This is why it is so important
that only the specified knots be used for a par-
ticular job. The following is a list of knots you
have to tie as you go about your job of servicing
parachute assemblies.
Overhand Knot
The overhand knot is the simplest knot
made, as shown in figure 4-39. It is very im-
portant, however, since it forms a part of many
other knots. You use the overhand knot at the
end of a single thread when you are hand sew-
ing.
Binder's Knot
A binder's knot is the simplest method of
joining two cords or threads together, as shown
in figure 4-40. Use it at the end of a double cord
when hand sewing to prevent the cord from pull-
ing through the material as you sew.
Square Knot
The square knot is the most common knot
for joining two ropes or cords, as shown in
figure 4-41. It can be easily and quickly tied and
untied and is secure and reliable except when
made with ropes and cords of two different
sizes.
Surgeon's Knot
The surgeon's knot is a modified form of the
square knot, figures 4-42 and 4-43. In fact, it is
BREAKS AT KNOT
Figure 4-38. Tensile strength decreased by knot.
Figure 4-40. Binder's knot.
B
Figure 4-39. Overhand knot.
Figure 4-41. Square knot.
4-33
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
Figure 4-42. Surgeon's knot.
3.218(3D)
Figure 4-44. Bowline.
Figure 4-43. Surgeon's and lock knot.
the same as the square knot, with the exception
of the first overhand knot, which is a double
turn. This double turn keeps the cord from slip-
ping while the last overhand knot is tied.
Bowline
The bowline is used to connect the parachute
pilot chute bridle line to the canopy vent lines
(see figure 4-44).
Half Hitch
The half hitch, shown in figure 4-45, is used
to form the tie for the safety ties on ripcord pins
on the various types of personnel, cargo, and
deceleration parachutes. Normally, three half
hitches in a series are used for the safety tie.
3.221
Figure 4-45. Round turn and two half hitches.
Clove Hitch
The clove hitch, shown in figure 4-46, is used
to secure the suspension lines to the connector
links on many parachute assemblies.
You know how to tie the most common
knots used in parachute rigging. For even
greater security, these knots can be modified to
form several other knots. The lock knot is an
overhand knot tied adjacent to many other
knots. For example, to prevent the square and
lock knots or the surgeon's and lock knot from
slipping, you tie overhand knots at each end of
the thread or cord. Also, the overhand knot can
4-34
Chapter 4 FABRICATION AND MANUFACTURE
STANDING
PART
AROUND
ONCE
AROUND
AGAIN
UNDER
ITSELF
3.220
Figure 4-46. Tying a clove hitch.
be tied in a series. The same applies to the
surgeon's knot. The binder's knot leaves a loose
end to form a slip knot, which is used to tem-
porarily tie an excess amount of cord. The
AS28A deployment bag uses this type of knot.
Also, when you secure the automatic ripcord
release's arming knot guide on the automatic
seat style parachute, you use a slip knot tied off
with a lock knot. The specific knots you use are
determined by the engineers who design, test,
and establish criteria for the operation and func-
tion of parachute assemblies.
4-35
CHAPTER 5
FLIGHT CLOTHING
Aircrew flight clothing plays an essential role
in the safety and survival of Navy aircrewmen. It
protects them from the elements and provides
necessary comfort for efficient mission perform-
ance. Its primary function is to protect them
against hazards such as fire, heat, cold, and im-
mersion in water. Different combinations of
protective clothing and equipment are used for
various flight, emergency, and environmental
conditions.
Naval aircrew protective equipment has also
been designed to provide camouflage and other
escape and evasion design features. Due to the
wide range of environmental conditions in which
aircraft must operate, a compromise between
comfort and protection has in some cases been
necessary. Post-crash fire and emergency cold
water exposure are two critical areas where
operational requirements are more important
than flight comfort. Emphasis has been placed
on developing materials and clothing assemblies
that improve survival chances and, specifically,
minimize injuries and prevent loss of life in case
of an aircraft accident in either normal or hostile
environments.
As an aircrew survival equipmentman some
of your responsibilities are the care and
maintenance of protective equipment. You may
be required to order, inspect, modify, and repair
this equipment.
MAINTENANCE SCHEDULING
AND RECORDS
Planned maintenance of protective flight
clothing is performed at the level of maintenance
set forth in OPNAVINST 4790.2 (Series). The
levels of maintenance are either Organizational,
Intermediate, or Depot. Mission, time, equip-
ment, facilities, trained personnel and opera-
tional needs are the basic considerations in
determining the level to be used.
Maintenance is divided into two categories;
preventive and corrective. Preventive
maintenance is the care and servicing needed to
maintain equipment and facilities in satisfactory
operating condition by providing for systematic
inspection, detection and correction of failures
either before they occur or before they develop
into major defects. Corrective maintenance is
performed as a result of failure of the part/
equipment, or to correct defects discovered dur-
ing preventive maintenance.
Upon completion of any maintenance ac-
tion, (e.g., inspections, repairs, modifications)
you must make appropriate entries on the ap-
plicable maintenance documents. By properly
maintaining these documents you provide a
complete maintenance history of the equipment
throughout its service life.
The maintenance/material control officer,
using the guidelines of OPNAV 4790.2 (Series)
schedules the preventive maintenance of all air-
crew personal protection equipment for which
he is responsible. Maintenance of this equipment
shall be thorough at all times. No careless treat-
ment or willful neglect of aircrew personal pro-
tective equipment will go unnoted. The vital
function of the equipment shall be uppermost in
the minds of all personnel concerned.
MAINTENANCE DOCUMENTS
Maintenance documents provide a
systematic means of recording equipment
history and documenting all maintenance ac-
tions performed on the equipment.
5-1
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
These documents consist of the following:
Aircrew Personal Protective Equipment
History Card, NAVAIR 10470/11 S/N:
0102-613-9110
VIDS/MAF, OPNAV Form 4790/59 or
4790/60
Support Action Form, OPNAV Form
4790/42
DOD Single Line Item Requisition System
Document, DD 1348 (Series)
Work Request, OPNAV Form 4790/36
Work Request-Customer Service, OPNAV
Form 4790/36A
NOTE: All entries are to be printed clearly
with blue or black ball-point pen, or typewrit-
ten. Felt tip pens or pencils are unacceptable for
maintenance document or history card entry
purposes. When you sign a maintenance docu-
ment or history card your full signature is re-
quired. Be sure to check the OPNAVINST
4790.2 (Series) for the most up-to-date form
numbers.
Aircrew Personal
Protective Equipment
History Card
This Aircrew Personal Protective Equipment
History Card contains information pertaining to
the personal protective equipment issued to one
specific aircrewman. The card is divided into
three sections: Section I records all aircrew per-
sonal equipment issued to the aircrewman. Sec-
tion II is used for recording when calendar
inspections are performed. It includes the in-
spector's full signature and Collateral Duty In-
spector (GDI) stamp. Section III records all
modifications and repairs performed on the
equipment. This card can be used as a custody
card by units which operate a flight gear issue
pool. When a new card is started for any reason,
the old card is stapled on the back of the new
card. When an aircrewman transfers to a new
unit and keeps his personal protective equip-
ment, the card is forwarded to his new unit.
Shop Process
Cards (SPC)
The Shop Process Cards (SPC) provide the
maintenance man with a ready reference for per-
forming scheduled maintenance on a specific
type of aircrew personal protective equipment.
Each SPC contains one or more detailed
maintenance requirements . Illustrations ,
clearances, tolerances, charts, and part numbers
are included when required. The minimum re-
quirements for the performance of all or part of
any particular periodic maintenance task (calen-
dar or special inspection) are contained in a set
of these cards. The work plan (or order of per-
forming the maintenance work requirements) is
prearranged and is issued by the work center
supervisor for the type of aircrew personal pro-
tective equipment being serviced.
Aircrew Personal
Protective Equipment
Manual, NAVAIR 13-1-6.7
When you are working with personal protec-
tive equipment your best friend is the Aircrew
Personal Protective Equipment Manual,
NAVAIR 13-1-6.7. This manual contains com-
prehensive and authoritative information on
configuration, application, function, inspection
and maintenance of aircrew personal protective
equipment.
MODIFICATIONS
Perform only authorized modifications.
Unauthorized modification and deviations from
the approved configuration of life support and
survival equipment by individual crewmen could
create unknown and possibly dangerous condi-
tions.
NAVAIRSYSCOM is the only authority for
modification to life support equipment and sur-
vival equipment. Such changes are usually ac-
complished by the Cognizant Field Activity
(CFA) via Aircrew System Changes or a change
to the equipment procurement package. The
NAVAIR 13-1-6.5 also permits an operating ac-
tivity, with approval of the controlling custo-
dian, to conditionally modify ONE unit of
equipment in service to correct or overcome
5-2
CHAPTER 5 FLIGHT CLOTHING
unsatisfactory conditions in that equipment
item. Any other type of deviation, peculiar con-
figuration or modification to life support and
survival equipment is not allowed at the
operating level. The fleet riggers have no
authority or responsibility to perform them.
If there is a conflict between CFA documents
and NATOPS requirements, or if there is a need
for clarification of equipment configuration or
if equipment deficiencies are discovered, the
CFA should be notified. The field activity hav-
ing cognizance of most of the life support and
survival equipment is the Naval Air Develop-
ment Center (NAVAIRDEVCEN) at War-
minster, Pa. For parachutes and related
hardware, including torso harness, the CFA is
the Naval Weapons Center (Code 6412) China
Lake, California, 93555.
NAVAIRREWORKFAC Pensacola has
cognizance over all survival radios and URT-33
emergency beacons.
TYPES OF FLIGHT CLOTHING
GENERAL PURPOSE
FLIGHT CLOTHING
The flight clothing covered in this chapter is
designated to be worn by aircrewmen as outer
garments while on flight operations in aircraft.
As a squadron aircrew survival equipmentman,
you may be asked to sew on squadron patches,
name tags, and rate insignias. These items are
authorized to be worn on flight clothing as
directed by the local command. However, the
total surface area of all patches (name tag ex-
cluded) may not exceed 50 square inches and no
one patch may be bigger than four inches in any
given direction.
SUMMER FLYER'S
COVERALL, CWU-27/P
The CWU-27/P Summer Flyer's Coverall
(see figure 5-1) is designed to be worn as an outer
HANGER
SEWN EYELET
(TYP)
WRIST STRAP
ADJUSTMENT
(TYP)
WAIST
ADJUSTMENT
HOOK TAPE
FASTENER
PILE FASTENER
THIGH POCKET
LEG SLIDE
FASTENER
(TYP)
NAME PLATE
PILE TAPE FASTENER
PENCIL POCKET
BREASTPOCKET
(TYP)
SLIDE FASTENER
FRONT CLOSURE
KNIFE POCKET
SHIN POCKET
PASS THROUGH
POCKET (TYP)
MULTIPLE
PENCIL
COMPARTMENT
FRONT
BACK
239.381
Figure 5-1. Summer flyer's coverall, CWU-27/P.
5-3
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
n warm temperature zones, and pro-
ection in the event of an aircraft fire,
nated for use by all aircrewmen.
ition
overall is a one-piece, unlined garment
aramid cloth, a high temperature
inherently flame retardant synthetic
dth no hot-melt point or drip
sties. The lightweight fabric does not
Dmbustion, but begins to char at 700 to
js F. The fabric has abrasion resistance
> nylon, and like nylon, aramid is
bent. Because of this characteristic cot-
srwear should be worn under the
or optimum comfort. The color of the
T is sage green.
VU-27/P (shown in figure 5-1) has a
stener (zipper) front closure, side pass-
s, bi-swing back and hook and pile
fastener size adjustments at the end of each leg.
Also included are two breast patch pockets, one
combination cigarette and multiple pencil com-
partment on the upper front left sleeve, two
thigh pockets and a multiple pencil compart-
ment pocket on the right lower leg patch pocket.
Except for the knife pocket on the left thigh and
the multiple pencil compartment pocket on the
right lower leg, all pockets and pass-throughs
have butted, beaded, covered, slide fasteners. If
a hook blade knife (shroud cutter) is carried, it
should be tied to the pocket cord and stowed in
the knife pocket with the hook blade open for
emergency use.
Fitting
The summer flyer's coverall is fitted to the
aircrewman and its size normally corresponds to
men's regular suit sizes. The coverall is used with
standard Navy personal equipment and may be
worn over or under the anti-g garment. The
coverall sleeves shall always be worn down and
closed at the wrist to ensure maximum fire pro-
tection.
Maintenance
The aifcrewman's responsibility for
maintenance of the coverall is limited to
cleaning. The summer flyer's coverall shall be in-
spected for general condition at intervals not to
exceed 91 days. Repairs you perform at the
organizational level are restricted to repairing
open seams, small holes or tears, replacement of
hook and pile fastener tape, and replacement of
slide fasteners.
Only high temperature resistant aramid cloth
(MILC-81280) and high temperature resistant
nylon thread (MIL-T-83193) shall be used for
repairs.
It is recommended that a new coverall be
laundered prior to use in order to soften the
fabric and eliminate any possible skin irritation
that might occur due to original fabric harsh-
ness. After tumble drying or during drip drying,
the overall should be hung on a wooden hanger.
The fabric is a drip dry type requiring no special
handling and may be washed as fre-
quently as needed. The coverall may be
laundered by the aircrewman at home or in a
commercial type washer and dryer. Laundering
in water up to 140 degrees F, and tumble drying
up to 180 degrees F does not damage or shrink
the coveralls.
Use of a commercial fabric softener in the
rinse cycle removes body oils during the launder-
ing process. The fabric softeners also stop static
cling. Ironing or pressing is permissible.
However it is difficult to remove wrinkles or
creases due to the high temperature resistant
qualities of the material. Coveralls which are
heavily soiled and/or stained with oil or grease
may be cleaned with solvents normally used in
commercial dry cleaning establishments. Dry
cleaning or laundering does not compromise the
flame retardant properties, and no renewable
flame retardant treatment is required.
INTERMEDIATE FLYER'S
COVERALLS, CWU-l/P
The Intermediate Flyer's Coverall, CWU-
l/P (MIL-C-25786) is designed to be worn on
overland flights as an outer garment in in-
termediate temperature conditions (figure 5-2).
When authorized by the local commander, it is
issued to individual crewmen instead of the sum-
mer flyer coverall.
5-4
CHAPTER 5 FLIGHT CLOTHING
239.382
Figure 5-2. Intermediate flyer's coverall, CWU-l/P.
Configuration
The CWU-l/P is a one-piece, lined coverall.
The outer shell is nylon twill, and the lining is
rayon faced with wool backing. The coverall
has a belted drop seat, a concealed hood in the
collar, a full length slide fastening front closure,
two breast pockets, two side pockets, two thigh
pockets, a knife pocket on the left leg, two leg
pockets, and a pocket on the left sleeve. The
coverall also has adjustable sleeve cuffs and leg
opening slide fasteners to ensure a snug fit. (See
figure 5-3.) Pass-through openings are provided
on each side. The coverall is available in twelve
sizes ranging from small short to extra large
long. Cold weather underwear may be worn
under the coverall for optimum comfort.
The intermediate flyer's coverall provides
fire protection and may be used in place of the
summer flyer's coverall. There is an opening
behind the leg pockets which may be sewn closed
if not used.
Fitting
The intermediate flyer's coverall is fitted to
the aircrewman and normally corresponds to his
suit size. The coverall is used with standard Navy
personal equipment and may be worn over or
under the anti-g garment. The coverall sleeves
are always worn down and closed at the wrist for
maximum fire protection.
Maintenance
The individual aircrewman is responsible for
dry cleaning his coverall which is the only type of
cleaning allowed. Inspect the coverall for general
condition at intervals not to exceed 91 days.
Repairs are limited to mending small tears and
holes. Replacement of slide fasteners shall be ac-
complished at the discretion of the repairing
maintenance activity.
WINTER FLYER'S SUIT
The Winter Flyer's Suit, (MIL-S-18342) is
designed to protect an aircrewman against
adverse, low temperature conditions. When the
aircrewman wears this suit with the QD-1 Anti-
Exposure Coverall (covered in chapter 7), cold
5-5
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
COLLAR (HOOD CONCEALED)
DRAWSTRING
ANTI-G COVERALL
EXTERNAL TUBE PATCH
PENCIL POCKET
ADJUSTABLE
CUFF (TYP)
ANTI-G COVERALL
EXTERNAL TUBE OPENING
FRONT CLOSURE
SLIDE FASTENER
SIDE POCKET (TYP)
DROP SEAT SLIDE
FASTENER (TYP)
THIGH POCKET (TYP)
LEG POCKET (TYP)
LEG SLIDE FASTENER (TYP)
Figure 5-3. CWU-l/P coverall nomenclature.
239.383
5-6
CHAPTER 5 FLIGHT CLOTHING
Figure 5-4. Winter flyer's suit.
239.384
water immersion protection is also provided.
The anti-g coverall, when used, is to be worn
over the winter flyer's suit. The winter flyer's
suit consists of trousers and a jacket (see figure
5-4).
Configuration
The trousers (shown in figure 5-5) are con-
structed of an inner liner of fire-retardant cot-
ton, an insulation layer of polyester knit
material and an outer surface of nylon oxford
weave cloth. The color is olive green. The
trouser cuffs are formed into a knit anklet with a
stirrup. The basic garment cloth extends outside
the anklet and is closed by elastic at the end. The
trousers have a large pocket on the lower portion
of each leg, two slash pockets and two hip
pockets. The leg pockets are closed by slide
fasteners and the hip pockets by snap fasteners.
Four suspender tabs, with buttons, mate with
the jacket suspender tabs. The top of the
trousers extend above the elastic waistband to
provide greater protection against loss of body
heat. The trousers are available in sizes from 30
Short to 43 Regular.
The jacket (figure 5-6) is constructed of the
same material as the trousers The collar and
wristlets are finished with a knit cloth to provide
a snug fit, to save body heat. The jacket is a
waist length garment provided with a slide
fastener at the front. Two large pockets are pro-
vided across the chest and a smaller one on the
left sleeve. There is an elastic waistband. Four
elastic suspender tabs are sewn to the inside of
the jacket for attachment of the trousers. The
jacket is available in 5 sizes from small to extra
extra large.
Application
When climatic conditions warrant, the
winter flyer's suit is worn by air crewmen aboard
aircraft in which the use of continuous-wear
anti-exposure suits is not authorized. The winter
flyer's suit may be worn in lieu of continuous-
wear anti-exposure suits when flights are not
over water.
5-7
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
SUSPENDER TAB (TYP
ELASTIC
WAISTBAND
OUTER CUFF>
ROLLED BACK
ANKLET (TYP)
FRONT
Figure 5-5. Trousers of winter flyer's suit.
239.385
5-8
CHAPTER 5 FLIGHT CLOTHING
COLLAR
COLLAR
CLOSURE
TAB
PENCIL POCKET
WRISLET (TYP)
SLIDE FASTENER
ELASTIC WAISTBAND
SUSPENDER TAB
{TYP 4 PLACES)
239.386
Figure 5-6. Jacket of winter flyer's suit.
Maintenance
The aircrewman's responsibility for
maintenance of the suit is limited to cleaning.
The jacket and trousers are dry cleaned only.
Winter flyer's suit repairs that are done at
the organizational level are limited to patching
small holes and tears, restitching loose seams
and replacement of suspender tabs. Standard
shop and sewing procedures shall be observed.
Replacement of the slide fasteners shall be per-
formed at the discretion of the maintenance ac-
tivity.
COLD WEATHER FLYER'S JACKETS,
CWU-17/P AND CWU-45/P
The Cold Weather Flyer's Jackets, CWU-
17/P or CWU-45/P (MIL-J-83388) are designed
to be worn as outer garments in cold weather.
See figures 5-7 and 5-8. They are designed to
provide thermal anti-exposure protection at low
temperatures.
Configuration
The CWU-17/P and CWU-45/P jackets are
identical except that CWU-45/P does not have a
hood. The jacket consists of an outershell with
wristlets and waistband of aramid material, and
a quilted lining. An emergency marker panel and
emergency marker panel pouch are included
with the jacket. A detachable fur ruff hood with
mouton lining and drawstring adjustment is pro-
vided with the CWU-17/P jacket. This jacket is
available in the following sizes:
Size
Chest Measurements
Small
34-36
Medium
38-40
Large
42-44
Extra Large
46-48
Extra Extra Large
50-52
5-9
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
FRONT
REAR
239.387^
Figure 5-7. Cold weather flyer's jacket, CWU-17/P.
Fitting
The cold weather flyer's jacket is fitted to the
aircrewman and normally corresponds to his
regular jacket size. The jacket is used with stand-
ard Navy personal equipment, and may be worn
under a parachute harness.
Maintenance
The aircrewman's responsibility for
maintenance of the jacket is limited to dry clean-
ing only.
Inspections, or other maintenance actions re-
quired shall be performed at the organizational
level or above, and is made every 91 days
Repairs at the intermediate level shall be limitec
to replacing cuffs and waistbands, restitchinj
partially opened seams and refinishing th<
aramid portions of the jacket. Repairs othe
than those mentioned above may be performec
at the discretion of the repairing maintenance
activity.
COLD WEATHER UNDERWEAR,
CWU-43/P AND CWU-44/P
The cold weather underwear, CWU-43/I
and CWU-44/P (MIL-D-85040), provide addec
thermal insulation. This cold weather underwea
5-10
CHAPTER 5 FLIGHT CLOTHING
EMERGENCY MARKER PANEL POUCH
VIEW A-A
Figure 5-8. Cold weather flyer's jacket, CWU-45/P.
239.387B
5-11
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
is to be worn by all aircrewmen operating in cold
temperatures. The underwear may be used with
standard Navy cold weather equipment. It con-
sists of drawers and an undershirt.
Drawers
The drawers are full length and the ankles
are of tight knit weave designed to fit snugly and
include a boxer style fly closure and elastic waist-
band. (See figure 5-9.)
Undershirt
The undershirt has full sleeves. The cuffs and
neck band are of a tight knit weave designed to
fit snugly. (See figure 5-10.)
The drawers and undershirt are also available
in two classes, Rhovyl Clevyl T poly vinyl
chloride (PVC) synthetic material and the CWU-
43/P, 44/P, aramid (Nomex) high temperature
resistant material. The Rhovyl Clevyl T poly
vinyl chloride cold weather underwear is no
239.389
Figure 5-10. Undershirt, CWU-44/P.
239.388
Figure 5-9. Drawers, CWU-43/P.
longer available through normal supply chan-
nels. The aramid (Nomex) high temperature
resistant cold weather underwear is presently
available through normal supply channels.
Fitting
The cold weather undershirt and drawers are
individually fitted to the aircrewman. The
proper size cold weather underwear normally
corresponds to the regular underwear size.
Maintenance
It is the aircrewman's responsibility to clean
the underwear as follows:
1 . Wash aramid cold weather underwear in
home or commercial washers and driers.
2. PVC underwear shall be washed at a mild
temperature, tumbled dry at low heat setting, or
drip dried. PVC underwear washed or dried at
hot temperatures will shrink.
FIRE RESISTANT FLYER'S
GLOVES, GS/FRP-2
The fire-resistant flyer's glove (MIL-
G-81188) is designated for use in warm-to-
moderate temperature zones and provides
5-12
CHAPTER 5 FLIGHT CLOTHING
239.390
Figure 5-11. Fire resistant flyer's gloves, GS/FRP-2.
protection in the event of aircraft fire. They are
used by all aircrewmen (shown in figure 5-11).
Configuration
The gloves are snug fitting and designed to
provide maximum dexterity and sense of touch.
If properly fitted they should not interfere with
the operation of the aircraft and use of survival
equipment. The gloves are available in sizes 5 to
11. Since the fabric is stretchable, the sizes will
accommodate any size hand. The gloves are con-
structed of soft cabretta gray leather (palm and
front portion of fingers), and a stretchable, sage
green, light-weight knit aramid fabric (entire
back of hand). The cloth portion of the gloves
does not melt or drip and does not support
combustion. The fabric does begin to char at 700
to 800 degrees F.
Fitting
The fire-resistant flyer's glove normally cor-
responds to the aircrewman's glove size. Deter-
mine the proper size glove on a trial fit basis.
The glove must fit snugly.
Maintenance
It is the aircrewman's responsibility to clean
the gloves. Repairs or other maintenance actions
required shall be performed at the organiza-
tional level or above, and is limited to restitching
seams.
The gloves are laundered as follows:
1. Put on the gloves and wash with a mild
soap in water not over 120F as if washing
hands. When the gloves are clean, rinse and
remove them from your hands. Squeeze, but do
not wring the gloves to remove excess water.
Never use a bleaching compound.
2. After removing excess water, place the
gloves flat on a towel and roll the towel to cover
the gloves. Ensure that the gloves do not contact
each other and are not exposed to hot air or
sunlight.
Letting the gloves come in contact with each
other may harm the soft leather palms. The ex-
posure to hot air or sunlight could cause the
gloves to shrink.
5-13
CHAPTER 6
ANTI-G GARMENTS
Although there is no limit to the speed a
human can endure in straight and level flight in
an aircraft, changing speed or direction can pro-
duce inertia to which the body has a sharply
limited tolerance. In the case of extreme stresses
exerted by forces of the type met in seat ejection,
ditching, or parachute opening shock, the short
duration of the force restricts its effects.
However, changing the direction of flight often
produces stress forces equal to several times the
normal value of gravity for periods longer than a
second. These forces can have dangerous ef-
fects.
At 5g's (five times the force of gravity), the
pilot's body is exposed to a force which increases
its " weight" and that of its components five
times. This increased " weight " has many ef-
fects. The pilot is pushed down into his seat. His
arms and legs feel like lead and manipulation of
the controls becomes more difficult. In addition,
the extra weight of the internal organs causes ab-
dominal and chest discomfort. Most important,
however, is the effect on the circulatory system.
At five g's the pressure exerted by the col-
umn of blood between the head and the heart
becomes just about equal to the blood pressure
in the arteries. As a result, the pressure supplied
by the heart is not great enough to pump an ade-
quate supply of blood to the head.
To counteract these effects, the pressure in
the arteries must be increased above the heart
level. At the same time, distended vessels and
tissue and fluid spaces in the regions below the
heart must be restored to normal. This is ac-
complished by the anti-g coverall or the anti-g
garment.
With the anti-g system, compressed air is
metered to the coverall in proportion to the
gravitational force being exerted. The bladders
of the coverall inflate compressing the legs and
abdomen of the wearer by an amount also pro-
portional to the gravitational force. Thus, the
coverall prevents blood collecting in the ab-
domen and lower extremities and forces blood
from the lower to the upper part of the body.
This effect increases blood flow to the heart and
increases resistance to the shifting of blood to
the lower limbs. In addition, it raises the
diaphragm, decreasing the distance between the
heart and the eyes and the brain. Altogether, it
increases the tolerance of the pilot an average of
about two g's.
Without an anti-g coverall, the average pilot
can withstand 4.5 to 5.5 g's without losing vision
or blacking out. With a coverall, he is capable of
withstanding 6.0 to 7.0 g's. However, this pro-
tection is available only for sustained accelera-
tions of four to five seconds or longer in
maneuvers other than snap maneuvers.
Anti-g equipment does not offer protection
in snap maneuvers where 10 to 12 g's can be ap-
plied in approximately one second. Such brief
forces are not as harmful to the body as lesser
forces sustained for a number of seconds.
MK-2A CUTAWAY
ANTI-G COVERALL
The Mk-2A Cutaway Anti-g Coverall (MIL-
C-23955) as shown in figures 6-1 and 6-2 is
designed to provide protection against blacking
out, loss of vision, and lowered mental effi-
ciency due to high g-forces experienced in high
performance aircraft.
6-1
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
239.391
Figure 6-1. MK-2A Cutaway Anti-g Coveralls.
CONFIGURATION
The anti-g coverall consists of a bladder and
outer shell. The bladder is constructed of
polychloroprene-coated nylon cloth and covers
the abdomen, thighs and calves. The bladder is
equipped with an air inlet port which attaches to
the aircraft anti-g system by means of a flexible
hose. The outer shell is constructed of heat-
resistant polyamide cloth and houses the blad-
der. It is cut away at the buttocks, groin and
knees for ease of movement and comfort. The
outer shell is equipped with waist and leg en-
trance slide fasteners, six adjustment lacings and
two leg pockets with hook and pile tape closures.
The anti-g coverall is available in four sizes.
When the aircrewman enters an aircraft, he
connects his "g" suit up to the aircraft by an
anti-g hose into an automatic valving system.
When a "g" force is applied, the bladder in-
flates automatically to pressures predetermined
in an automatic valving system installed in the
aircraft. The bladder, when inflated, restricts
the flow of blood downward to the
aircrewman's waist and feet as we have
described. Individual garment configurations
are discussed in the section covering the gar-
ment.
FITTING
Coverall
The anti-g coverall is fitted and adjusted to
the aircrewman on a best- fit basis. With a
proper fit, the lace adjustments should be
tightened approximately half way, and the
cutouts should expose the knees, groin and but-
tocks without binding or hindering movement.
The coverall should fit snugly, but not tight with
the bladder deflated. The inflated bladder
should compress the waist, thighs and calves
firmly and evenly.
With the bladder deflated, lace adjustments
shall be tightened to provide a snug (not tight)
comfortable fit at the waist.
Hose
The anti-g hose must be cut to length and fit-
tings installed on each end after correct coverall
6-2
Chapter 6 ANTI-G GARMENTS
AIR INLET
PORT
WAIST LACE
ADJUSTMENT
(TYP)
WAIST SLIDE
FASTENER
STIFFENER (TYP)
LEG LACE
ADJUSTMENT
(TYP)
SHIN POCKET
(TYP)
239.392
Figure 6-2. MK-2A Cutaway Anti-g Coverall Nomenclature.
size is determined. To fit and assemble the anti-g
hose, proceed as follows:
To fit the anti-g suit hose, have the air-
crewman don the coverall and sit in an aircraft.
Now, you can determine the required length of
the anti-g hose. You will find that the flexible
hose comes in 6-foot lengths. Cut the 6-foot
length of flexible hose to desired length in the
following way:
Using a razor blade or sharp knife, cut
through the hose between the turns of reinforc-
ing wire at the desired length (see figure 6-3).
Cut around the hose 360 degrees and sever
the reinforcing wire with wire cutters.
6-3
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
FIRST CUT
239.393A
Figure 6-3. Step 3 Cutting Flexible Hose.
Grasp the end of the reinforcing wire and
carefully pull away approximately one-half turn
of wire from the hose, and again, sever the wire
close to the hose (see figure 6-4). If necessary,
deburr the cut end of wire and press it back into
the hose.
Trim the end of hose evenly if necessary, and
remove any hose particles or other foreign mat-
ter from the interior of the hose.
When cutting stockinette (covered hose), use
the tip of a hot soldering iron or similar heat
source to trace completely around the end of the
hose to lightly sear frayed ends of the outer
covering.
Now, slide a clamp over each end of the cut
length of flexible hose.
Inspect the insert portion of the connector
and remove any burrs or sharp edges.
Using water or silicone paste (MIL-S-8660),
lubricate the insert portion of nozzle assembly
and quick disconnect hose connector. Do not
use oil, grease, or similar organic contaminants
as a lubricant.
Holding the hose in one hand and the con-
nector in other, install the insert of the connec-
tor into the hose with a right hand (clockwise)
screwing motion. Use moderate force when in-
serting the connector into the hose to avoid
damaging the interior of the hose.
239.393B
Figure 6-4. Step 5 Cutting Flexible Hose.
NOTE: If undue difficulty is experienced in
inserting the connector, machine the raised bead
on the insert end of connector to 0.662-inch
diameter. To prevent corrosion treat the
machined surface with Alodine 12 or equivalent
chemical film.
Slide the clamp over the hose and position it
between the body of the connector and the bead
on the end of the insert (see figure 6-5).
Ensure the fittings are properly inserted in
the hose and the clamps are properly positioned
between the raised beads and the body. Ensure
the clamps are tightened sufficiently by grasping
hose and jerking sharply on the fittings.
In some instances you may have to build up
the outside diameter of the hose under the clamp
with three to six turns of electrical insulation
tape so the clamp can tighten properly.
Cover each clamp with three turns of elec-
trical insulation tape.
You may find it neccessary to attach an
adapter ring to the end of the nozzle so you can
mate the ring and nozzle to the coverall air inlet
port.
6-4
Chapter 6 ANTI-G GARMENTS
CONNECTOR
BEAD
CLAMP
HOSE
239.394
Figure 6-5. Assembly of Hose and Connector.
MAINTENANCE
Preflight Inspection
The preflight inspection of the anti-g suit
shall be performed by the aircrewman prior to
each flight. The interval between preflight in-
spections shall not exceed 14 days. The preflight
inspection consists of the following:
Checking the slide fasteners for secure at-
tachment, ease of operation, and corrosion.
Visually inspect all seams for loose or broken
stitching, and the nylon outer shell for holes,
tears, and abrasion.
Check the air inlet port for bends, dents,
nicks, corrosion, and missing or damaged hook
tape fastener.
Inspect the laces and lacer loops for secure
attachment and wear.
If any discrepancy is noted, the coverall and
hose shall be subjected to a periodic inspection.
Calendar Inspection
The calendar inspection shall be performed
by an Aircrew Survival Equipmentman upon
issue prior to placing the anti-g coverall in serv-
ice and every 91 days after that to coincide with
life preserver calendar inspections. This inspec-
tion consists of the tasks required for the
preflight inspection and also the following addi-
tional tasks:
NOTE: First, you must remove the tape
which covers the hose fitting clamps. Reinstall
three turns of new tape after inspection.
1. Inspect the anti-g hose for frayed cover-
ing, cracks, damaged or corroded fittings, and
loose or corroded hose fitting clamps. Inspect
fittings for looseness by grasping the hose and
jerking sharply on the fittings.
2. Perform the leakage test. To do this test
on a MK-2A anti-g suit, you should use a special
test fixture which inflates the suit and measures
the inside pressure. You are required to inflate
the g-suit to 5 psi. The bladder shall not drop
more than 1.0 psig in 30 seconds. A pressure
drop greater than 1.0 psi in 30 seconds con-
stitutes a failure. The MK-2A cutaway anti-g
coverall shall remain in service until it fails the
leakage test.
3. Date and sign the History Card.
Repairs
Repairs shall be performed by the lowest
maintenance level possible and are limited to
mending small holes and tears (that do not re-
quire partial removal of the bladder), replace-
ment of adjustment laces, and replacement of
leg pockets. Repair or replacement of the blad-
der or air inlet port is NOT authorized. Repairs
to the anti-g hose shall be limited to tightening
or replacing hose fitting clamps. Any other
damage requires fitting and assembly of a new
hose.
If the fitting clamps are loose and cannot be
tightened, they must be replaced. To replace the
clamps, proceed as follows:
1 . Remove and discard the tape covering the
clamp if this has not already been done.
2. Loosen the clamp, and remove the fitting.
3. Remove and discard the clamp.
4. Slip a new clamp over the hose.
6-5
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2, VOLUME 1
5. Lubricate and reinstall the fitting, and
position the clamp between the raised bead on
insert portion of fitting and fitting body.
6. Tighten the clamp. Ensure the clamp is
sufficiently tightened by grasping the hose and
jerking sharply on the fitting.
7. Cover the clamp with three turns of a
3/4-inch pressure-sensitive electrical tape.
Cleaning
Cleaning shall be performed at the lowest
maintenance level possible. To clean the Mk-2A
anti-g coverall, proceed as follows:
1 . Seal the air inlet port with a cork or a rub-
ber stopper. Do NOT allow water to enter the
bladder. NEVER machine-wash or dry clean the
anti-g coveralls.
2. Immerse the coverall in a solution of
bacteriostat detergent and cold water. Do not
wash the coveralls in hot water. Mix the
detergent in accordance with instructions
printed on the container. If instructions are not
printed on the detergent container, use a ratio of
one cup detergent to three gallons of water.
Allow to soak for five minutes. Agitate gently
(by hand) for two minutes and drain the water.
3. Rinse in cool, fresh water and drain the
water. Repeat the rinse process until all traces of
detergent have disappeared from the rinse water.
4. To dry the coveralls, it is very important
that you do not try to wring, tumble, or spin dry
the coveralls. This action could damage the
bladder or air inlet port. The proper procedure
for drying is to hang the coveralls on a wooden
hanger in a dry, well-ventilated area. Do not dry
them in direct sunlight because ultra-violet
radiation can weaken the fabric.
CSU-15/P ANTI-G GARMENT
CONFIGURATION
The anti-g garment (figure 6-6), consists of a
fire-resistant aramid cloth outer shell which
239.395
Figure 6-6. CSU-15/P Anti-g Garment.
6-6
Chapter 6 ANTI-G GARMENTS
houses a bladder. It is cut away at the buttocks,
groin, and knees. The outer shell has waist and
leg entrance slide fasteners, six adjustment lac-
ing areas with lacing covers, and two easily
detached leg pockets with slide fastener closures.
The bladder system is constructed of
polyurethane-coated nylon cloth and covers the
abdomen, thighs, and calves. The bladder
system is fitted with a hose for connecting
directly to the aircraft anti-g system. This anti-g
garment is available in six sizes.
CSU-15/P anti-g garments are issued to in-
dividual aircrewmen, and are used in conjunc-
tion with standard Navy personal equipment.
The CSU-15/P is replacing the Mk-2A anti-g
coverall.
FITTING
Coverall
The anti-g garment is fitted and adjusted to
the aircrewman on a best-fit basis. The cords
shall be laced in the same direction as the ap-
plicable lacing slide fastener closure. With a
proper fit, the lace adjustment should be
tightened approximately halfway, and the
cutout should expose the knees, groin, and but-
tocks without binding or hindering movement.
The garment should fit snugly, but not tight,
with the bladder deflated. The inflated bladder
should compress the waist, thighs, and calves
firmly and evenly.
With bladder deflated, lace adjustments shall
be tightened to provide a snug (not tight) com-
fortable fit, especially at the waist.
Hose
This anti-g hose also must be cut to size and
an end fitting installed after correct garment size
has been determined. To fit the anti-g hose, pro-
ceed as follows:
Have the aircrewman don the anti-g garment
and sit in the aircraft. Attach the quick discon-
nect on the hose to the aircraft supply system. If
the hose is too long, measure it and mark where
to cut it.
Lay the hose out flat. In a single operation,
cut the outer covering, inner hose, and
spacer /reinforcement at the mark. Sear com-
pletely around the end of the outer cover to pre-
vent fraying.
Remove the tape, clamp, and severed portion
of hose from the quick disconnect connector.
Position the spacer/reinforcement on the
rubber extension of the connector (see figure
6-7). Butt the end against the raised portion of
the connector, and cover it with three turns of
electrical tape.
Slide the inner hose (bladder material) over
the connector and butt it against the raised por-
tion of the connector. Ensure the spacer/rein-
forcement is not twisted. Secure it with three
turns of tape.
NOTE: In some instances it may be
necessary to build up the outside diameter of the
hose area under the clamp with three to six turns
of tape to get the clamp tight.
Slide the outer cover of the hose over the
inner hose until it butts against the raised por-
tion of the connector. Install a clamp as shown
in figure 6-7. Cover the clamp with three turns
of tape.
Finally, ensure that the fitting is prop-
erly inserted in the hose and clamp it properly
positioned between the raised bead and the
body. Ensure that the clamp is tightened suffi-
ciently by grasping the hose and fitting and jerk-
ing sharply.
CONNECTOR
SPACER/REINFORCEMENT
BEAD / INNER HOSE
\ f
CLAMP RUBBER EXTENTION OUTER COVER
239.3%
Figure 6-7. Assembly of Hose and Quick Disconnect Fit-
ting.
6-7
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
MAINTENANCE
Preflight Inspection
A preflight inspection shall be performed by
the aircrewman prior to each flight. The interval
between preflight inspections shall not exceed 14
days. To perform the preflight inspection, do
the following:
Check the slide fasteners for secure attach-
ment, ease of operation, and corrosion.
Visually inspect all seams for loose or
broken stitching.
Visually inspect outer shell and hose covering
for holes, tears, and abrasion.
Check the quick-disconnect connector for
nicks, corrosion, and proper operation.
Inspect the laces and lacer loops for secure
attachment and excessive wear.
If you find any discrepancies, forward the
garment to the Aviator's Equipment Branch for
a periodic inspection.
Calendar Inspection
The calendar inspection is made by an Air-
crew Survival Equipmentman prior to placing
the anti-g garment in service and every 182 days
after that, which coincides with every second life
preserver calendar inspection. The calendar in-
spection shall also be done whenever a
discrepancy is discovered during preflight
inspection. This inspection consists of the
preflight inspection items, and the following ad-
ditional tasks:
You will be required to perform a leak test
and repair any discrepancies found after you
complete the leakage test.
To do the leak test on the CSU-15/P
Anti-"G" Garment, you use the same test pro-
cedures as you would for the Mk-2A anti-g gar-
ment. These test procedures are found in the
NAVAIR 13-1-6.7. The CSU-15/P anti-g gar-
ment shall remain in service until it fails the
leakage test.
If everything is in order, date and sign the
History Card.
Repairs
Repairs shall be performed at the lowest level
of maintenance possible. They are limited to
repairing small holes and tears in the outer shell,
replacement and adjustment of lacings. Since
the hose is part of the bladder system, repairs to
it are limited to it tightening or replacing the
clamp and replacement of quick-disconnect fit-
tings.
Cleaning
Cleaning shall be done at the lowest
maintenance level possible. To clean the
CSU-15/P anti-g garment, you use the same
procedures shown for the MK 2 A coverall. As
you did with the MK 2A coverall, the proper
procedure for drying is to hang the cover-
alls on a wooden hanger in a dry, well- ventilated
area.
6-8
CHAPTER 7
ANTI-EXPOSURE ASSEMBLIES
This chapter covers constant wear and quick-
donning anti-exposure assemblies. Anti-
exposure assemblies are composed of several
garments which protect the aircrewman in the
event of immersion. Constant wear assemblies
provide additional protection from cold
weather. The constant wear assemblies consist
of a waterproof outergarment worn over a ven-
tilation liner and/or cold weather underwear.
The quick-donning anti-exposure suit is car-
ried in the aircraft, and donned only in case of
emergency. It consists of a waterproof outer gar-
ment equipped with permanently attached
boots, wrist and neck seals. An inflatable hood
and anti-exposure mittens are stowed in the
pockets. In case of emergency, the assembly is
donned over the regular flight clothing.
Either continuous-wear or quick-donning
anti-exposure suits, as appropriate, shall be pro-
vided for flight personnel and passengers when
there is a significant risk of crashing in the water
and when any of the following conditions pre-
vail:
1. The water temperature is 50 degrees
Fahrenheit or below.
2. The outside air temperature (OAT) is 32
degrees Fahrenheit (wind chill factor cor-
rected) or below.
If the water temperature is between 50 and 60
degrees Fahrenheit, the commanding officer of
the unit concerned considers the following
search and rescue (SAR) factors:
1. The maximum probable rescue time. This
should be a function of mission distance, SAR
equipment and SAR location.
2. The lowest temperatures that will occur in
the mission area during the time period of the
flight.
3. Then by utilizing table 7-1, he determines
whether anti-exposure suits are required.
4. When water temperature is below 60
degrees Fahrenheit and anti-exposure suits are
not required, the flight equipment shall include
anti-exposure, high-temperature resistant
undergarments. Wearing double layers of these
undergarments can significantly improve anti-
exposure protection.
CWU-33/P SERIES VENTILATED
ANTI-EXPOSURE COVERALL
ASSEMBLIES
The CWU-33/P Series Ventilated Anti-
Exposure Coverall Assemblies (see figure 7-1)
are designed for continuous wear and protect
the aircrewman from exposure to cold water,
wind, and spray. The assemblies incorporate a
ventilation system which should be used in
conjunction with a conditioned or ambient air
source.
The CWU-33/P Series Anti-Exposure
Coverall Assemblies are available in twenty
sizes. A size which approximates the air-
crewman's suit size should be chosen as an initial
guide. Final size should be determined by trial
and error until the closest fit with the least
amount of discomfort and restriction is at-
tained. A properly fitted coverall should not
show excessive material around the arms, legs
and crotch area. The front torso should fit taut
and the back should show excess material across
7-1
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
Table 7-1. Anti-exposure suit requirements
3
ec
Ul
2
ANTI-EXPOSURE
SUIT REQ'D
ANTI-EXPOSURE
SUIT NOT REQ'D
50 F
55 F
WATER TEMPERATURE
60 F
239.424
the shoulder blades and waist area. A taut
front prevents material from bunching in
the waist area and prevents coverall ride-up
which could cause neck chafing. Excess material
is allowed across the shoulder blades to
allow outward and upward arm mobility. Small
size adjustments can be made to allow for
particular body sizes that require an in-between
size. To obtain the required protection, the
CWU-33/P must be worn with polyvinyl
or aramid underwear, heavy wool socks, in-
flatable hood, anti-exposure mittens, and all
slide fasteners must be fully closed on water
entry.
The CWU-33/P coverall assembly is fabri-
cated of 1/8-inch thick polychloroprene cellular
rubber. Donning the coverall is accomplished
through the entrance slide fastener opening in
the front of the assembly, which extends from
the crotch to the collar.
SUPPLEMENTARY EQUIPMENT
The Mk-2A anti-g coverall is used in con-
junction with the CWU-33/P. Each innershell
of the CWU-33/P is furnished with an
anti-g coverall fitting which you will have
to install if the "g" suit is to be worn
with the anti-exposure suit. When this fitting is
installed in the exposure suit and the aircrewman
isn't wearing a "g" suit, the open inlet port must
be closed by a cover plate which is supplied with
the suit.
APPLICATION
In general, the coverall should be worn when
the combined temperature of the air and water is
below 120 degrees Fahrenheit. Table 7-2 in-
dicates approximate conditions under which the
CWU-33/P coverall is worn.
7-2
Chapter 7 ANTI-EXPOSURE ASSEMBLIES
LABEL
AIR INLET PORT
CLOTH REINFORCEMENT
PATCH
ENTRANCE
SLIDE FASTENER
PILE TAPE(TYP)
SLEEVE SLIDE
FASTENER (TYP)
LEG SLIDE
FASTENER (TYP)
FRONT VIEW
REAR VIEW
239.425
Figure 7-1. CWU-33/P series anti-exposure flying coveralls.
Table 7-2. CWU-33/P series application by areas
Area
Season
Latitude
North Atlantic Area
East
West
Summer
Winter
Summer
Winter
40 Degrees N
30 Degrees N
40 Degrees N
35 Degrees N
South Atlantic Area
East and West
Summer
Winter
35 Degrees S
15 Degrees S
North Pacific Area
East
West
Summer
Winter
Summer
Winter
30 Degrees N
25 Degrees N
40 Degrees N
30 Degrees N
South Pacific Area
East
West
Summer
Winter
Summer
Winter
15 Degrees S
30 Degrees S
30 Degrees S
35 Degrees S
FUNCTION
Normal
When aboard the aircraft, the aircrewman
connects his ventilation and, if applicable, anti-g
hoses to the aircraft supply systems. To maintain
comfort, the suit is equipped with a ventilation
system (see figure 7-2). Air introduced through a
vent fitting on the left side of the suit flows into
a manifold and ducting system to provide ven-
tilation for the arms, legs, and crotch. Air flows
back over the body and exits at the neck.
Emergency
In event of emergency egress (exit), the fit-
tings on the hoses disconnect from the aircraft
sources. In the water, check valves prevent water
from entering the coverall through the ventila-
tion or anti-g connections. To use the anti-
exposure hood, the survivor removes all other
7-3
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
CHEST (TYP)
239.426
Figure 7-2. Ventilation ducts.
head gear and dons the hood. After securing the
snap fasteners, the hood is inflated through the
oral inflation valve until a snug fit is achieved.
Fitting and Assembly
The final fitting, customizing and assembly
of the CWU-33/P shall be accomplished at the
AIMD. It is not possible to fit on a trial and
error basis using a full range of sizes. Each
garment must be pre-ordered based on tables
SEE DETAIL A
(TYP)
239.427
Figure 7-3. Customizing CWU-33/P.
outlined in NAVAIR 13-1-6.7 as guidance for
the closest fit. Customizing may be required to
assure the best possible fit (see figure 7-3).
WARNING
It is necessary to consider the fit of
other pieces of life support and survival
equipment when wearing the CWU-33/P.
Such items as the MA-2 Torso Harness
and the SV-2 Survival Vest may have to
be resized. Exposure protection and
mobility can be seriously compromised
by improper fitting.
7-4
Chapter 7 ANTI-EXPOSURE ASSEMBLIES
MAINTENANCE
All maintenance operations are performed
by organizational level or above.
Service Life
The CWU-33/P coverall may remain in
storage for three years from its date of manu-
facture. After that time you must inspect it
annually until it is placed in service. In-service
coveralls shall remain in service until beyond
economical repair. Repairs should not normally
be performed on CWU-33/P coveralls after five
years from date of manufacture. The schedule
of inspection for the CWU-33/P coverall does
not apply when the coverall is in seasonal
storage.
Calendar Inspection
The calendar inspection shall be performed
by organizational level maintenance or above
prior to placing the CWU-33/P coverall in serv-
ice and every 30 days thereafter. The calendar
inspection shall also be performed prior to plac-
ing the assembly in storage and when removing it
from storage. To perform the calendar inspec-
tion, proceed as follows:
1. Inspect the assembly for cuts, tears, abra-
sions or other damage
2. Look at all seams for separation, cuts,
and tears
3. Inspect the entrance, sleeve, and leg slide
fasteners for proper operation and corro-
sion.
CWU-21/P ANTI-EXPOSURE
ASSEMBLY
The CWU-21/P Anti-Exposure Assembly
(see figures 7-4 and 7-5) is a continuous-wear
garment designed to provide the aircrewman
with cold water, wind, and spray protection.
/NECK SEAL
STRETCH PANEL
INSERTS
ENTRANCE SLIDE
FASTENER
RELIEF PORTAL
SLIDE FASTENER
STRETCH PANEL
INSERT (TYP)
FRONT VIEW
REAR VIEW
239.428
Figure 7-4. CWU-21/P coverall.
7-5
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
ENTRANCE SLIDE
FASTENER
NOTCHED LEG
OPENING (TYP)
239.429
Figure 7-5. CWU-23/P liner.
The garment is worn beneath an aramid
(Nomex) flying coverall and any other special
flying clothing. It is a dry-suit type anti-exposure
garment, not equipped with pockets or hose
pass-through connections.
The CWU-21/P Anti-Exposure Assembly
shall be worn by aircrewmen for flight opera-
tions in accordance with the climatic and opera-
tional requirements established by the NATOPS
General Flight and Operational Instructions
Manual, OPNAVINST 3710.7 (Series). The
CWU-21/P Anti-Exposure Assembly, when
worn, enables the aircrewman to perform all
required flight operations without the necessity
of a separate ventilating garment. The coverall
is moisture/vapor-permeable when dry, and
prevents an excessive buildup of body heat. In
the event of immersion in water, the coverall
fabric swells, and seals out water. The quick-
donning mittens and inflatable hood must be
worn to achieve the greatest level of anti-
exposure protection.
The complete CWU-21/P Anti-Exposure
Assembly consists of the CWU-21/P Anti-Expo-
sure Flying Coverall, CWU-23/P Anti-Exposure
Coverall Liner and SRU-25/P Rubber Men's
Socks.
CWU-21/P ANTI-EXPOSURE FLYING
COVERALL
The CWU-21/P coverall is a one-piece gar-
ment supplied in twelve sizes. The coverall shall
not be worn in direct contact with the skin. Neck
seal, wrist seals and stretch panel inserts are
fabricated of chloroprene-coated nylon stretch
fabric. Stretch panel inserts are located on the
back, back waist, elbows and knees to permit
unrestricted body movements. The entrance
opening across the chest and the relief portal are
sealed with water- and pressure-sealing slide
fasteners.
CWU-23/P LINER
The CWU-23/P liner is a one-piece garment
supplied in twelve sizes. The liner shall be worn
directly under the CWU-21/P coverall, and over
recommended underclothing. The liner provides
a layer of in-water thermal protection. It is
fabricated of an inner-layer of 100-percent
cotton, and an outer-layer of polypropylene net-
ting. Each sleeve ending has a coated stretch
fabric insert to permit easy insertion of the
hands, and to reduce bulk. The leg endings are
short enough to clear the tops of flight boots,
thereby eliminating bulk, and are notched at the
front to allow standard wool or cotton socks to
be pulled up over the liner legs and hold the liner
legs in place when the CWU-21/P coverall is
donned.
SRU-25/P COTTON-FLOCKED
RUBBER SOCK
SRU-25/P cotton-flocked rubber socks are
supplied in eight sizes. The rubber socks are
one-piece and are molded to shape to provide
comfort and a good fit. The tops of the socks ex-
tend above the flight boots to reduce bulk and
restriction.
SIZING
The CWU-21/P Coverall and CWU-23/P
Liner shall be properly sized to the aircrewman
7-6
Chapter 7 ANTI-EXPOSURE ASSEMBLIES
based on height, weight and chest measure-
ments. Determine chest circumference by taking
a tape measurement at nipple height with the air-
crewman wearing one cold weather undershirt.
Refer to NAVAIR 13-1-6.7 for proper size.
The size of the SRU-25/P Rubber Socks
shall be selected based on the aircrewman's
flight boot size. Rubber socks should usually be
one size smaller than the flight boots if the rub-
ber socks are to be worn over standard cotton
cushion-soled type socks. If heavy cold weather
socks are worn, larger rubber socks and larger
flight boots probably will be required. In all
cases, the rubber socks shall be worn in a slightly
stretched condition to prevent wrinkles and ex-
cessive bulk. Under no circumstances shall the
socks fit tight.
FITTING
CWU-21/P Coverall
The neck and wrist seals of the coverall
should not be trimmed at the initial fitting, as
they tend to adjust to the wearer after a short
period of time. If no excessive seal restriction
exists, and the seal fit is acceptable to the air-
crewman, the seals shall be left as issued. Neck
seals shall fit snugly, and remain in direct con-
tact with the neck through all normal head
movements. Wrist seals should fit tight enough
to prevent water entry, but not tight enough to
restrict blood flow. If seal sizing is required, pro-
ceed as follows:
1. Measure the aircrewman's neck circum-
ference below the Adam's apple, and the cir-
cumference of the wrists below the wrist bone.
2. Measure the circumference of the neck
seal opening. A neck seal comfortably fits a neck
which is 1 to 1 1/2 inches greater in circum-
ference.
3. If the neck seal requires trimming, make a
mark 1/4 inch down from its top edge, and on
each centerline of the neck seal seam tapes. Posi-
tion correct trimming marks from the top edge
of the trimming template so they match up with
the marks on the seam tapes.
4. Holding the appropriate front or back
template firmly against the neck seal, draw a line
along the top edge of the template. Turn the
coverall over and, using an appropriate
template, repeat the procedure. Carefully cut
along the continuous line (which should be
parallel to the top edge of the neck seal) with a
pair of sharp shears.
5. Trim the wrist seals in the same manner as
you did the neck seals, except trimming in-
crements shall not exceed 1/8 inch at a time. Use
one wrist seal template to mark both sides of
wrist seal.
6. After trimming the seals, have the air-
crewman don the coverall to determine any seal
restriction and water-sealing characteristics.
Make any adjustments that may be necessary.
After all seals have been properly fitted, cement
a 1/4-inch wide strip of unsupported rubber tape
to all trimmed and untrimmed neck and wrist
seal openings to prevent tearing (see 7 below). If
the proper tape isn't available, cut a 1/4-inch
strip from the excess seal material and use this as
tape for the neck and wrist opening. When
cementing the tape on vertical seams use 1-inch
tape.
7. Mix equal amounts of toluene and ad-
hesive, and cement a 1/4-inch wide strip of
unsupported rubber tape to the outside surface
of all seals so the tape is flush with each seal
opening. Prior to positioning tape, apply three
coats of adhesive to each strip of tape, and to the
area on the seals where the tape is to be applied.
Apply tape to seals while the third coat is still
tacky. Overlap ends of tape approximately one-
inch. Do not stretch tape when cementing to
seals.
Fitting the CWU-23/P Liner
Select the correct size liner. No customizing
of the CWU-23/P liner is authorized.
Fitting the SRU-25/P Rubber Socks
Select the correct size rubber socks and fit
them to the CWU-21/P coverall as follows:
1 . Have the aircrewman put on the complete
CWU-21/P assembly. Include one set of cold
weather underwear, the CWU-23/P liner,
CWU-21/P coverall, socks, and, if applicable,
7-7
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
the MA-2 torso harness. If you do not have the
aircrewman don the entire equipment, the suit
will not fit properly after the rubber socks are
installed.
2. Have the aircrewman sit in a straight-back
chair with legs drawn back, heels directly below
kneecaps and feet flat on the floor.
3. Turn the top of the rubber socks one inch
over, forming a temporary cuff. Mark all the
way around each coverall leg where it meets the
top of this folded cuff. Have the aircrewman
take off the coverall. Cut off excess material
below the marks.
4. Insert a locally-manufactured paper,
wood, or metal cylinder 5 inches in diameter by
8 inches long into the leg end. Leave half the
length of the cylinder exposed, and butt the
folded-over top edge of the sock against the
bottom of the leg opening (see figure 7-6). If the
top of the sock is larger than the end of the leg
opening, pleat the sock equally on both sides.
Secure the pleats with adhesive.
5. Mix equal amounts of toluene and ad-
hesive, and apply one coat to the turned-back
MARK AND CUT
COVERALL
CYLINDER
INSIDE
COVERALL
LEG
-1 IN.
TEMPORARY
CUFF
BUTT EDGES
RUBBER SOCK
239.430
Figure 7-6. Fitting the SRU-25/P rubber socks.
surface of the temporary cuff on the sock, and
to the bottom 1-inch outside surface of the
coverall leg (see figure 7-6). Brush adhesive well
into the fabric and allow it to dry. Apply a
second coat to each area, and allow that to dry.
CAUTION
To ensure seam integrity, allow all
final cemented seams to dry thoroughly
for a minimum of 24 hours before using
the assembly.
6. Apply a third coat of adhesive to both
surfaces, and allow it to dry until tacky. Roll the
folded-back top of the sock up over the leg end-
ing, forming a 1-inch lap joint. Thoroughly roll
the joint with a hand-roller to remove all
wrinkles and air bubbles. The adhesive shall ex-
tend not less than 1/8 inch, nor more than 1/4
inch past the edges of the seam tape.
7. Cement a length of unsupported rubber
seam tape completely around, and centered on
the lap joint seam. Overlap the ends of seam
tape approximately one inch. Secure the loose
end of the tape with two coats of adhesive.
8. Turn the coverall inside out and repeat
step 7 on the inside exposed lap seam. Apply
talcum powder to the cemented area, and brush
off excess powder.
DONNING
Before putting on the coverall, it is im-
portant that you read the donning procedures
outlined in NAVAIR 13-1-6.7. You may have a
problem with the slide fastener when putting on
the coveralls. Proper slide fastener teeth align-
ment during opening and closing is imperative to
prevent kinking of the chain. If the fastener
hangs up, slowly move the pull tab back and
forth while tilting the chain from side to side.
MAINTENANCE
Calendar Inspection
The calendar inspection is done at the
organizational level or above upon issue, and
every 91 days thereafter. The inspection
7-8
Chapter 7 ANTI-EXPOSURE ASSEMBLIES
schedule does not apply to CWU-21/P
assemblies in seasonal storage. The calendar in-
spection shall also be performed prior to placing
the assembly in storage, and when removing
from storage. Only authorized repairs shall be
made. To perform the calendar inspection, pro-
ceed as follows:
1. Place the CWU-21/P coverall on a flat,
clean surface. Inspect the assembly for stains
that may be harmful to the fabric. If necessary,
clean the assembly in accordance with cleaning
procedures outlined in NAVAIR 13-1-6.7.
2. Inspect the exterior surface of the coverall
for damaged fabric, broken or loose stitching
and loose or damaged seam tapes. Inspect seals
and stretch panels for excessive looseness, frayed
edges, damage and pin holes. (A flashlight, or
similar light source, placed inside the coverall
will assist in finding small holes and broken
threads.)
3. Inspect coveralls for oil and acid stains. If
oil or acids are found, treat them in accordance
with instructions outlined later in this chapter.
4. Inspect the entrance and relief portal slide
fasteners for damaged chain, loose teeth, im-
proper chain alignment and damaged or loose
seal blocks.
5. Turn coverall inside out and repeat steps 2
through 4 above.
6. If required, treat the CWU-21/P coverall
with a water-repellent compound.
7. Repair any other damage.
Service Life
The CWU-21/P Anti-Exposure Assembly
(each component) shall remain in service until
beyond economical authorized repair.
Cleaning CWU-21/P Coveralls
It is recommended that you avoid frequent
laundering of the CWU-21/P coverall since it
degrades the special fabric characteristics. Do
not attempt to remove oil stains with solvents or
detergents.
Any portion of the coverall that is suspected
of having been in contact with acid compounds
shall be swabbed with a 50 percent solution of
ammonia and distilled water.
Squeezing, wringing or spin-drying the
coverall is prohibited. Remove the coverall from
service if it cannot be cleaned using the pro-
cedures outlined in this chapter.
Treat the coverall with a water-repellent
compound following any water immersion.
Do not launder the CWU-21/P assembly
prior to placing it in service or when removing it
from storage.
When it becomes necessary to clean the
CWU-21/P coveralls, proceed in the following
manner:
1. If the coverall has been immersed in salt
water, soak it in cold, fresh water for a
minimum of 30 minutes. Remove the coverall,
and discard the water.
2. Rinse the coverall in cold, fresh water.
3. Hang the coverall by its shoulder on a
wooden hanger and allow to drip-dry. Remove
any accumulation of moisture from rubber
socks with an absorbent material (terry cloth,
sponge, etc).
4. When it is thoroughly dry, hang the
coverall so you have easy access to both of its
sides.
5. Treat the coverall with water-repellent
compound (SCOTCHGUARD). Hold the
aerosol can four to six inches from the coverall
and spray compound evenly over entire surface.
Overlap each spray path slightly to ensure
complete coverage. The compound should
thoroughly soak the fabric, but not so much that
it begins to drip. Allow the coverall to air-dry.
6. After it is dry, turn the coverall inside
out, and repeat step 5.
Cleaning the CWU-23/P Liner
To clean the CWU-23/P liner, proceed as
follows:
1. Hand launder or use an automatic washer
that has a delicate cycle. The water must be
either lukewarm or cold. Use 3/4 ounce of
detergent to each gallon of water. The wash
cycle shall not exceed three minutes.
7-9
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
2. Rinse the garment three times. Use clean,
fresh water for each rinse. Each rinse cycle shall
last at least one minute.
CAUTION
Squeezing, wringing, or spin-drying
the liner is prohibited.
3. Hang the liner on a wooden hanger and
allow it to drip-dry.
4. Inspect the liner to be sure it is clean and
dry.
Storage
Proper storage of the CWU-21/P assembly is
very important in preserving its condition.
To properly store the CWU-21/P, you should
follow the steps listed below:
1. Ensure that the coveralls and liner are
clean and completely dry. Close the entrance
and relief portal slide fasteners to within four
inches of the seal blocks.
2. Fold the coverall and liner as shown in
figure 7-7. Folding procedures for the coverall
are shown. The liner is folded in the same
manner.
3. Loosely pack the coverall and the liner
into a suitable container. The container should
be sealed to prevent the assembly from being ex-
posed to dirt, dampness, or sunlight.
4. Store the closed container in a low-
humidity area. Temperature range in the storage
area must be kept between 68 degrees Fahrenheit
and 75 degrees Fahrenheit. Do not store con-
tainers near high-voltage electrical equipment,
acid, or petroleum products.
Patching
Petroleum (oil) stains, acid stains, cuts,
tears, holes and worn areas in the CWU-21/P
coverall may be patched provided they are
within the following allowable limits:
1. Straight cuts shall be repaired with seam
tape provided the cut does not exceed four
inches in length, and provided the cut edges can
be aligned to permit at least 5/16 inch of seam
tape to extend over each side of the cut. Other-
wise, a rectangular patch shall be applied to the
cut.
2. No more than two patches shall be ap-
plied to each arm; two to each leg; and no more
than four patches on any other part of the gar-
ment.
3. Patch size shall not exceed two inches
square (square patch), 1-inch x 4-inch (rec-
tangular) or 3 inches in diameter (round). All
patches shall extend a minimum of 1/2-inch
beyond damaged area. Round all corners
(3/8-inch radius).
4. Applying the patch is outlined in NAV-
AIR 13-1-6.7. To apply the patch you need to
refer to this manual.
QUICK-DONNING ANTI-EXPOSURE
COVERALL, QD-1/CWU-16/P
At the time of the writing of this chapter, the
Navy has stopped procurement of the QD-1
Quick-Donning Anti-Exposure Suit. However,
it will take some years before the current QD-1
coveralls are phased out of service. Therefore,
this book covers both the Quick-Donning Anti-
Exposure Suits, QD-1 and the CWU-16/P.
The Quick-Donning Anti-Exposure cover-
alls, QD-1 or the CWU-16/P are designed to
provide protection for an aircrewman in cold
weather conditions, particularly in the water.
The suit is normally used in conjunction with the
Winter Flying Suit or the Intermediate Flying
Coveralls, CWU-l/P. The QD-1/CWU-16/P
are not worn continuously, but are stowed on
board the aircraft for emergency use. (See figure
7-8.)
They are available in one size only. Water-
proof insulated mittens and an inflatable hood
are used with the basic coverall. The QD-
1 /CWU-16/P coveralls (see figure 7-8) are con-
structed of nylon life preserver cloth coated with
a chloroprene rubber waterproofing compound.
The aircrewman gets into the coverall through
an opening in the front of the shell which ex-
tends from the crotch to the left shoulder. This
opening is sealed by a waterproof slide fastener.
7-10
Chapter 7 ANTI-EXPOSURE ASSEMBLIES
STEP 3
A
STEP 4
FOLD LEGS
SECOND TIME
FOLD LEGS
AND BODY OF
COVERALL
STEP 1
FOLD ARMS IN
FOLD LEGS
FIRST TIME
STEP 2
Figure 7-7. Folding of CWU-21/P.
A
STEPS
TUCK SLEEVES BETWEEN
FOLDS 2 AND 3 OF
THE COVERALL
239.431
7-11
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
NECK SEAL
ENTRANCE SLIDE
FASTENER
ANKLE ADJUSTMENT
STRAP (TYP)
239.432
Figure 7-8. QD-1/CWU-16/P parts nomenclature.
The leg portions of the coverall end in boots of
the same material as the shell with an outer
covering of nylon duck cloth. Wrist seals and a
neck seal are attached to the garment. There is a
pocket on the upper front portion of each leg.
Ankle and wrist straps are provided to prevent
suit sagging from hindering movement during
escape.
ANTI-EXPOSURE MITTENS
The mittens (shown in figure 7-9) are
constructed of chloroprene-coated nylon life
preserver cloth (inner and outer surfaces)
and a urethane-foam insulation layer. Elastic
bands and straps are provided for fitting the
mittens. Retention lines prevent loss of the mit-
tens. The mittens are stored in the pockets until
needed.
ANTI-EXPOSURE HOOD
The hood (see figure 7-10) is normally stored
in one of the pockets. During a survival situa-
tion, it is donned in place of the helmet. A layer
of air provides insulation. The hood is inflated
through an oral inflation valve located on the
left side of the hood. The hood is constructed of
chloroprene-coated nylon life preserver cloth.
DONNING
To don the QD-1 or the CWU-16/P, you
must remember that the QD-1 and CWU-16/P
are worn over clothing but under parachute
harness, survival vest, and life preserver.
239.433
Figure 7-9. Anti-exposure mittens.
7-12
Chapter 7 ANTI-EXPOSURE ASSEMBLIES
239.434
Figure 7-10. Anti-exposure hood.
Donning is very simple. First, you remove
the parachute harness, survival vest and life
preserver, then remove the coverall from its con-
tainer and unroll it. Next, you spread the suit
out in front of you and insert your feet through
the opening and into boots. Pull the coverall up
over your shoulders, and insert your arms into
the sleeves. Ensure that no material from the
garments that are worn under the exposure suit
is trapped under the seals. This material could
allow water to enter the suit. Grasp the neck seal
in both hands, spread it apart and pull it over
your head. Ensure that fabric of undergarments
is not trapped under the neck or wrist seals.
Close the entrance slide fasteners. The slide
fastener must be fully closed to properly seal
your suit. Remove any excess air by stretching
the neck seal away from your neck and squat-
ting for a moment. Release the neck seal
before standing. Adjust the waist and leg straps.
Finally, don the survival vest, life preserver and
parachute harness.
FUNCTION
In the water, the QD-1/CWU-16/P provides
at least temporary buoyancy. You must,
however, inflate the preserver and enter a raft as
soon as possible. The waterproof suit fabric and
seals at wrist and neck prevent water from wet-
ting the clothing worn under the garment. This
preserves the insulation properties of the cloth-
ing, greatly extending the time you may survive
under adverse conditions. Immediately after
entering the raft, put on the mittens and hood.
To use the hood, you remove all other headgear
and don the hood. After securing the snap
fasteners, inflate the hood through the oral
inflation valve until it fits snugly.
MAINTENANCE
During the aircraft inspection cycle
designated in Planned Maintenance System
(PMS) publications, you inspect the coveralls if
they are part of the plane's equipment. In no
case shall the inspection interval exceed 225 days
whether the coveralls are aircraft-installed, shop
spares, or maintained in a flight gear pool.
Service Life
In-service suits shall remain in service until
they are beyond economical repair. Economical
repair is limited to replacement of wrist and neck
seals, replacement of entrance slide fastener,
repair of tears up to 2 1/2 inches (not to extend
across any seams) and one to five holes (not to
exceed one inch in diameter) in no more than
two general areas of the coveralls.
Routine Maintenance
To maintain a QD-1/CWU-16/P, proceed as
follows:
1. If the suit is soiled, clean it in accordance
with NAVAIR 13-1-6.7. Procedures are also
outlined later in this chapter.
2. Lightly coat rubber-coated sides of fabric
with talcum powder. Do not allow talcum
powder to contact the slide fastener.
3. B.F. Goodrich Slide Fastener P/N 2430
ONLY. Wipe this slide fastener with a soft,
clean, lint-free cloth moistened with water.
Allow it to dry and apply a light coat of silicone
lubricant to the chain and the rubber seal of the
fastener. To ensure the slide fastener is well-
lubricated, open and close it three times.
7-13
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
4. Talon Slide Fastener P/N 84 ONLY.
Wipe this slide fastener ^ith a soft, clean, lint-
free cloth moistened with water. Allow it to dry
and apply paraffin wax to it. To ensure the slide
fastener is well-lubricated, open and close it
three times.
5 . Pack the QD-1 /CWU-1 6/P in accordance
with instructions in NAVAIR 13-1-6.7.
Cleaning
To clean a QD-1 or CWU-15/P, proceed as
follows:
1 . Mix a solution of detergent in lukewarm,
fresh water. The strength of the detergent should
be in accordance with instructions printed on its
container. If no instructions are printed on the
detergent container, use a ratio of one cup
detergent to three gallons of water.
2. Lay the coverall, inside out, on a table.
Sponge the detergent solution onto cloth seals
and boots.
CAUTION
Do not scrub the coated side of the
cloth.
3. Using a soft bristle brush, clean the cloth
seals and boots.
4. Rinse with cool, fresh water.
5. Now, turn the coverall right side out.
Close the slide fastener and scrub the exposed,
uncoated, side of the cloth. Do not scrub any
exposed coated material.
6. Rinse well in cool, fresh water. Do not
wring or squeeze.
7. Open the entrance slide fastener and hang
the garment on a broad-shouldered wooden
hanger until its outer surface is dry.
8. Turn the suit inside out and hang it again
until dry.
9. Perform a leak test in accordance with
NAVAIR 13-1-6.7 after the cleaning process has
been completed. This leak test is also outlined in
this chapter.
ACCEPTANCE/CALENDAR/PHASE
INSPECTION
The Acceptance/Calendar/Phase Inspection
shall be performed by an Aircrew Survival
Equipmentman upon issue prior to placing the
QD-1/CWU-16/P in service, during aircraft ac-
ceptance inspection, and every second aircraft
Calendar/Phase Inspection cycle thereafter.
Refer to the applicable Planned Maintenance
System (PMS) publication for the specific inter-
vals. In no case shall the interval exceed 225 days
whether the coveralls are aircraft installed, shop
spares, or maintained in a flight gear pool.
Test Procedures
In order for you to properly test the QD-
1/CWU-16/P for leaks, you will need a test fix-
ture that is described in the NAVAIR 13-1-6.7.
The first step in testing for leaks is to:
1 . Turn the suit inside out and attach a wrist
seal clamp to one wrist.
2. Install the test fixture end adapter in the
other wrist seal and tighten the clamp.
3. Close the entrance slide fastener through
the neck seal.
4. Install the neck seal clamp.
5. Connect the test fixture to the test fixture
end adapter. Rotate the three-way valve to the
air source and inflate the suit. Rotate the valve
to the measuring device to check the pressure.
Continue this process until the suit is inflated to
a pressure of 6 inches of water.
6. Allow the suit to remain undisturbed for
five minutes, then check the pressure. Maximum
pressure loss allowed in five minutes is 1.0 inch
of water.
7. If pressure falls below 5.0 inches of water,
inflate again to test pressure, apply soap solu-
tion, locate and mark any leaks you can find.
8. If repairs are made, retest.
7-14
Chapter 7 ANTI-EXPOSURE ASSEMBLIES
Repairs and Fabrications
Instructions for performing authorized
repairs and fabrications to maintain the QD-
1/CWU-16/P in a Ready For Issue (RFI) condi-
tion can be found in the NAVAIR 13-1-6.7.
COMMERCIAL NON-VENTED
WET SUIT
The commercial wet suit assembly is an ex-
posure protective assembly for continuous wear
and protects the aircrewman from exposure to
cold, water, wind and spray resulting from
emergency egress from an aircraft at sea. The
wet suit, after being modified by the procedures
in this section, incorporates a ventilation system
which is used in conjunction with a conditioned
or ambient air source.
HOOD
FULL LENGTH
WET SUIT
GLOVES
SLIDE FASTENER (TYP)
SLIDE FASTENER (TYP)
BOOTS
239.435
HOOD
JACKET
GLOVES
TROUSERS
BOOTS
SLIDE FASTENER
(TYP)
SLIDE FASTENER
(TYP)
239.436
Figure 7-12. Two-piece wet suit.
Figure 7-11. Full-length wet suit.
NOTE
Due to the wide variety of commer-
cially obtained wet suits that have been
made available, it would be impossible to
cover every known suit in existence. Two
of the most basic and common con-
figurations are shown in figures 7-11 and
7-12.
Single or two-piece wet suits are available
in four basic sizes small, medium, large, and
extra large.
APPLICATION
When authorized by the cognizant type com-
mander, the modified commercial wet suit is
worn by aircrewmen for flight operations where
climatic conditions warrant. In general, the wet
7-15
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
Table 7-3. QD-1/CWU-16/P application by area
Area
Season
Latitude
North Atlantic Area
East
West
Summer
Winter
Summer
Winter
40 Degrees N
30 Degrees N
40 Degrees N
35 Degrees N
South Atlantic Area
East and West
Summer
Winter
35 Degrees S
15 Degrees S
North Pacific Area
East
West
Summer
Winter
Summer
Winter
30 Degrees N
25 Degrees N
40 Degrees N
30 Degrees N
South Pacific Area
East
West
Summer
Winter
Summer
Winter
15 Degrees S
30 Degrees S
30 Degrees S
35 Degrees S
suit should be worn when the combined temper-
ature of the air and water is below 120 degrees
Fahrenheit. See table 7-3 for an approximate
idea of when the wet suit is to be worn.
MAINTENANCE
All maintenance operations are performed
by organizational level or above.
Service Life
The commercial wet suit shall remain in serv-
ice until it is beyond economical authorized
repair or until you are directed to remove it from
service by the NAVAIR 13-1-6.7.
Special Inspection
The special inspection shall be performed by
organizational level or above on all assemblies
every 14 days. To perform a Special Inspection
examine the following:
1. Assembly for cuts, tears, abrasions and
deterioration.
2. Seams for separation, stitching, cuts and
tears.
3. Entrance, sleeve and leg slide fasteners for
proper operation and corrosion (if applicable)
and if needed. Apply a very light coating of
silicone lubricant (MIL-S-8660) to slide fastener
chains.
4. Inspect vent air fitting, if installed, for
corrosion. Inspect each fitting for looseness by
grasping and jerking.
5. Inspect hook and pile tape, if installed,
for security of attachment.
6. If discrepancies are noted, the wet suit
should be repaired.
Calendar Inspection
The Calendar Inspection shall be performed
by activities at the organizational level, or
above, upon issue, prior to placing the wet suit
in service, and every 30 days thereafter. The
Calendar Inspection shall also be performed
before you place the assembly in storage and
when you remove it from storage. Only
authorized repairs shall be made. The following
inspections and maintenance are done:
1 . Inspect the assembly for cuts, tears, abra-
sions or other damage.
2. Inspect the seams for separation, cuts and
tears.
3. Inspect entrance, sleeve, and leg slide
fasteners for proper operation and corro-
sion.
4. Inspect hook and pile tape, if installed,
for security of attachment.
5. Inspect vent-air fitting, if installed, for
corrosion. Inspect fitting for looseness by
grasping and jerking.
6. Clean assembly in accordance with para-
graph 4-134U.
7. Repair assembly, as required.
Cleaning
To clean the wet suit, proceed as follows:
1. To clean the assembly, shower-wash it
with mild soap.
7-16
Chapter 7 ANTI-EXPOSURE ASSEMBLIES
CAUTION Storage
Do not wring; do not damage ventila- When storing the wet suit, you should use
tion ducts. plenty of cellulosic material. This material will
prevent cracking of the wet suit material. The
2. To dry the assembly, hang it on a wooden celluosic material should be inserted at the folds
hanger fitted with a nail or screw on each of the wet suit when placed on a wooden hanger,
shoulder. Hang the wet suit from the nails or Remember that the wet suit does not require, or
screws by the sleeve and leg slide fastener tabs. get, any inspections while in storage; so proper
Place it in a dry, well-ventilated area. storage procedures are a must.
7-17
CHAPTER 8
INTEGRATED TORSO HARNESSES
DESCRIPTION
The MA-2 Integrated Parachute-Restraint
Harness (figure 8-1), also known as the In-
tegrated Torso Harness Suit, integrates the air-
crewman's parachute harness, lap belt assembly,
and shoulder restraint harness. The parachute
harness is reeved through the torso suit to retain
it in a position to make it easier to put on and
take off. The MA-2 provides optimum mobility
to the aircrewman while restraining the air-
crewman to the seat during emergency condi-
tions, and serves as a parachute harness in case
of aircraft ejection or bail out.
The MA-2 consists of a nylon webbing
harness encased in nylon fabric and is con-
figured into a sleeveless, legless, torso garment
available in sixteen sizes, extra small-short to
extra-extra large long. For proper suit fitting see
table 8-1. Shoulder restraint adjustable straps
with quick-release fittings provide attachment of
the parachute riser assembly. A lap belt with
quick-release adapter is attached to the lap belt
alignment webbing. The lap belt assembly pro-
vides attachment to a survival kit or parachute
and prevents damage to the abdominal area dur-
ing parachute deployment. The suit is closed by
a slide fastener with hooks and eyes for align-
ment. An adjustable chest strap provides the
final necessary chest restraint adjustments. The
chest strap is secured by a friction adapter and
hook and pile tape. A gated D-ring or a V-ring is
attached to the right shoulder adjustable strap
near the quick-release fitting. The rings are for
attaching a helicopter rescue hook.
The MA-2 (Cutaway) is approved for use
and is fabricated from an MA-2 by cutting away
non-structural nylon cloth. This is done to im-
prove comfort in warmer climate operations and
does not decrease either function or reliability of
the assembly. The MA-2 (cutaway) is fabricated
at the discretion of the individual aircrewman.
The MA-2 is worn by aircrewmen aboard an
aircraft fitted with a parachute designed for use
with the integrated system.
SIZING
When pilots or aircrewmen check aboard
your activity they may have their own flight
gear. If it is necessary for you to order a new
harness for them, refer to table 8-1 for proper
sizing. After properly measuring the air-
crewman, by using this chart you will have no
problems in selecting the proper size. If after
selecting the proper size torso you find that the
aircrewman requires a smaller size than the extra
small, which is the smallest size stocked, it will
be necessary to make a custom torso harness. In-
structions for making the custom harness can be
obtained by contacting the Parachute Testing
Facility Naval Weapons Center (NWC), China
Lake, CA. Consult the local physiology unit to
determine if a custom harness is necessary.
TAKING MEASUREMENTS
The proper technique for making the
measurements required to select the proper torso
harness is as follows:
Chest Circumference at Bust Point
Have the aircrewman stand erect looking
straight ahead, heels together and weight
distributed equally on both feet. The arms are
8-1
/AL EOUIPMENTMAN 3 & 2. VOLUME 1
NOTES
1 REFERTONA 13 1 64FOR
FABRICATION PROCEDURES
2 D RING FOR ATTACHMENT OF
SURVIVAL VEST
(S-3A AIRCRAFT
CREWMEMBERSONIY)
OXYGEN MASK
STORAGE BAG
(SEE NOTE 1)
D-RING (TYP)
(SEE NOTE 2)
Figure 8-1. MA-2 Torso harness suit (cutaway).
239.397
8-2
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8-3
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
lifted sufficiently to allow clearance of the
measuring tape between the arms and trunk.
FOR MALES: Hold the tape horizontally
and to the nearest half inch measure the cir-
cumference of the trunk at the level of the nip-
ples.
FOR FEMALES: Hold the tape horizontally
and to the nearest half inch measure the cir-
cumference of the trunk at points of each bra
cup. When taking this measurement the air-
crewman should take a normal breath and hold
it. Do not over expand the chest.
Vertical Trunk Circumference
Standing
Have the subject stand with legs slightly
apart. Using a length of tape, pass it between the
legs, over the protrusion of the right buttock,
and up the back to lie over the mid-shoulder.
The other end of the tape is brought up over the
right bust to the mid-shoulder completing the
circumference. Hold the tape into the hollow of
the back to make it follow the contour of the
back. The measurement is taken to the nearest
half inch after the aircrewman has taken a nor-
mal breath and held it.
Waist Circumference
Have your subject stand erect looking
straight ahead, heels together and weight
distributed equally on both feet. With a tape
held in a horizontal plane, to the nearest half-
inch measure the circumference of his/her trunk
at the level of the navel. Instruct the crewman to
breathe shallow breaths while you are measur-
ing. The subject must not pull in his/her
stomach.
Hip Circumference
Have the subject stand erect looking straight
ahead, heels together and weight distributed
equally on both feet. Measure the circumference
(to nearest half inch) of the trunk at the level of
the maximum posterior protrusion of the but-
tocks. The subject must not pull in his/her
stomach.
Thigh Circumference
Have the subject stand erect, heels approxi-
mately 5 inches apart and weight distributed
equally on both feet. Holding the tape perpen-
dicular to the long axis of the right thigh,
measure (to nearest half inch) the circumference
of the thigh at the level of the crotch.
FITTING
With the aid of a Flight Surgeon (if available)
or Naval Aviation Physiologist you will proceed
as follows:
1. Have the aircrewman put on the torso
harness. Ensure that the main sling saddle is
under the buttocks.
2. Check the location of the male Koch fit-
tings. The optimum location of the male Koch is
in the cavity /hollow below the clavicle (collar
bone) when the aircrewman is standing or sit-
ting.
3. Adjust the main sling webbing (it is that
portion of the main sling located between the leg
strap and the chest strap) as shown in figure 8-2;
it should be flush to the torso with no bulging or
surplus webbing evident. This condition should
exist under standing, sitting, or in a hanging
position.
4. Ensure that the chest strap does not cross
the torso above the armpit when the aircrewmen
is standing or suspended and shall not be below
the breast of the female aircrewmen.
5. Inspect the diagonal back strap D-rings
(see figure 8-2) and assure that they are posi-
tioned in the same horizontal plane and equally
spaced from the center of the back.
6. When the aircrewman has completed the
final adjustment of the harness, the cinch straps
are adjusted to a snug position.
With the subject wearing his own flight
helmet, suspend the aircrewman a few inches
above the deck using a riser assembly with a
12-inch cross connector strap. Inspect the chest
strap, main sling, diagonal back strap adjustable
links and main sling saddle for proper position.
Observe closely the aircrewman's weight
distribution in the harness. The main sling
8-4
Chapter 8 INTEGRATED TORSO HARNF.SSFS
^T"X
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^--JS-'"i V
1<- >yffi \
, "^^ ' V
MAIN j^>iii\ X
SLING ,\ ;x.JK\
x ^-v/liiU-
-^ k
< :X >I'\ \ ^-^ /
i - v ^lir^ BACK STRAP D RINGS /
!Xfi \ \ /'' /
STRAP, LAP BELT/ X
v UNDER / /
/
/"-
A!,
55-1 '\.
LOWER
CHANNEL
VELCRO
HOOK
VELCRO
PILL
LEG STRAP
Figure 8-2. MA -2 Torso nomenclature.
239.398
8-5
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
saddle when properly positioned supports the
body weight much like sitting in a swing. Weight
stress is carried from the main sling saddle up
through the main sling to the canopy release fit-
tings and riser assembly. Observe that when
suspended the aircrewman's body has not
shifted out of the main sling saddle.
LAP BELT AND SHOULDER
ADJUSTMENTS
In order to make the lap belt and shoulder
harness adjustments, the aircrewman must sit in
an ejection seat. Connect the lap belt fitting and
adjust the lap belt until it is snug. Leave no slack
in the lap belt. If the lap belt has been com-
pletely adjusted to the stop and slack remains,
try a smaller harness. If this does not work, the
aircrewman is considered a candidate for a
custom fit harness.
The canopy release/riser/shoulder restraint
system shall be connected. With the subject sit-
ting upright, shoulders back, there should be no
slack in the shoulder harness restraint. If the
shoulder harness is fully retracted and there is
slack, adjust the torso harness Koch fitting
down until slack is removed.
Personnel whose prescribed torso harness
does not meet the above criteria will be further
evaluated in other size MA-2 harnesses, if ap-
propriate.
INSPECTIONS
There are two inspections that are performed
on the MA-2 torso harness; one is the preflight
check. The MA-2 preflight check is done before
each flight and at intervals not to exceed two
weeks. This check is to be performed by the air-
crewmember. The other inspection is a calendar
or initial issue inspection. The MA-2 torso
harness shall be inspected upon initial issue and
at intervals coinciding with inspection of per-
sonal issue protective equipment (i.e., life
preserver, helmet, etc.). These inspections shall
consist of the following:
NOTE: Before you perform any inspection
on the torso harness you must determine
whether the harness is over-aged or not. You
would be wasting your time to perform an in-
spection and then find out that the harness isn't
fit for service due to its being over-aged.
1. Check the harness for its service life by
first checking the date of its manufacture. This
date is located on the inside of the right front leg
strap. The service/total life of the torso harness
is 12 years from when it was placed in service, or
15 years from the date of manufacture,
whichever occurs first. When an assembly
reaches its service life limit, remove it from serv-
ice and forward it to supply for disposition. If
the torso harness hasn't reached 15 years from
date of manufacture you still have to check the
service life. The date the torso harness was
placed into service is stenciled in the center of
the lap belt strap on the outer surface. Whenever
an in-service MA-2 lacks the stenciled start of
service date, its service life expires 12 years from
its date of manufacture. Now you are ready to
perform a calendar inspection.
2. Check the chest strap friction adapter
for corrosion, distortion, cracks, presence of the
locking bar, sharp edges, and security of the at-
tachment.
3. Inspect the shoulder canopy release fit-
tings for corrosion, distortion, presence of the
locking bar, absence of sharp edges, proper
routing of the webbing, and security of the pin
and locking screw. Ensure that the slot head
screw is installed and the red lacquer tamper dot
is intact.
4. Inspect the lap belt quick-release adapter
for corrosion, distortion, sharp edges, and
security of attachment.
5. Check the adjustable links located at the
rear inside of the suit for corrosion, distortion,
cracks, and sharp edges. Ensure that the chest
strap webbing is routed through these links.
6. Check the entrance slide fastener for
corrosion, missing teeth, presence of sliders
(single slider on the MA-2 cutaway modified),
security of attachment, and ease of operation.
7. Inspect the eyes and hooks at the en-
trance for damage and security of attachment.
8-6
Chapter 8 INTEGRATED TORSO HARNESSES
8. Inspect the gated D-ring or V-ring at the
right shoulder for corrosion, distortion, cracks,
and sharp edges.
9. Check the life preserver retention strap
for cuts, rips, frayed or weakened webbing,
security of stitching, and presence and condition
of snap fasteners.
10. Inspect the fabric panels for cuts, tears,
fraying, deterioration, and security of stitching.
11. Inspect the harness webbing for cuts,
tears, fraying, deterioration, and security of
stitching.
12. Repair any discrepancies and update the
MA-2 configuration in accordance with pro-
cedures outlined in NAVAIR 13-1-6.2.
General repair on the MA-2 consists of
replacement of the hardware and repair of cloth.
Do not replace any hardware which requires
restitching of the harness webbing. Harnesses
that are damaged must be discarded.
For more detailed information concerning
repairs and modifications to the MA-2 and
cutaway modified torso harness suits, refer to
NAVAIR 13-6-1.2.
8-7
CHAPTER 9
PROTECTIVE HELMETS AND OXYGEN MASKS
HELMETS
The wearing of protective helmets while fly-
ing in Navy aircraft depends upon the designa-
tion of the aircraft. You will find that aircraft
such as fighters, attack planes, and helicopters
usually require aircrew members to wear a pro-
tective helmet during takeoff, in flight, and
landing. Other aircraft may require that the
helmet be worn only during takeoff and landing.
The Navy headgear for an aircrew member is
considered to be a pilot's protective equipment.
Maintenance and upkeep is the responsibility of
the Aircrew Survival Equipmentman.
There are a number of different types of
headgear. Each has its own specific function. As
you work with the different types you'll find
that with very little effort, you can change their
basic configuration to meet requirements for all
fixed-wing aircraft.
The helmet assemblies in current use are
designated as the HGU Series. These lightweight
helmet assemblies are designed to provide face,
eye, aural, and head protection when properly
assembled and fitted to the aircrew member. The
helmet assemblies also house the headset com-
munications. Some helmet configurations offer
specialized features such as VTAS (Visual Target
Acquisition System), laser protective lenses,
sonar operator binaural cables, and boom
microphones. This series of helmets is based on
one type of helmet shell, the PRK 37/P.
MAJOR HELMET ASSEMBLIES
By taking the basic shell assembly PRK-37/P
and adding different liners, visors, and com-
munication systems (see figure 9-1) you can
make 15 different helmet configurations.
HGU-33/P HELMET ASSEMBLY The
HGU-33/P is a single lens, form-fit helmet for
use in aircraft where an oxygen mask is used
exclusively.
HGU-34/P HELMET ASSEMBLY The
HGU-34/P is a single lens, pad-fit helmet
required for use in aircraft where an oxygen
mask is used exclusively. This helmet assembly is
also an interim backup for the HGU-33/P when
a form-fit liner cannot be fabricated.
HGU-43/P HELMET ASSEMBLY The
HGU-43/P is a dual lens, form-fit helmet incor-
porating a neodymium laser protective lens for
use in A-6 Target Range Acquisition Multisen-
sor (TRAM) aircraft.
HGU-44/P HELMET ASSEMBLY The
HGU-44/P is a dual lens, form-fit helmet used
in aircraft where an oxygen mask is used
exclusively.
HGU-45/P HELMET ASSEMBLY The
HGU-45/P is a dual lens, form-fit helmet for use
in OV-10A aircraft where an oxygen mask and
boom microphone are both used.
HGU-45A/P HELMET ASSEMBLY The
HGU-45A/P is a dual lens, form-fit helmet
incorporating a neodymium laser protective lens
for use in the OV-10D aircraft where an oxygen
mask and boom microphone are both used.
HGU-46/P HELMET ASSEMBLY The
HGU-46/P is a form-fit helmet incorporating
the VTAS (Visual Target Acquisition System)
visor assembly for use in the F-4 VTAS aircraft.
9-1
g!SBfv0 ASSEMBLY
H-87B/U
EARPHONES
(T YP 2 PLACES)
MK-634/AIC
CLIP
239.413
9-2
Chapter 9 PROTECTIVE HELMETS AND OXYGEN MASKS
HGU-47(V)1/P HELMET ASSEMBLY
The HGU-47(V)1/P is a single lens, pad-fit
helmet required in aircraft where a boom
microphone is used or where a boom
microphone and oxygen mask are used inter-
changeably.
HGU-47(V)2/P HELMET ASSEMBLY
The HGU-47(V)2/P is a single lens, pad-fit
helmet incorporating a boom microphone
without amplifier and the CX-13155/A com-
munication cable for use in C-1A and C-2A air-
craft.
HGU-47(V)3/P HELMET ASSEMBLY
The HGU-47(V)3/P is a single lens, pad-fit
helmet incorporating a boom microphone
without amplifier and the CX-13164/A com-
munication cable for use in T-34 aircraft.
HGU-47(V)4/P HELMET ASSEMBLY
The HGU-47(V)4/P is a single lens, pad-fit
helmet incorporating a boom microphone
without amplifier and the CX-4832A/AR com-
munication cable for use in P-3 aircraft.
HGU-49/P HELMET ASSEMBLY The
HGU-49/P is a single lens, form-fit helmet
incorporating a boom microphone and CX-
13128/A communication cable for use in S-3A
aircraft.
HGU-50/P HELMET ASSEMBLY The
HGU-50/P is a single lens, form-fit helmet
incorporating a binaural headset required for
use in the aft stations of the EA-3B aircraft.
HGU-52/P HELMET ASSEMBLY The
HGU-52/P is a single lens, form-fit helmet
incorporating a boom microphone and CX-
13155/A communication cable for use in E-2
and A-3 type aircraft.
MAJOR HELMET COMPONENTS
The following helmet components are
available to achieve the desired configuration for
the aircrew member helmet.
PRK-37/P HELMET SHELL ASSEM-
BLY The PRK-37/P helmet shell assembly is
intended to protect the head during in-flight
buffeting and emergency situations such as ejec-
tion, bailout, or crash landings. It resists projec-
tile penetration and distributes impact forces
over the entire head. The helmet shell is the plat-
form for other components such as the visor
assembly, communication devices, and the
oxygen mask.
PRU-39/P HELMET SHELL LINER
ASSEMBLY The PRU-39/P is a helmet shell
liner which is form-fit, foam-in place type,
installed in the PRK-37/P helmet shell assembly.
The PRU-39/P consists of a rigid polyurethane
foam liner molded to fit the aviator's head.
The KMU-439/P (Liner Mold Kit) is positioned
on the pilot's head and foam chemicals
are injected into it. The liner is finished with
a soft urethane foam comfort pad and leather
covering. When properly fitted, the liner pro-
vides impact energy absorption, helmet stability,
and comfort.
PRU-39A/P HELMET SHELL LINER
ASSEMBLY The PRU-39A/P is a helmet shell
liner which is form-fit and constructed from
one-ply fiberglass backing (contour-molded to
fit within the PRK-37/P helmet shell) a leather
covering, and a comfort pad. The leather cover-
ing and comfort pad are cemented to the
fiberglass backing. The fiberglass backing has
two holes for introduction of foam chemicals.
When properly fitted, the liner absorbs impact
energy and makes the helmet stable and
comfortable. The aircrew member wears a
perspiration-absorbing cotton skull cap to
extend the life of the liner.
PRK-40/P HELMET SHELL LINER
ASSEMBLY The PRK-40/P helmet shell
liner, which comes in two sizes and consists of a
premolded 1/2-inch thick polystyrene foam
liner, is molded to fit inside the PRK-37/P
helmet shell assembly. Final fitting of the PRK-
40/P is accomplished by a series of different fit-
ting pads. Also included in the assembly is a
nape strap to allow a snugger fit. When properly
fitted, the liner is designed to provide impact
energy absorption, helmet stability, and com-
fort.
9-3
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2, VOLUME 1
EEK-4A/P HELMET VISOR, SINGLE
LENS The EEK-4A/P is a single lens helmet
visor assembly. When installed on the helmet
shell, it protects the face and eyes from impact,
projectile penetration, sun glare, dust, wind-
blast, and fire. Each assembly comes with inter-
changeable clear and neutral lenses.
PRU-36/P HELMET VISOR, DUAL
LENS The PRU-36/P is a dual lens helmet
visor assembly which provides the aircrew
member with the same protection as the EEK-
4A/P.
EEK-3/P HELMET VISOR, DUAL
LENS The EEK-3/P is a dual lens helmet visor
assembly which gives the aircrew member the
same protection as the EEK-4A/P. Each
assembly comes with a neodymium laser protec-
tive inner lens and an interchangeable clear and
neutral outer lens.
R-1825/AVG-8, R-1826/AVG-8 HELMET
VISORS The R-1825/AVG-8 mounts on a
large size helmet shell while model
R-1826/AVG-8 mounts on a medium. The
receiver includes a parabolic visor which pro-
vides the pilot with a collimated reticle image.
Two sensor electronic assemblies, one mounted
in each side of the receiver housing, assist in con-
verting the pilot's line of sight into aircraft coor-
dinates. The main assemblies of the receiver are
the housing, the visor assembly, and the harness
assembly.
COMMUNICATION CABLE ASSEM-
BLIES Each of the helmet assemblies is out-
fitted with the appropriate communication
components for operation with aircraft ICS
(Intercommunication System).
M-87/AIC BOOM MICROPHONE AS-
SEMBLY The boom microphone assembly
provides communication when the oxygen mask
is not in use, as well as walkaround capabilities.
NOTE: Detailed information on the fabrica-
tion of the form-fit liners can be found in the
NAVAIR 13-1-6.7.
SIZING THE PRK-37/P
When building up the HGU pilots protective
helmet it is very important that you start with
the proper size helmet shell (PRK-37/P). The
PRK-37/P is available in four sizes, (medium,
medium/large, large, X-large). To determine the
proper size you must first measure the cir-
cumference of the head, at the hatband line,
with a tape measure. Once you have the correct
measurement you can determine the equivalent
helmet size by referring to table 9-1.
HELMET CONFIGURATION BUILDUP
Once the basic PRK-37/P helmet shell and
major components are received, carefully in-
spect the shipping containers fpr evidence of
damage or signs of abuse. Open each container
and verify that all the required items have been
included. If any parts are defective, damaged, or
missing, replace all items in the shipping con-
tainer, prepare a Deficiency Investigation
Report and notify the proper authority. Once
the helmet shell and related components have
been accepted, the shell may be built up by add-
ing or removing major components in order to
obtain the desired configuration for required
aircrew or aircraft application. Before you
attempt to build up the helmet, it is necessary to
follow the steps outlined in the NAVAIR
13-1-6.7 for each major component you are
installing.
MAINTENANCE
As with all equipment that you work with
and maintain, proper care of the Fixed Wing
Series Helmet Assemblies is essential to ensure
optimum performance during emergencies and
routine flights. The aircrew member is responsi-
ble for cleaning and proper handling of the
helmet. All repairs and modifications are done
by the PR at the organizational maintenance
level or above.
INSPECTION
There is one basic inspection that you must
perform on the helmet and that is the calendar
inspection. In addition, the aircrew member is
9-4
Chapter 9 PROTECTIVE HELMETS AND OXYGEN MASKS
Table 9-1. PRK-37/P helmet shell sizing guide
CIRCUMFERENCE
(SEE NOTE 1)
COMPARABLE
HAT SIZE
SHELL AND LINER
SIZE REQUIRED
PART NUMBER
(FSCM)
21
63/4
Medium
954AS300-1
(FSCM30003)
22
7
Medium
954AS300-1
(FSCM 30003)
23
71/4
Medium/Large
(SEE NOTE 3)
24
71/2
Large
954AS300-2
(FSCM 30003)
24 1/2
73/4
Large
954AS300-2
(FSCM30003)
25 or more
7 7/8 or more
X-Large
(SEE NOTE 2)
79D444-7
(FSCM 97427)
or
(FSCM 92 114)
NOTES:
1. Circumference dimensions in inches.
2. Available through direct procurement from the manufacturer.
3. Whenever possible, the aircrewmembers are fitted with a medium size helmet.
responsible for a preflight/postflight inspection
before and after each flight.
Calendar Inspection
The calendar inspection is conducted by
organizational level activities upon issue and
every 91 days thereafter. The 91 day inspection
consists of a visual inspection, functional check,
and a thorough cleaning.
NOTE: Every other calendar inspection, or
every 180 days, the chin strap, nape strap pad,
ear seals and skull cap shall be replaced.
Visual Inspection
To visually inspect the helmet you must
make a thorough sight inspection for broken
parts, security of attached parts, loose or broken
stitchings, and also inspect the earcups for
sound attenuation and pliability.
Functional Check
The functional check shall be performed
with the aid of a REDAR oxygen hose test set. If
this unit is not available, standard shop pro-
cedures should be performed. Refer to NAVAIR
17-15BC-7 for the proper testing sequence.
9-5
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
Cleaning
You must clean all parts of the helmet at
least every 91 days. To clean the shell and edge
roll, mild detergent and water usually do the
trick. Sometimes you may have to use a mild
abrasive scouring powder to remove stains or
scuff marks. The chin strap, nape strap and fit-
ting pads may be cleaned by lightly sponging
with a solution of detergent and water. The skull
cap may be laundered in a machine, but this is
the responsibility of the aircrew member.
The visor assemblies are probably the most
important parts that require cleaning. If you
have ever worn sunglasses and they became
dirty, you know how aggravating that can
become. By using a solution of mild soap and
water and a soft cloth you can clean most visor's
lenses. Rinse off the solution and allow to dry. If
lenses are still soiled or slightly scratched clean
the outside visor only with liquid canopy polish.
The inside of the visor shall be cleaned with a
soft, lint free cloth. After cleaning apply an
antifog solution.
Addition of Reflective Tape
The addition of reflective tape on the helmet
provides for improved detectability of the
downed aircrew member. The tape must be
affixed to all helmets. However, in combat areas
the tape may be removed, as the crew com-
mander directs. White and red reflective tapes
are recommended, as they afford the greatest
detectability. When applying the tape, you use
any pattern specified by the unit commander, as
long as the tape pattern covers a minimum of 80
percent of the helmet visor housing and outer
shell.
To apply the tape, it is recommended that
both the helmet and the tape be preheated to
approximately 100 degrees. This improves the
adherence qualities and ease of application.
SPH-3B HELMET
The SPH-3B helmet shown in figure 9-2 is
designated for use by all helicopter aircrew
members.
The SPH-3B helmet protects the wearer's
head during in-flight buffeting or crash
landings. It is designed to distribute impact
forces over the entire head, and to absorb these
forces so that a minimum amount of impact
reaches the wearer's head. The SPH-3B helmet
is supplied in two sizes, regular and extra large.
The helmet consists of an outer shell assembly,
an inner foam liner, sizing liner, inner cloth liner
assembly, dual integrated visor, communication
cord set, and a microphone adapter.
The outer shell assembly is molded from
fiberglass and polyester resin and provides
impact and penetration protection. An edgeroll,
made of neoprene foam, provides protection
from the helmet edges.
The inner foam liner is made of cellular
polystyrene sheets molded to fit the inside con-
tour of the outer shell. The liner is provided to
absorb and dissipate impact forces.
The sizing liner, which is optional, aids in fit-
ting the helmet to the aircrew member's head
contour by padding the helmet at the nape of the
neck.
Sizing liners are provided in 1/4, 1/2, 5/8,
and 3/4-inch sizes.
The inner cloth liner assembly includes the
sonic earcup assemblies and foam pads for sizing
and comfort; it also has adjustable crown and
nape straps.
The dual integrated visor provides protection
from sun glare, dust, windblast, foreign par-
ticles, and flash fires. The visors are protected by
a molded fiberglass housing when not in use.
Two visors, clear and neutral, are available. The
percentage of visible light transmittance of the
neutral visor is 12 to 18 percent. The percentage
of light transmittance of the clear visor is 90 per-
cent or greater.
The communications cord set connects the
aircraft communications system to the helmet
earphones. The microphone adapter, located on
the helmet, allows attachment of a boom type
microphone.
Fitting
The SPH-3B protective helmet must be
individually fitted to the aircrew member. For
maximum protection, comfort, and sound atten-
uation, a good fit is a snug fit at the cheeks,
forehead, and nape of the neck. A loose fitting
helmet is more apt to produce pressure areas and
discomfort.
9-6
Chapter 9 PROTECTIVE HELMETS AND OXYGEN MASKS
239.319
Figure 9-2. SPH-3B protective helmet.
To fit the helmet, the aircrew member must
first select the size by trial fit. Don the helmet by
placing the thumbs on the inside of the earcups
and pulling the helmet outward, inserting the
forehead into the helmet between the thumbs,
and rolling the helmet backward until satisfac-
torily positioned on the head. The three crown
straps may be adjusted to allow the head to set
as far into the helmet as possible without in-
terfering with vision or touching the inner foam
liner. All three crown straps must have the same
tension when the crown pad is pressed in the
center.
The earcup tension strap and chin strap
should be adjusted in conjunction with the
spacer and sizing liner to obtain proper stability,
maximum protection, comfort, and sound atten-
uation. Use one thickness of sizing liner as
required and mate the hook and pile tape firmly.
Spacers are secured to the back of the earcup
assemblies. If necessary, tighten the nape strap,
with the helmet on, by pulling on the free end.
To loosen, raise the protrusion on the buckle
and pull the secured end of the strap. Tighten
the nape strap to provide a snug fit with the chin
strap fastened.
To ensure a proper helmet fit and stability
after making adjustments, don the helmet,
snugly tighten the nape and chin straps, and
shake the head vigorously.
9-7
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
If the helmet moves independently of the head,
readjust the sizing liners, spacers, and
adjusting straps. If necessary, file and sand the
visor nose indentation to fit the contour of the
aircrew member's nose. Ensure that the visor at
the nose indentation is free of nicks and
roughness.
MAINTENANCE PROCEDURES
Minimal maintenance, which is cleaning the
visor and outer shell, can be performed by the air-
crew member as needed. All other maintenance
operations must be performed upon issue and at
least every 91 days thereafter by qualified person-
nel at the lowest level of maintenance possible.
Inspect the sizing liners and inner foam liner
for looseness, re-cement where applicable and
replace worn or torn sizing liners. Inspect the shell
assembly for cracks, dents, scratches, splits, and
delaminations. Inspect all hardware for damage
and security of attachment, tighten or replace
hardware as necessary. Inspect straps, com-
munications cord set, earphones, and dual visor
assembly for damage. Replace parts as necessary.
The visor may be cleaned with mild soap and
water and dried with a soft, clean cloth. To
remove minor scratches or remaining soiled areas,
use acrylic plastic polish.
To preserve the visor's plastic surface, use
polishing wax for the final application. Do not
use solvent or abrasive type cleaners.
OXYGEN MASKS
Oxygen masks are the final link in conveying
oxygen from the aircraft system to the user. A
satisfactory regulator and oxygen system or a full
cylinder of oxygen is of little value to a pilot if
his oxygen mask is not operating properly in every
respect.
Oxygen masks are pilots' personal equipment,
that is; after initial fitting, they are retained by
the individual to whom issued. Fitting, ad-
justments, maintenance, cleaning, and incor-
porating modifications are the responsibility of
the PR.
The important factor to remember about iden-
tifying any oxygen mask is its compatibility
with the oxygen system with which the mask is
to be mated.
PRESSURE-DEMAND OXYGEN
MASK MBU-12/P
Oxygen mask assemblies are designed to be
worn over the face, forming a seal to the cheeks
over the bridge of the nose and under the chin.
The mask is designed for use with a regulator
which provides breathing gas (100% oxygen or
oxygen diluted with air) upon demand at a
pressure schedule dependent on the altitude. The
mask can also be used with continuous flow
bailout or walkaround oxygen sources. The mask
also provides facial protection from projectiles
and fire as well as working at depths of 16 feet
underwater. A properly fitted oxygen mask is also
essential to helmet retention in high-speed ejec-
tions. The facepiece permits utilization of the
valsalva maneuver to equalize pressure in the mid-
dle ear during descent.
The MBU-12 pressure demand O 2 mask is the
basic mask used to configure any of the follow-
ing oxygen mask assemblies:
MBU-14(V)1/P
MBU-14(V)2/P
MBU-14(V)3/P
MBU 15/P
MBU 16/P
MBU 17(V)1/P
MBU 17(V)2/P
Information on each assembly can be found
in NAVAIR 13-1-6.7. Figure 9-3 shows a MBU
12/P configured into a MBU 14(V)2/P.
MBU-12/P OXYGEN MASK SUBASSEM-
BLY The MBU-12/P is a lightweight, low
profile, pressure-demand type oxygen mask.
The mask features an integral facepiece/
hardshell. The facepiece is of pliable
silicone and the hardshell is of polysul-
phonate. The mask also features a combination
inhalation/exhalation valve, a flexible soft
silicone hose, and an MS27796 connector.
The mask is fitted with an antistretch cord
which is secured at the upper end to the
valve and at the lower end to the MS27796
connector. The hardshell is outfitted with
a microphone receptacle assembly on the
9-8
Chapter 9 PROTECTIVE HELMETS AND OXYGEN MASKS
OFFSET
BAYONET
RECEPTACLE
ASSEMBLY
M-94B/A
MICROPHONE
CX-13126/A
COMMUNICATION
CABLES
CX 4434/A
COMMUNICATION
CABLES
MBU 12/P
OXYGEN MASK
SUBASSEMBLY
MINIATURE
REGULATOR
(SEE NOTE)
OFFSET
BAYONET
NOTE. CRU-79/P MINIATURE REGULATOR SHOWN.
239.414
Figure 9-3. MBU-14 (v)2/P oxygen mask assembly.
9-9
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
FLAPPER
MASK SIDE
-GASKETS
(TYP)
HOUSING
EXHALATION
PORT
SPRING
HOSE SIDE
Figure 9-4. Cross sectional view of a combination inhalation/exhalation valve.
239.415
outside and a microphone bracket on the inside
for positioning the noise cancelling microphone.
COMBINATION INHALATION/
EXHALATION VALVE
The valve offers the advantage of miniature
size, but does exhibit slightly higher exhalation
resistance. The valve is sensitive to both dust and
contamination. As a PR you are responsible for
cleaning the mask. More about this is covered
later in this chapter.
Operation of the valve is very simple. The
valve is installed in the mask hardshell in such a
way that one side of the valve "sees" mask
pressure and the other side "sees" hose pressure
(see figure 9-4). Upon inhalation, the pressure
within the mask becomes less than the pressure
within the oxygen hose; the flapper of the valve
opens and oxygen from the hose enters the oxy-
gen mask (see figure 9-5). Upon exhalation, the
pressure within the mask becomes greater than
the pressure within the hose; the flapper closes;
the spring/diaphragm collapses; and the exhala-
tion is exhausted (see figure 9-6).
SIZING
In order to operate properly the MBU-12/P
oxygen mask must be the correct size for the
aircrewman.
The concept of sizing as used here refers to
the basic methods to be followed by the Aircrew
Survival Equipmentman for requisitioning the
proper size oxygen mask assembly from supply.
Once the basic oxygen mask size has been deter-
mined and requisitioned, the MBU-12/P oxygen
mask is ready for buildup to the ultimate con-
figuration desired. To select the proper size use
the caliper shown in figure 9-7; measure the
distance from the tip of the bottom surface of
the chin to the point of maximum depression of
the nasal root (smallest part of the upper
end of the nose). Once the basic size has been
9-10
Chapter 9 PROTECTIVE HELMETS AND OXYGEN MASKS
239.416
Figure 9-5. Cross sectional view of valve during inhalation.
determined requisition a new mask through nor-
mal supply channels.
ATTACHMENT OF BAYONET
AND RECEIVER MECHANISM
Before you fit the mask to the helmet you
should check to see if the MBU-12/P has been
configured to the correct assembly. For com-
plete information on configuration buildup refer
to chapter 13 in the NAVAIR 13-1-6.7. Once
you have a complete assembly of the right size
you're ready to fit the mask to the helmet.
The mask has four mask retaining straps.
You should thread the straps through the slots in
the offset bayonet fittings as shown in figure 9-8.
Then insert each offset bayonet fitting into a
receiver mechanism to the second locking posi-
tion. When the bayonet is inserted in the
receiver, the first click is caused by the entry of
the bayonet into the entrance of the receiver
housing and is not a locking position. There are
normally three clicks when inserting the bayonet
to the second locking position of the receiver.
When the bayonet is in the second locking posi-
tion, the end of the bayonet will be approxi-
mately even with the outer edge of the exit slot
on the back of the receiver. This proper posi-
tioning of the bayonet end can be checked either
visually or by passing a finger over the exit slot
on the back of the receiver.
Have the aircrew member place the helmet
on his head and hold the oxygen mask in proper
position on his face.
Inspect each receiver mechanism assembly to
be sure that the rotating feature of the device is
locked in its central position. If the rotating
9-11
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
MASK SIDE
-V- V-T
l^S^gS^
HOSE SIDE
Figure 9-6. Cross sectional view of valve during exhalation.
NOTE HOLD CALIPER AS SHOWN ABOVE TO READ
MBU 12/P MASK SIZE OPPOSITE SIDE INDICATES
MBU 5/P SIZES AND IS NOT TO BE USED
239.418
Figure 9-7. Measuring for proper size of O 2 mask.
239.417
239.419
Figure 9-8. Mask retaining straps.
9-12
Chapter 9 PROTECTIVE HELMETS AND OXYGEN MASKS
feature is found not to be centered, loosen the
two locking screws on the nameplate of the
receiver. Adjust the receiver until the bayonet is
,at right angles to the receiver. Retighten the
locking screws (figure 9-9).
The receiver has a rotating feature which
allows a 15 angle of freedom so that the
receiver can be adjusted slightly in either direc-
tion if this becomes necessary after attachment
to the helmet. Locate the receiver on the helmet
so that the upper and lower straps have equal
tension. The receiver should be positioned as
close to the edgeroll as possible to minimize
bayonet/edgeroll interference.
With a grease pencil, trace around each
receiver to mark its outline on the helmet (figure
9-10). You should use this outline to align the
receiver on the helmet. Now remove the helmet
from the wearer and using the back plate of the
receiver as a template, mark the locations for the
four receiver mounting holes on the helmet
(figure 9-11). Remove the ear cup assemblies and
drill four mounting holes in the helmet. Do this
on each side by using a No. 25 (0.1495-inch
diameter) drill. It is necessary to peel back the
pile fastener tape inside the helmet to allow the
attachment of the bayonet receivers. Attach the
receiver mechanism assemblies to the helmet
with the back-up plate inside the helmet. Note
that the forward receiver holes nearest the edge
of the helmet need longer screws. At this time
you can replace the pile fastener tape and replace
the earcup assemblies. NOTE: It may be neces-
sary to use adhesive when replacing the pile tape.
FITTING
The concept of fitting as used here refers to
procedures required for necessary component
adjustment following oxygen mask assembly
buildup. Fitting instructions are provided only
as a general guide. Because of the wide variation
in facial shapes likely to be encountered, it is not
possible to present detailed guidance. A suc-
cessful fit depends largely on the skill and
experience of the Aircrew Survival Equipment-
man in selecting and adjusting the oxygen mask
239.420
239.421
Figure 9-9. Adjusting receiver assembly.
Figure 9-10. Marking helmet.
9-13
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
239.422
Figure 9-11. Marking holes.
assembly to the aircrew member's face.
Improperly fitted oxygen masks do not provide
a positive face seal for pressure breathing and do
not protect the aircrew member in emergency
situations.
Have the aircrewman don the helmet and
ensure that the helmet nape strap has been
adjusted to a snug fit. Insert each bayonet into
the second locking position of the receiver and
adjust the straps until the mash is snug and com-
fortable. Attach the straps in place with two
turns of "E" thread. Perform a functional
check on the oxygen mask.
NOTE: If leaks occur between faceform and
face, check to see if proper mask size has been
issued. If leakage still occurs, adjust helmet
bayonet receivers. Refer to table 9-2 for trouble
shooting.
ADJUSTMENT OF
BAYONET RECEIVERS
To adjust the bayonet receivers, loosen the
two adjusting screws (see figure 9-12) and rotate
the receivers until the mask fits properly.
Retighten the adjusting screws.
239.423
Figure 9-12. Removing locking nut.
NOTE: Ensure that the top buckles are
tacked down prior to any adjustment.
Adjustment of the bayonet receivers is per-
formed with the helmet assembly and oxygen
mask assembly donned by the aircrew member.
When properly fitted, the MBU-12/P oxygen
mask can retain a pressure in excess of ambient
pressure up to the maximum pressure supplied
by the regulator.
MAINTENANCE
Proper care and use of oxygen masks is
essential to ensure optimum performance during
routine flight operations and emergencies. The
aircrew member's responsibility for maintenance
of the oxygen mask is limited to cleaning.
Repairs or other maintenance actions required
shall be performed at organizational level or
above.
PREFLIGHT/POSTFLIGHT
INSPECTION
The preflight/postflight inspection is a visual
inspection performed by the aircrew member to
whom the oxygen mask is issued before each
9-14
Chapter 9 PROTECTIVE HELMETS AND OXYGEN MASKS
Table 9-2. Troubleshooting
TROUBLE
PROBABLE CAUSE
REMEDY
Leakage from facepiece
Loose fit
Hold mask tighter against face.
If mask is connected to a flight
helmet, tighten straps on strap
and buckle assemblies.
Improper mask size
Use next smaller mask size.
Refer to Section 13-1.
Leakage at microphone
connector
Loose screws
Carefully tighten screws.
Refer to Section 13-7.
Improper seating or
defective microphone
bracket
Check mating of microphone
bracket with microphone.
Refer to Section 13-7.
Check microphone connector
and bracket for damage or
cracks. Replace as necessary.
Damaged or misplaced
gasket
Replace gasket. Refer to
paragraph 13-71.
Leakage from delivery
tube
Loose inlet connection or loose or
defective hose clamp
Tighten or secure inlet connection.
Refer to Section 13-7.
Tighten or replace mask hose
clamp. Refer to Section 13-7.
Damaged or deteriorated
delivery tube
Replace delivery tube.
Refer to paragraph 13-76.
Breathing is difficult
or inhalation/exhalation
valve sticks
Defective oxygen
valve
Replace oxygen valve assembly.
Refer to paragraph 13-75.
Improperly seated
valve nut or washers
Check for proper seating
alignment of valve assembly.
Reseat as necessary
Voice communication difficult or
impossible (if microphone is
present)
Defective microphone
connector or microphone
bracket
Replace microphone connector
amplifier and/or bracket if necessary.
Refer to paragraphs 13-70 and 13-71.
Leakage at strap screw
Defective seal on strap screw
Replace strap screw and tee nut as
necessary.
9-15
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
flight. The preflight/postflight inspection con-
sists of the following procedures:
NOTE: Defects or questionable areas noted
during this inspection shall be referred to the
proper maintenance activity for required correc-
tive action.
1. Check the communication system and
microphone for proper installation.
2. Check the mask for damage and proper
operation by using the tester and/or aircraft
oxygen and communications system.
Calendar Inspection
The calendar inspection is conducted every
30 days at the organizational level and consists
of a visual inspection, a functional check, and a
thorough cleaning of the oxygen mask assembly.
Refer to NAVAIR 13-1-6.7 for visual inspection
and functional check.
NOTE: If a discrepancy is noted, refer to
table 9-2, Troubleshooting.
Cleaning Mask
To clean and sanitize the oxygen mask
facepiece and housing assembly, proceed as
follows:
(Preferred solution) Make a one-percent by
weight solution of cleaning compound
(Detergent, General Purpose, MIL-D-16791,
Type I) by adding 1/4 to 1/2 ounce (liquid) of
the compound to one gallon of water.
CAUTION: When the following alternate
cleaning solution must be used, only the lather
from the solution shall be used for cleaning.
This prevents undissolved soap solution from
getting into the valve.
(Alternate solution) Make a suitable soap
solution by adding approximately four table-
spoons of soap powder (P-S-600) to one gallon
of water. Hardness of water may require more
soap, but the solution must be sufficiently
strong to readily form lather when agitated.
Make sure that all soap particles are dissolved.
CAUTION: Ensure that cleaning solution
does not enter inhalation/exhalation valve
assembly.
Moisten a gauze pad with the cleaning solu-
tion and wash the facepiece and housing
assembly both internally and externally.
After washing, the mask should be
thoroughly and repeatedly rinsed with warm
water.
NOTE: Another alternate sanitizer, Aerosol
Antiseptic Spray SET- 12 (dibromosalicyl
bromanicide), manufactured by Lever Brothers,
Inc., can be used. Directions for use are in-
dicated on the container.
After all parts are dry, disinfect by using a
gauze pad or other lint-free wipers, with a solu-
tion of 2 tablespoons of chlorine bleach per
gallon of water; rinse with clear water and air-
dry. Be certain disinfectant reaches inner
crevices of the faceform.
To clean the delivery hose, wash it with a
cleaning solution and rinse it with clear water.
Allow all parts to air dry.
When cleaning the inhalation/exhalation
valve assembly it will be necessary for you to
obtain a container just large enough to partially
submerge the valve. Fill the container half full of
benzalkonium chloride solution MIL-B-37451 or
a solution of 70 percent isopropyl alcohol and 30
percent distilled water.
By using the valve wrench shown in figure
9-12, unscrew the valve nut and remove the lock-
ing nut, bearing washer, and isolation washer
from the inside of the mask. This will allow the
valve, sealing washer, delivery tube, and connec-
tor assembly to be removed as a unit from the
outside of the mask. Hold the base portion of
the valve and submerge the operating portion of
the valve into the solution. Normally only a few
seconds are required to remove any stains and
residue. For stubborn residues use a cotton swab
saturated with benzalkonium chloride and rub
lightly to remove. Gently shake excess solution
from oxygen valve and allow it to air-dry com-
pletely.
9-16
CHAPTER 10
SURVIVAL ITEMS
When an aircrewman has to leave his aircraft
in a hostile environment, survival items provide
a means of sustaining life, attracting the atten-
tion of rescuers, and aid in evading the enemy.
Survival items may be packed in liferafts, drop-
pable kits, and kits intended to be carried or
worn by the aircrewmen.
As an Aircrew Survival Equipmentman,
your responsibility to the aircrewman is to main-
tain these survival items. You need to know how
they work and be able to pass that information
on to the aircrewman.
Here we discuss many of the items that are
frequently carried. The ones that are not covered
in this chapter are described in the NAVAIR
13-1-6.5 Manual.
SIGNALING EQUIPMENT
AND DEVICES
DYE MARKER
The dye marker (figure 10-1), is an aniline
dye powder in a sealed container. When placed
in the water, it produces a bright color that ap-
pears orange or fluorescent green depending
on how the light strikes it. It is used to attract the
attention of rescue aircraft. The dye is exhausted
from the package in 20 to 30 minutes and ceases
to be a good target after one hour. The dye ex-
posed water area is visible at an approximate
distance of 10 miles from 3,000 feet altitude. If
rapid dispersion of the dye is desired, agitate the
packet of dye vigorously in the water.
SIGNALING MIRROR
The emergency signaling mirror is approx-
imately 3 by 5 inches and consists of an
239.399
Figure 10-1. Dye marker.
aluminized reflecting glass mirror, a back cover
glass, and a sighting device. It is used by person-
nel in rafts or on land to attract attention of
passing aircraft or ships by reflection either in
sunlight or in hazy weather. The reflections of
this shatterproof mirror can be seen at a distance
3 to 5 times as great as those which a raft can be
sighted at sea. On a clear sunny day, the mirror
reflects the equivalent of 8 million candlepower.
Flashes from the mirror have been seen from a
distance of 40 miles (figure 10-2). A smaller mir-
ror, measuring 2- by 3-inches is also used in
some kits.
Figure 10-2 illustrates the operation of the
signaling mirror. Past experience indicates that
10-1
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
SUNLIGHT
(A) REFLECT SUNLIGHT FROM MIRROR
ONTO A NEARBY SURFACE.(RAFT,
HAND, ETC.)
(B) SLOWLY BRING MIRROR TO EYE
LEVEL a LOOK THROUGH SIGHT-
ING HOLE. A BRIGHT LIGHT SPOT
v WILL BE VISIBLE, THIS IS THE
AIM INDICATOR.
(C) HOLD MIRROR CLOSE TO EYE S
SLOWLY TURN S MANIPULATE IT
SO THAT THE BRIGHT LIGHT
SPOT IS ON THE TARGET.
239.340
Figure 10-2. Operation of the signaling mirror.
personnel may have difficulty using the mirror in
a bobbing raft at sea. Signaling practice with the
mirror should be encouraged as part of the train-
ing program for flight crews. Such practice
reduces the difficulty in case of emergencies.
Before using the mirror, read the instructions
printed on its back.
MK-79 MOD ILLUMINATION
SIGNAL KIT
The Mk-79 signal kit is supplied with one
pencil-type launcher (Mk-31-1), seven screw-in
cartridges, and a bandolier for storing the flares
until use. Protective caps should be used over
the primers of the cartridges when not using the
bandolier.
Each cartridge flare has a minimum duration
of 4 1/2 seconds and can be launched
up to 200 feet. When the launcher is stored in the
survival vest, it should be in the COCKED posi-
tion and empty (figure 10-3). Refer to NAVAIR
11-100-1 for proper handling and storage of the
signal kit.
MK-13 MOD
SIGNAL FLARE
The Mk 13 MOD signal is intended to at-
tract the attention of SAR aircraft and to give
them drift direction. To avoid being burned by
sparks, the ignited Mk-13 MOD signal must be
held at arms length and no more than shoulder
high. If the Mk-13 MOD signal is being used at
sea, hold it over the side of the lif eraft to prevent
damage to the lif eraft from hot residue. The
Mk-13 MOD signal may be put out by dousing
in water or snuffing in sand. Refer to NAVORD
2213 and NAVAIR 11-100-1 for precautions,
handling and storage procedures.
The Mk-13 MOD consists of a metal
cylinder closed at each end. There is a tear fric-
tion tape igniter on a clip at each end. One end
contains a red flare for nighttime use; the op-
posite end houses an orange smoke signal for
daytime use. Each end of the signal burns ap-
proximately 20 seconds. The night end of the
flare has protrusions that you can feel in
darkness. On the outside of the Mk-13 MOD
are operating instructions and a lot number. (See
figure 10-4). The lot number should be checked
each time the flare is inspected to ensure that the
-TRIGGER SCREW
"PLASTIC BANDOLIER
HAND FIRED
SIGNAL
239.400
Figure 10-3. MK-79 MOD Illumination Signal Kit.
10-2
CHAPTER 10 SURVIVAL ITEMS
y
V
/
UIHCMC MOMNTAftllV IN WATCH ANO SMOKE VN.L NOW*
\
4/Tf* U5f , 00Ur f**4L IH MITT* 4*0
f4K </*77i OTHf* CUD HAS ttH (IMD
\ *IMAL, $UOKf AMD ILLUWMATIOM
\ UA*INt, AM MJC 19 MOO
239.401
Figure 10-4. MK-13 MOD Marine Smoke and Illumina-
tion Signal.
flare is still serviceable. A list of lot numbers that
are not serviceable can be found in NAVAIR
13-1-6.5. Any flares manufactured before 1960
should also be removed from service.
DISTRESS LIGHT (SDU-5/E)
The SDU-5/E equips aircrew members and
shipboard personnel with a high-intensity visual
distress signal. The infrared filter and blue flash
guard, contained in the SRU-31/P survival kit,
are used in conjunction with the SDU-5/E for
signaling purposes in combat areas.
The SDU-5/E is commonly called a strobe
light. It emits a high-intensity flashing light. This
light is visible for great distances at night.
The SDU-5/E strobe light requires an inspec-
tion by the PR each time the aircrewman's flight
gear is inspected (every 91 days). It is recom-
mended that the aircrewman perform a daily in-
spection to ensure that the light is operative. The
calendar inspection consists of activating the
light for two minutes. If the light does not
operate at 50 flashes per minute (plus or minus
10 flashes) for the 2-minute duration, replace the
battery. Repeat the procedure; if the light still
does not operate, remove the light from service.
You must perform this test both in total
darkness and also in a lighted area. Some lights
operate in a lighted area but do not operate in
TOTAL darkness.
When storing the batteries for the SDU-5/E,
it is recommended that your supply of batteries
be stored in a cold area (refrigerator) to prolong
their service life and dependability.
To avoid causing possible night blindness to
the crewman by accidental activation, install the
SDU-5/E in the SV-2 survival vest with the
dome down and a protective cap installed over
the switch.
INDIVIDUAL AIRCREWMAN'S
SURVIVAL KIT (SRU-31/P)
The complete SRU-31/P kit consists of two
parts; the first packet contains medical items
that an aircrewman might need in an emergency
situation. The local medical department has
responsibility for the medical items that are con-
tained in packet number one.
Packet number two contains general survival
items. They are also intended to be used only in
an emergency situation.
Packet one and packet two are contained in a
carrying bag. Each packet can be replaced in-
dividually. Each item within a packet is packed
in a transparent bag, which is hermetically sealed
and retained in place by means of hook-and-pile
tape. Additional adhesive-backed discs of hook-
and-pile tape are contained in the spare pocket
of each container.
The following is a listing of all the items con-
tained in the SRU-31/P and a description of the
function and inspection, where applicable:
MEDICAL PACKET
Soap. Nonperfumed, intended to avoid
detection.
Instruction Card. Provides general con-
densed instructions on use of survival items.
Anti-Diarrhea Tablets. Dosage rates listed
on instruction card. Expiration four years.
Pain Killer (Aspirin). Expiration date listed
on foil packet. Replace as required. Dosage rate
listed on instruction card.
Bandaids.
Surgical Tape. Ensure the package is intact
and its sterile seal is not damaged.
10-3
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
Eye Ointment. Expiration five years.
Water Purification Tablets. Manufacturer's
date and applicable instructions listed on bottle.
Bandage (Elastic). Ensure package is intact
and sterile seal is not damaged.
Insect Repellent.
GENERAL PACKET
Metal Matches. These may cause spon-
taneous ignition through oxidation. The match
should remain in its original sealed container
(foil wrapped) until ready for use. All metal
matches in polyethylene and open packets shall
be removed from service and discarded in a
fireproof container.
Mirror. This is the signaling mirror described
at the beginning of this chapter.
Tinder. Mark the bag of tinder locally with
the following statement: TINDER. Apply this
marking to pressure-sensitive tape and tape it to
the transparent plastic bag.
Water Bag. One quart capacity. Belt loops
provided for convenient carrying.
Signal Panel. Silver/orange paulin, im-
printed with the ground-to-air emergency code.
It also may be used as a blanket for protection
against unfavorable weather.
Razor Knife.
Mosquito Headnet and Mittens. Provided
for protection against insect bites.
Chiclets. Multi-flavored, designed to relieve
tension.
Multi-flavored candy. Service shelf life is in-
definite.
Flash Guards. The flash guards are used in
conjunction with the SDU-5/E light as a signal
device during rescue operations. The flash
guards are blue or red in color.
The packet also contains surgical tape, a
water receptacle, mirror, wrist compass, razor
knife, tweezers, and pins.
INSPECTION
You should inspect all the items in the
SRU-31/P survival kit during periodic equip-
ment inspections and replace them as nec-
essary.
RATIONS
The rations carried by aircrew personnel
are not intended for subsistence but as a
source of quick energy when no other food is
available.
The food packet contains two packets of
candy and gum, twine, and an instruction sheet.
When you inspect any item that contains these
rations, you should remove and replace any
food packet that is older than 61/2 years (see
figure 10-5).
FOOD PACKET,
LIFE RAFT, AIRCRAFT
239.402
Figure 10-5. Rations.
10-4
CHAPTER 10 SURVIVAL ITEMS
CANNED DRINKING WATER
Canned drinking water (figure 10-6), is in-
tended for use in emergencies when no other
clean water is available. One can of water sup-
ports a survivor for about one day.
A can of drinking water contains 10 ounces
of pure drinking water and may be carried in this
ready-to-use state.
IWPEITY U.S. SWT
EMERGENCY
DRINKING
WATER
239.403
Figure 10-6. Canned drinking water.
INSPECTION
The canned drinking water shall be in-
spected upon issue and every 91 days there-
after, or at intervals to coincide with the
inspection schedule of the kit or assembly in
which the can is stored. Inspection shall
consist of the slap test and the shelf life and
service life check.
Slap Test
The slap test consists of slapping the can of
water against the palm of your hand and listen-
ing for a sharp metallic click. This noise
is caused by the absence of air to cushion the im-
pact of the water against the can. If this distinct
noise is not heard, then air has leaked into the
can and it should be replaced.
Shelf Life and
Service Life Check
The shelf life and the service life of canned
water are both indefinite as long as the cans pass
the slap test and there are no signs of exterior
deterioration.
10-5
CHAPTER 11
SURVIVAL RADIOS AND BEACONS
Today's rescue procedures are based upon
early detection and fast recovery of the surviving
aircrewman. Once an aircrewman has been
placed into a survival position, it is essential that
he be located as soon as possible. The one item
that can accomplish this is the survival radio.
Navy aircrewmen carry, as part of their
personal survival equipment, a two-way com-
munication radio. This radio is either the
AN/PRC-63 or the AN/PRC-90. You must
check each aircrewman' s radio when you per-
form the 91 day calendar inspection on his sur-
vival equipment.
This chapter describes the operation and
inspection of these radios. It also covers the
AN/URT-33A and the AN/PRT-5 radio
transmitters.
AN/PRC-63
The AN/PRC-63 Radio Set is a compact,
rugged, light-weight, battery-powered micro-
electronic transceiver. (See figure 11-1.) The
radio set has three basic modes of operation:
a. Beacon tone transmission (activated
either manually or by means of an automatic
deployment device).
b. Voice transmission.
c. Voice reception.
Simplicity of operation has been the keynote
in the Design of the AN/PRC-63 Radio Set. A
slide switch turns the radio set on (in beacon
modejf or off, and a three-position toggle switch
changes from beacon transmit to either voice
transmit or voice receive. A volume control,
located in the upper corner of the radio set
controls the level of sound output of the beacon
confidence tone (used to verify that the beacon
signal is getting out) and the receiver. No other
controls have been provided or are required. All
these controls can be operated with either
hand bare or gloved. If the user loses con-
sciousness and releases the radio set (once turned
on), it automatically returns to the beacon mode
of operation.
AUTOMATIC
DEPLOYMENT
DEVICE
FLEXIBLE
WHIP
-ANTENNA
WRIST
STRAP
Figure 11-1. AN/PRC-63 radio set.
239.437
11-1
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
GENERAL PRINCIPLES
OF OPERATION
The AN/PRC-63 Radio Set provides two-
way voice communication with a searching
aircraft up to 25 miles away equipped with com-
patible transmitting and receiving equipment,
flying at an altitude of 10,000 feet. A search
aircraft flying at 10,000 feet and equipped with
compatible direction-finding equipment can
locate an AN/PRC-63 Radio Set transmitting in
the beacon mode at a distance of approximately
70 miles (line of sight) between the search air-
craft and the radio set.
The AN/PRC-63 Radio Set can be worn as
part of the aircrewman's flight clothing or life-
jacket and secured to the garment by a strap at-
tached to the slots in the battery housing. The
automatic deployment device supplied with the
radio set, when suitably connected to the
parachute harness of the aircrewman by the
user, will allow automatic transmission of the
beacon tone upon parachute deployment. The
radio can also be packed in a seat pack and, with
the same deployment device suitably connected,
can be automatically placed in beacon tone
transmission mode upon ejection from the air-
craft. The lanyard attached to the deployment
device has been designed to withstand a pull
force of 20 pounds without breaking.
The downed aircrewman may remove the
radio set from his flight clothing, lifejacket or
survival kit and change its mode of operation to
either voice transmit 01 voice receive by pressing
the appropriate end of the rocking toggle ac-
tuator. In the event that he becomes injured,
disabled or otherwise incapable of selecting the
desired mode of operation, the radio set will
continue to transmit MCW beacon signals until
the battery power is exhausted.
FUNCTION AND USE OF
OPERATING CONTROLS
The function and use of the operating
controls are described in table 11-1.
Table 11-1. Operating controls and functions
Control
Function
POWER OFF
Radio set is in storage condition.
POWER ON
Radio set is in beacon mode of operation.
POWER ON
Deployment device installed
Radio set is in standby condition ready for
automatic activation.
POWER ON
RECEIVE VOICE
PRESS AND HOLD
Radio set is in receive mode. (Refer to
paragraph 2-9.)
POWER ON
TRANSMIT VOICE
PRESS AND HOLD
Radio set is in transmit mode.
11-2
Chapter 11 SURVIVAL RADIOS AND BEACONS
NOTE
When POWER ON/OFF actuator is in
OFF position or in ON position with the
deployment device installed, all other
operating controls are disabled.
The radio set can be held in either hand and
operated by the thumb or fingers respectively. In
the normal operating position, the speaker/mike
faces the operator.
NOTE
During operation, the radio set must be
held in the upright position (antenna ver-
tical), or loss of transmission or recep-
tion will result. For best results, hold the
radio set approximately 1 to 2 inches
from the mouth when speaking, or ear
when listening.
In the receive mode the sound is controlled
by the volume control knob located in the upper
corner of the radio set (opposite the flexible
whip antenna) marked VOLUME MAX < .
Full clockwise rotation gives maximum volume;
full counterclockwise rotation gives minimum
volume. The sound of the beacon monitoring
tone is also controlled by this knob.
NOTE
Neither the beacon nor voice-transmitter
output is affected by the position of the
volume control knob.
INSPECTIONS
There are three inspections/test intervals
prescribed for this type of radio. (They are also
prescribed for the AN/PRC-90.) The first
daily/preflight is performed at the squadron
level by the aircrewman. It is to be performed
daily or prior to each flight. It consists of a basic
operational check using an AN/PRM-32 radio
tester or with the aid of a known good radio.
Prior to testing the emergency radio, a call to
flight operations is in order informing them that
you are testing a radio.
Every 90 days the radio shall be inspected by
the PR at the organizational level. It is best to
make this inspection in conjunction with the
inspection performed on the aircrewmen's per-
sonal survival equipment.
The last of the three inspections is performed
at the intermediate level (AIMD).
This inspection is performed every 180 days
by personnel in the avionics rating.
The testing procedures for all three inspec-
tions are outlined in NAVAIR 16-30PRC 90-2
for the AN/PRC-90 radio and in NAVAIR
16-30PRC 63-1 for the AN/PRC-63.
BATTERY REPLACEMENT
The Mallory battery will require frequent in-
spections in order to ensure that it hasn't lost
any of its operating life. When operating in a
high temperature area the inspection should be
conducted at least every 30 days. The service and
shelf life of the battery expires 36 months from
the date of manufacture. At any time the battery
fails to produce the power for the radio to
operate at maximum operating range, you must
replace it. Any battery that shows evidence of
swelling, chipped, or cracked surface, or
moisture shall be condemned and a new battery
installed.
AN/PRC-90
The AN/PRC-90 (figure 11-2) radio set is a
dual channel, battery-powered personal
emergency rescue device used principally for
two-way voice or MCW (modulated continuous
wave which is used to send Morse code signals)
communications between a downed aircrewman
and a rescue aircraft. The radio transmits either
voice, tone (MCW), or swept- frequency homing
beacon signals to guide rescue aircraft to the
downed aircrewman. Although the PRC-90 is a
line-of-sight communications device, it has a
voice range under ideal conditions of 60 nautical
miles to aircraft operating at 10,000 feet. The
automatic direction finder has a range of 50
nautical miles and the tone (code signal) range of
80 nautical miles to aircraft operating at an
altitude of 10,000 feet.
11-3
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
18
BATTERY
1. Earphone case
2. Battery cap
3. TALK microphone
4. VOL control
5. LISTEN speaker
6. EARPHONE jack
7. MCW button
8. PUSH TO TALK button
9. Function switch position indicator
and arrow button
10. Function switch knob
11. Antenna retaining loop
11 A. Half -wave antenna retaining band
12. Earphone connector
13. Earphone
14. Antenna
15. Instruction plate
16. Rear cover
17. Rear cover holding screws
18. Battery
Figure 11-2. AN/PRC-90 controls and indicators.
239.438
11-4
Chapter 11 SURVIVAL RADIOS AND BEACONS
BATTERIES
The batteries are tested by using a Test Set
(TS 2530/UR). Batteries are considered to have
a maximum shelf life of 36 months from the date
of manufacture. This shelf life is based upon a
storage temperature of 70 F. If the temperature
increases, their storage life is shortened. For
example, if the temperature reaches 130F the
storage life can be reduced to as short as one
month. When you are in an activity that uses this
battery, it is recommended that you refer to
NAVAIR 16-30PRC 90 for the most current
shelf life information.
OPERATING PROCEDURE
Refer to table 11-2 for the functions of each
control on the PRC-90. The set is operated as
follows:
1 . Free the antenna from its stowed position
by pulling its end from the retaining ring or band
as appropriate. The antenna snaps into an
Table 11-2. Operating controls and indicators
Control or
Indicator
Control Position
Function
Function switch
PUSH TO TALK
button
OFF
VOICE/MCW
243.0
BCN 243.0
VOICE 282.8
NOTE
The button, (9, figure
2-1) must be de-
depressed to place
function switch in the
VOICE 282.8 posi-
tion.
Depressed
Released
Completely removes power from radio set.
Turns on the guard channel receiver to
the emergency frequency of 243.0 MHz. Also
enables voice and MCW guard channel
transmission which are keyed by the PUSH
TO TALK or MCW buttons.
Turns on 243.0 MHz guard channel transmit-
ter, and transmits a beacon tone. Swept audio
tone is continuously transmitted for rescue air-
craft to home on.
Turns on alternate channel to receive on 282.8
MHz. Also enables voice transmission on
auxiliary channel when PUSH TO TALK
button is depressed.
Turns receiver off and turns transmitter on
when function switch is in either
VOICE/MCW 243.0 or VOICE 282.8 position.
Best voice transmissions are obtained when
spoken directly into the talk microphone.
Turns off transmitter and turns on receiver;
received signal is heard with ear close to
LISTEN speaker or earphone.
11-5
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2. VOLUME 1
Table 11-2. Controls and indicators Continued
Control or
Indicator
Control Position
Function
MCW button
Depressed
Released
VOL control
Fully up, MAX
Fully down
LISTEN speaker
TALK microphone
Earphone jack
Earphone
connected
NOTE
Connector may be
joined to jack in
either of two
polarities.
Earphone
disconnected
Battery cap
This button is a telegraph key; it enables the
operator to transmit code when the normal trans-
mitting level of his voice may reveal his position.
MCW is only obtainable when the function
switch is in the VOICE/MCW 243.0 position.
Causes radio set to transmit a continuous tone,
receiver off.
Turns transmitter off, receiver on.
This controls the volume of the sound from
the LISTEN speaker or earphone. It controls
received signals, not sidetone.
Loudest sound
Quietest sound, but radio set is not turned off.
NOTE
Volume control does not affect transmitted
power output.
Sound of received signal is heard by placing ear
close to LISTEN speaker. Sound of MCW or
beacon transmitter may also be heard. The
LISTEN speaker is shut off when the earphone is
connected.
Picks up the voice being transmitted when PUSH
TO TALK button is depressed and function
switch is set to either VOICE/MCW 243.0 or
VOICE 282.8.
Causes sound to be heard in earphone. A magnet
in the earphone connector (12, figure 2-1) shuts
off the LISTEN speaker.
Sound is heard through LISTEN speaker.
Holds battery in place.
11-6
Chapter 11 SURVIVAL RADIOS AND BEACONS
upright position. Fully extend all five telescopic
sections of the half-wave antenna by grasping it
by its tip and pulling outward.
2. Set the function switch to the mode of
operation that you want. The function switch is
set by rotating the thumb knob on the right-
hand side so that the arrow points to the mode
selected. The function switch is detented and
clicks into each position. Rotate the knob down
one click (from OFF) for VOICE/MCW 243.0
operation, or two clicks for BCN 243.0 opera-
tion. For VOICE 282.8 operation (secondary
channel) push the button with the arrow and
rotate the function switch knob up one click.
3. For voice operation, hold the radio set
and adjust the VOL control. To transmit, push
down the PRESS TO TALK button and speak
directly into the TALK microphone.
4. If guard channel steady-tone transmission
or Morse code operation is desired, set the func-
tion switch to VOICE/MCW 243.0. Depress the
MCW button to transmit the tone. Listen for the
sidetone in the LISTEN speaker or earphone
while the MCW button is depressed. This side-
tone indicates proper transmitter operation.
5. For guard channel beacon operation, set
the function switch to BCN 243.0. The transmit-
ter continuously sends the swept-tone beacon
signal at this setting. Listen for the sidetone as
an indication of proper operation. In the beacon
mode, the sidetone is a chirping sound.
NOTE
Since the transmitter is keyed
automatically in the beacon mode, and
since continuous transmission may be
needed for a prolonged period of time,
the AN/PRC-90 may be placed upright
on a flat surface. It will then transmit
automatically.
AN/URT-33A
The Beacon Set Radio, AN/URT-33A
(figures 11-3 and 11-4), is an emergency radio
ANTENNA
CAP
LESCOPING
ANTENNA
AUTOMATIC ACTIVATION
CORD a PLUG
MANUAL SWITCH
BUTTON
RETRIEVAL
LANYARD
239.439
Figure 11-3. Beacon set, radio, AN/URT-33A (front view).
11-7
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
and a telescopic antenna that is built into the
radio is used.
The AN/URT-33A is battery-operated. The
battery is a mercury type with a storage life of 24
months provided that the storage temperature is
70 F. At a storage temperature of 100 F, the
storage life is only 12 months. For survival
equipment applications, such as Rigid Seat Sur-
vival Kits and liferafts, the service life of the
battery assembly is two years from the date of
manufacture or 225 days from the date placed
into service. The normal calendar inspection for
this equipment is 210 days and you charge the
battery at that time.
D-RING
LOCK
REMOVABLE
BATTERY
BACK PLATE
239.440
Figure 11-4. Beacon set, radio, AN/URT-33A (rear
view).
beacon transmitter which, when properly ac-
tuated, transmits a tone-modulated radio fre-
quency signal on the emergency guard frequency
of 243.0 MHz.
Although the AN/URT-33A was designed to
be placed into a parachute pack, the Navy nor-
mally places the beacon radio into the seat pan
(RSSK) or life rafts. Instructions for properly
rigging the AN/URT-33A can be found in
NAVAIR 13-1-6.1.
The AN/URT-33 radio has two types of
antennae. One type is the flexible wire antenna.
This antenna is used during parachute descent
since the radio is activated when the aircrewman
leaves the aircraft.
The flexible wire antenna serves as the prin-
cipal antenna during descent. Upon landing, the
flexible antenna is removed by the aircrewman,
AN/PRT-5
Transmitting Set, Radio AN/PRT-5 (figure
11-5) is a battery-operated, emergency beacon
transmitter which, when properly activated,
transmits a tone modulated radio frequency
signal on the emergency guard frequencies of
8.364 MHz and 243.0 MHz simultaneously. The
transmitting set includes an inflatable float
assembly which keeps the transmitting set afloat
at sea, and provides a support platform on land.
The entire set is packed in a carrying case for
stowing in a life raft.
The transmitting set is intended for signaling
the location of downed aircraft or airmen.
Because it provides signals in both the High Fre-
quency (HF) and Ultra High Frequency (UHF)
portions of the spectrum, it can be detected by
search aircraft, surface vessels, and coastal-
based stations at considerable distances.
The battery pack is designed to provide
72-hour continuous operation at 25 C (77 F)
with at least 250 milliwatts output from each
transmitter at the end of this period. The
transmitting set will continue to transmit until
the battery pack is completely discharged.
Modulation of the transmitter is by internal
means only. No provision has been made for
voice or code communications, or for receiving
signals from search craft.
11-8
Chapter 11 SURVIVAL RADIOS AND BEACONS
MOUTH VALVE
FLOAT ASSEMBLY
UHF ANTENNA
EM
L-HF ANTENNA
POWER SWITCH
SAFETY PIN
C0 2 CARTRIDGE
TRANSMITTING BATTERY
SET
CARRYING CASE
239.441
Figure 11-5. Transmitting set, radio AN/PRT-5, identification of components.
11-9
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
OPERATION
To prepare the radio for use is a simple
procedure.
1. Pull the free end of the UHF antenna
through the grommet in the float assembly to
allow the antenna to stand vertically.
2. Unscrew the top section cap of the
telescopic HF antenna, and pull the antenna out
to its full length. When fully raised the antenna
sections are alternate black and gray with the
top section gray. The antenna, when fully
extended, is approximately 9 feet high. (See
figure 11-6.)
3. Pull out the switch safety pin (figure
11-5).
4. Turn the POWER toggle switch to ON
(figure 11-5).
5. Place the entire assembly in the water and
tow it behind the life raft.
6. When operating on land, be sure the
transmitting set is placed on level ground so that
the antennas are vertical. Do not stand close to
the transmitting set because this can cause
changes in the radiation pattern of the trans-
mitted signals.
7. If desired, the safety pin can be replaced
to prevent the transmitting set from being turned
off accidentally.
9
239.442
Figure 11-6. Transmitting set, radio AN/PRT-5 with
flotation collar.
11-10
CHAPTER 12
HELICOPTER RESCUE DEVICES
Every Aircrew Survival Equipmentman
should be familiar with the equipment used in
rescue from the sea or land by helicopters.
(Refer to Navy Search and Rescue Manual,
NWP 37-1 for procedures and techniques in-
volving at-sea aircrew rescues.) The helicopter's
ability to land and take-off in a small area and to
hover over a spot lends itself very effectively to
rescue work.
There are three methods by which a
helicopter may make a rescue. The first is by
hovering, the second by landing, and the third
by making a low ilow pass with the rescue device
hanging near ground level. The latter is used
mainly in hostile areas when the helicopter pilot
does not wish to present the aircraft or the sur-
vivor as a stationary target for enemy gunners.
By far, the most common helicopter pickup is
made by hovering.
NOTE: When the rescue device is lowered to
the survivor, he should avoid touching it until it
has contacted the s face. The static charge of
electricity built up in tiie helicopter must be
dissipated by grounding. Otherwise, a stunning
electrical shock may result.
Research, development, test, and evaluation
of air rescue devices have been continuous since
the helicopter became the primary rescue vehi-
cle. The various types of rescue devices, their
functions, and associated maintenance pro-
cedures are discussed in the sections that follow.
All helicopter rescue devices shall be sched-
uled into periodic maintenance under the direc-
tion and control of the maintenance/material
control officer to which the equipment is
assigned. Maintenance shall be thorough at all
times. No instance of careless treatment or
willful neglect of aircrew personal protective
equipment shall be condoned. The vital function
of the equipment shall be uppermost in the
minds of all personnel concerned.
Individual paralofts normally store and
maintain all helicopter rescue devices and
checkout is on an individual basis. Due to the
lack of individual identification of the rescue
devices, it is impossible to match the Aviation
Crew Systems History Card to the rescue device.
It is recommended that all rescue devices be
locally serialized by individual paralofts to en-
sure positive control of inspection cycles per-
formed on helicopter rescue devices.
SURVIVOR'S SLING
CONFIGURATION
The survivor's sling is a buoyant device con-
sisting of a kapok filling encased in a bright
yellow waterproof cover to make it highly visible
during rescue operations. Webbing, reeved
through the cover with both ends terminating in
two V-rings, is used to attach the sling to the
helicopter rescue hook. Two retainer straps, one
long with a quick ejector snap and one short
with a V-ring, are fastened t : the webbing of the
sling and are enclosed in slide fastener-secured
envelopes. Refer to figures 12-1 and 12-2.
APPLICATION
The survivor's sling (also known as the
''horse-collar" and rescue sling) is used to assist
personnel performing rescue work from a
helicopter over water or land. The survivor's
sling is lowered on a hoist cable from a
helicopter to the rescue swimmer and survivor.
The sling is designed to accommodate one sur-
vivor at a time.
12-1
ATRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
Figure 12-1. Survivor's sling.
239.404A 239.404B
Figure 12-2. Survivor's sling retainer straps pulled out.
MAINTENANCE
The aircrewman's responsibility for
maintenance of the survivor's sling is limited to a
fresh water wash. Repairs or other actions shall
be performed by organizational level or above.
All survivor's slings shall be subjected to a
calendar inspection upon issue and at intervals
not to exceed 225 days. All survivor's slings shall
be subjected to a preflight inspection. This ac-
tion is performed by the aircrewman before each
flight and at least every 14 days. This inspection
consists of a visual inspection outlined in the
calendar inspection procedures.
CALENDAR INSPECTIONS
Survival slings shall be subjected to a calen-
dar inspection upon issue and at intervals not to
exceed 225 days. The calendar inspection con-
sists of a visual inspection and a proof load test.
To perform the visual inspection, proceed as
follows:
1. Inspect all fabric for cuts, deterioration
and abrasion.
2. Inspect seams for proper adhesion and
stitching.
3. Inspect the retainer straps for security of
attachment and wear.
4. Inspect all hardware for security of at-
tachment, corrosion, damage, wear and, if ap-
plicable, ease of operation.
5. Inspect all markings. If the markings are
faded or incorrect, they must be corrected by
using black wash-proof ink.
The proof load test is performed on the
survivor's slings, during the calendar inspec-
tion and after each flight during which
12-2
Chapter 12 HELICOPTER RESCUE DEVICES
salt water immersion has occurred. To perform a
proof load test, proceed as follows:
1 . Allow the sling to dry completely.
2. Inspect for damage to webbing of sur-
vivor's sling. Damage other than frayed or
separated stitches is cause for replacement.
3. Place the survivor's sling in a webbing
testing machine.
NOTE: If a webbing testing machine is not
available, refer to NAVAIR 13-1-6.5 for a
suitable alternate testing method.
4. Apply a load of 500 pounds at a rate of
one inch per minute.
5. Inspect for any damage to the webbing of
the survivor's sling. Damage other than frayed
or separated stitches shall be cause for replace-
ment.
6. Remove the sling from the webbing
testing machine.
The survivor's sling shall be cleaned after
every immersion in salt water. To clean the sur-
vivor's sling, you will proceed as follows:
1. Clean the sling and its cover with mild
soap and water solution. Rinse well with fresh
water.
2. Dry the sling and its cover with a clean,
dry, lint-free cloth.
RESCUE SEAT
CONFIGURATION
The rescue seat is a buoyant aluminum
device consisting of a hollow flotation chamber
and a three-pronged seat with prongs 120
degrees apart. See figure 12-3. Lead is inserted in
the base of the assembly to minimize roll and to
provide the proper degree of submergence of the
seat in the water. A safety strap is provided to
assist the survivor to remain in the seat during
hoisting to the helicopter. The flotation chamber
and hoist bracket of the seat are bright orange.
The lower seat assembly is yellow for high
visibility.
STRAP FOLDED
a "STOPPED"
WITH BREAKABLE
(SIZE FF) THREAD
TO MINIMIZE EN-
TANGLEMENT
POSSIBILITY OF
DANGLING STRAP
239.405
Figure 12-3. Helicopter rescue seat.
APPLICATION
The helicopter rescue seat is intended for use
in retrieving survivors and assisting the rescue
swimmer in performing rescue operations when
it is difficult to make a helicopter landing over
land or water.
When conducting a rescue the helicopter
rescue seat is lowered on a hoist cable from a
12-3
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2, VOLUME 1
helicopter, to the rescue swimmer and survivor.
The rescue seat is designed to accommodate one
person at a time.
MAINTENANCE
The aircrewman's responsibility for
maintenance of the rescue seat is limited to fresh
water wash after usage. Repairs or other
maintenance actions required shall be performed
by organizational level or above.
INSPECTION
All rescue seats shall be given a calendar in-
spection upon issue and at intervals of 225 days.
The calendar inspection is a visual inspection.
To visually inspect the condition of the rescue
seat, proceed as follows:
1. Inspect all components for security of at-
tachment, corrosion, damage, wear, discolora-
tion and ease of operation.
2. Check for sharp edges or projections.
3. Check material for imperfections or
damage.
4. Check safety strap for fraying or tears.
5. Compare markings on seat to markings
listed in applicable table in NAVAIR 13-1-6.5.
If the markings are faded, restore them with
black wash-proof ink. If marking is incorrect,
paint it out and enter the correct marking as
close to the proper location as possible using
black wash-proof ink.
CLEANING
The rescue seat shall be cleaned after every
immersion in salt water. Clean it as follows:
1. Wash the rescue seat with mild soap and
water solution. Rinse well with fresh water.
2. Dry the rescue seat with a clean, dry, lint-
free cloth.
3. Return the seat to service.
FOREST PENETRATOR AND
FLOTATION COLLAR
CONFIGURATION
The forest penetrator is bright yellow for
high visibility, and is a compact device weighing
about 21 1/2 pounds. The forest penetrator is 34
inches long and 81/8 inches in diameter with the
three seats retracted, and 26 inches in diameter
with the seats extended. Each seat is 4 3/4
inches wide, 11 1/2 inches long and is spring-
loaded in the retracted position (flush against
the shaft of the penetrator). A spring-loaded re-
taining latch is provided under each seat to
secure the seat in the extended position. To
release the seat, push down on the seat and pull
down on the latch. The seat then snaps back into
the retracted position. Three webbing safety
straps are provided to hold the survivors in
place. Each strap extends 4 feet 91/4 inches,
with an adjustable quick ejector hook attached
to the upper section of the penetrator. The
straps terminate with a yellow fabric, marked
TIGHTEN. Yellow webbing tabs (with hook
tape) marked PULL OUT are sewn to the safety
straps for attachment to fabric cover stowage
openings. The yellow fabric cover has a 17-inch
slide fastener and three stowage openings (with
pile tape for securing safety straps). (See figure
12-4.)
The flotation collar is made of bright orange
foam rubber for high visibility and weighs about
1 1/2 pounds. (See figure 12-5.) It is 2 1/4 inches
long, with a 7 3/4-inch diameter at the top and a
4-inch diameter at the bottom. When the flota-
tion collar is installed on the forest penetrator,
the retracted diameter at the penetrator is 9
inches.
APPLICATION
The forest penetrator and flotation collar are
intended to assist the rescue swimmer to perform
rescue operations in the water or to rescue sur-
vivors on land.
The flotation collar is a device which, when
fastened around the forest penetrator, allows
flotation of the complete assembly during air-sea
rescue operations.
During land rescue operations the forest
penetrator is lowered to the survivor with the
12-4
Chapter 12 HELICOPTER RESCUE DEVICES
1ST
PULL
DOW
239.406A
Figure 12-4. Forest penetrator.
seats retracted. For sea operations the forest
penetrator is lowered to the rescue swimmer and
survivor with the flotation collar installed, safety
straps hanging free, and the seats retracted. In
this configuration, the penetrator will float its
top about 6 inches above the surface of the
water.
The forest penetrator is designed to ac-
commodate one, two, or three survivors at one
time.
MAINTENANCE
The aircrewman's responsibility for
maintenance of the forest penetrator is limited
to washing with fresh water. Repairs or other ac-
tions shall be performed by organizational level
or above.
239.406B
Figure 12-5. Flotation collar installed on forest
penetrator.
INSPECTION
AH forest penetrators receive a calendar in-
spection upon issue and at intervals not to ex-
ceed 225 days.
The calendar inspection consists of visually
inspecting both the forest penetrator and flota-
tion collar.
When inspecting the condition of the forest
penetrator and flotation collar, examine the
following:
1. All fabrics for cuts, tears, deterioration
and abrasion.
2. Seams for proper stitching.
12-5
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
3. Straps for security of attachment and wear.
4. Any other parts for wear, damage, and
security of attachment.
5. All hardware for security of attachment,
corrosion, damage, wear, and, if applicable, ease
of operation.
6. The cover for strains, dirt, and general
condition.
7. The slide fastener for damage, corrosion,
and ease of operation.
8. Compare markings on the forest penetrator
and flotation collar to markings listed on the ap-
plicable tables in NAVAIR 13-1-6.5. Restore any
faded markings and correct markings, if
necessary, with indelible ink.
CLEANING
The forest penetrator and flotation collar shall
be cleaned after every immersion in salt water as
follows:
1 . Wash the penetrator and collar with a mild
soap and water solution. Rinse well with fresh
water.
2. Wipe the penetrator and collar with clean
lint-free cloth and allow to dry.
3. If necessary, apply silicone lubricant to
slide fasteners on the cover of the penetrator to
ensure ease of operation.
4. Apply a lubricating oil to all pivot points
of the penetrator. Wipe off excessive lubricating
oil.
5. Return both assemblies to service.
RESCUE NET
CONFIGURATION
The rescue net looks like a conically-shaped
birdcage with an opening on one side. The net
weighs approximately 20 pounds and is bright
yellow for high visibility. To stabilize the net dur-
ing use, a sea anchor is provided. A 10-foot
sea anchor retaining line with two single
snaphooks is also provided. One halyard
snaphook permits complete removal of the sea an-
chor from the net, while the other snaphook per-
mits shortening of the sea anchor to five feet to
be used in moderate seas. During high seas, the
10-foot retainer line is used. The rescue net has
a snaplock lower frame and three upper support
ribs with sliding sleeves that form a rigid cage
when the net is fully extended. Foam plastic floats
are provided on the rigid upper frame of the net.
(See figure 12-6.).
APPLICATION
The rescue net is used to assist the rescue swim-
mer performing rescue work from a helicopter
over water or land. The rescue net may also be
used to ferry or pick up cargo.
WARNING
The sea anchor shall not be used when
hoisting personnel out of the water.
MAINTENANCE
The aircrewman's responsibility for
maintenance of the rescue net is limited to a fresh
water wash after use. Repairs or other actions re-
quired shall be performed by organizational level
or above.
INSPECTION
All rescue nets shall be given a calendar in-
spection upon issue and at intervals of 225 days.
The calendar inspection for the rescue net con-
sists of the following visual inspection:
1 . Erect the net by unfolding its lower frame
assembly and forcing the assembly down. The
frame will snap open.
2. Suspend the open section of the net and
slide sleeves or the upper support ribs between the
swivel joints. The sleeves rest on the support rib
stops.
3. Inspect all hardware for security of at-
tachment, corrosion, damage, wear, and ease of
operation.
12-6
Chapter 12 HELICOPTER RESCUE DEVICES
PLASTIC FLOAT
(TYP)
UPPER FRAME
SUPPORT RIB
(TYP)
FIELD NUMBER
I- INCH STENCIL
LOWER FRAME
(SNAPLOCK)
HALYARD SNAPHOOK
(TYP)
NOTE
SEA ANCHOR
CARGO DOOR AND SEA ANCHOR ARE ALSO SUPPLIED AS OPTIONAL
PIECES OF EQUIPMENT WITH THE RESCUE NET
Figure 12-6. Rescue net, parts nomenclature.
239.407
CLEANING
To clean the rescue net, proceed as follows:
1. Wash the rescue net with mild soap and
water solution. Rinse well with fresh water.
2. Allow the net to air dry.
RESCUE HARNESS
CONFIGURATION
The rescue harness consists of nylon webbing
shoulder straps, riser straps, back strap, an ad-
justable chest strap and a lifting strap. (See
figure 12-7.) The end of the lifting strap,
12-7
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
RIGHT SHOULDER STRAP
SHOULDER
POCKET
(SDU5E LIGHT)
LEFT SHOULDER STRAP
RIGHT
RISER
POCKET
(MK 13 FLARE AND
SHROUDLINE
CUTTER)
LEFT RISER STRAP
SCABBARD (KNIFE)
TRIANGLE LINK
S GATED D RING
239.408
Figure 12-7. Rescue Harness.
equipped with a gated D-ring, adapter assembly,
release assembly and parachute harness triangle
link are stowed in a pouch on the front of the
harness. A handle on the pouch allows for ease
of accessibility of the gated D-ring during rescue
operations. Right and left pocket assemblies are
located at each junction of the riser and
lifting strap. The left pocket is designed to hold
one Mk-13 Mod Marine Smoke and Illumina-
tion Signal and the right pocket is designed to
hold the other Mk-13 Mod Marine Smoke and
Illumination Signal and the suspension line cut-
ter. A knife scabbard is attached to the left side
of the lifting strap.
12-8
Chapter 12 HELICOPTER RESCUE DEVICES
APPLICATION
The rescue harness is designed specifically to
be worn by the rescue swimmer, providing him
maximum mobility and a means for performing
rescue operations in the water.
MAINTENANCE
The aircrewman's responsibility for
maintenance of the harness is limited to fresh
water wash after usage. Repairs or other
maintenance actions required shall be performed
by intermediate mantenance level or above
unless otherwise specified.
PREFLIGHT INSPECTION
The rescue harness preflight inspection is ac-
complished prior to each flight, and at intervals
not to exceed 14 days. This inspection is made by
the aircrewman. To perform a preflight inspec-
tion, examine the following:
1. Fabric and webbing for cuts, tears, open
seams, loose or broken stitching.
2. Signs of contamination, such as stains
and discoloration.
CALENDAR INSPECTION
The calendar inspection is performed by
organizational level or above upon issue prior to
placing the rescue harness in service and every 91
days thereafter. To perform the calendar inspec-
tion, proceed as follows:
1. Service life check. The service life of the
rescue harness is 7 years from the date it was
placed in service or 8 years from the date of
fabrication, whichever occurs first. When an
assembly reaches its service life limit, it shall be
removed from service and scrapped. To perform
a service life check, proceed as follows:
(a) (Start of service). When a rescue
harness is placed in service, the date
shall be stenciled on the inside of the
chest strap.
(b) When an in-service rescue harness
lacks a start of service date, service
life shall expire 7 years from date
of manufacture.
(c) The date of manufacture is located on
the inside of the chest strap.
2. Contamination inspection. To inspect a
rescue harness for acid or alkaline contamina-
tion, proceed as follows:
CAUTION
Ensure area to be tested is
isolated from any source of con-
tamination which may result in
erroneous readings.
(a) Dampen the suspected area with
distilled water.
(b) Place a piece of full-range test paper
on the dampened area. Compare it to
the color standard provided with the
paper. The color it changes to
indicates the approximate pH reading
and which specific short-range test
paper to use.
(c) Place the short-range test paper on the
dampened area. Its color indicates
what the pH factor is at the affected
area.
(d) If acid contamination is found, the
assembly shall be considered
nonrepair able and scrapped.
(e) If alkaline contamination is found,
rinse the assembly in cool, fresh water
until a safe -eading is obtained. All
fabric and webbing shall then be
carefully inspected for any sign of
deterioration.
3. Visual inspection. To inspect the rescue
harness, examine the following:
(a) Harness webbing for cuts, tears,
fraying, deterioration and security of
stitching.
(b) Front pouch and right and left
pockets for cuts, tears, fraying
deterioration and security of stitch-
ing.
12-9
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2, VOLUME 1
(c) Gated D-ring and all other hardware
for corrosion, distortion, sharp edges,
security of attachment and ease of
operation.
(d) Hook and pile tape fasteners
condition and proper mating.
for
CLEANING
Clean the rescue harness as often as
necessary to remove perspiration stains, dirt and
other stains which may degrade performance of
the assembly. To clean a rescue harness, proceed
as follows:
1. Wrap all metal fittings in heavy flannel
cloth.
CAUTION
Do not scrub rescue harness
2. Soak the assembly in cool, fresh water
for two to three hours to loosen any set
stains.
3. Drain this water and immerse the harness
in a tub of fresh water (not over 120 degrees
Fahrenheit). Gently agitate by hand.
4. After 5 to 10 minutes of agitating, repeat
step 3.
5. Petroleum and other stubborn stains may
be removed by repeated applications of a mild
soap and water solution. Each application shall
be followed by a rinse in cool, fresh water.
6. Hang the rescue harness on a wooden
hanger until dry.
RESCUE HOOK
CONFIGURATION
The rescue hook consists of one large hook,
an adjacent small hook and ring located at the
bottom of both hooks. A bearing assembly is
attached to the upper section allowing the hook
to rotate freely about its axis. The large hook
supports 3,000 pounds and is used to hoist per-
sonnel. The smaller hook supports 1,000 pounds
and is used to hoist equipment. The ring at the
bottom supports 1,500 pounds and is also used
to hoist miscellaneous equipment. Both hooks
have a spring-loaded latch to prevent inadver-
tent release of personnel or equipment. (See
figure 12-8.)
APPLICATION
The rescue hook is attached to the hoist cable
and is used to assist rescue personnel in perform-
ing rescue operations from a helicopter. The
rescue hook can hoist personnel and/or equip-
ment during both sea and land helicopter
rescues.
MAINTENANCE
The aircrewman's responsibility is to inform
maintenance control if equipment has been im-
mersed in salt water. Repairs or other actions re-
quired shall be performed by organizational
level or above.
239.409
Figure 12-8. Rescue Hook.
12-10
Chapter 12 HELICOPTER RESCUE DEVICES
CALENDAR INSPECTION
All rescue hooks get a calendar inspection
upon issue and at intervals to coincide with the
aircraft cycle. In no case shall the intervals
between calendar inspections exceed 225 days.
The calendar inspection consists of the following
visual inspection:
1. Inspect for missing, bent, fractured or
damaged components.
2. Check hardware for security of attach-
ment, corrosion, wear, and ease of operation.
3. Check for sharp edges and projections.
CLEANING
Clean the rescue hook after every immersion
in salt water. To clean the rescue hook, proceed
as follows:
1. Clean devices with an acceptable cleaning
agent.
2. Remove all foreign objects with low-
pressure air.
3. Lubricate all moveable parts of the rescue
hook. Wipe off excess lubricant with a clean,
dry, lint-free cloth.
4. Return the rescue hook assembly to serv-
ice.
HOIST QUICK-SPLICE PLATE
CONFIGURATION
The hoist quick -splice plate is made of 1/4
inch aluminum, 6 5/8 inches in length by 3
inches wide. The corners are rounded off and
holes are grooved in places where the hoist cable
rests. A stainless steel clip 1/32 inch thick is
attached to the plate with two, 5/32-inch steel
rivets. A rescue hook is attached to the
plate with thimbles, swaging sleeve and a length
of hoist cable. The distance between the rescue
hook and the plate is 5 inches. (See figure
12-9.)
APPLICATION
The hoist quick-splice plate is used when
the hoist cable is cut or broken during
a rescue operation. It is used when time is a
factor and no other means are available
for rescue.
MAINTENANCE
The aircrewman's responsibility for
maintenance of the hoist quick-splice plate is
limited to giving it a fresh water wash. Repairs
or other actions shall be performed by organiza-
tional level or above.
CALENDAR INSPECTION
All hoist quick-splice plates shall be given a
calendar inspection upon issue and at intervals
of 225 days. The calendar inspection shall con-
sist of a visual inspection for bends, corrosion,
sharp edges and projections.
HOLES NUMBERED AND
PAINTED OR SCRIBED
ARROWS INDICATE
CABLE DIRECTION
BACK (REF)
5 MAX
NOTE: BEVELED (SHADED)
AREAS PREVENT CABLE
KINK UNDER LOAD
239.410
Figure 12-9. Hoist quick-splice plate.
12-11
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2. VOLUME 1
SHACKLE
LOWER
JAW
FIELD NUMBER
METAL STAMP
SPRING
MOUNTING
PLATE
SPRING
ARM
VIEW SHOWING JAWS OPEN
FOR LOCATING GUARDS
VIEW SHOWING JAWS CLOSED
239.411
Figure 12-10. Cable grip.
CLEANING
You have to clean the hoist quick-splice plate
after every immersion in salt water. To clean it,
proceed as follows:
1. Clean with an acceptable cleaning agent.
2. Dry with a lint-free cloth.
CABLE GRIP
CONFIGURATION
The cable grip (which opens and closes on
the cable) and a shackle, which enables the cable
grip to be attached to the crewman's safety belt
to take the weight off the hoist assembly during
a hoist failure. The cable grip is capable of sup-
porting 1,000 pounds. (See figure 12-10.)
APPLICATION
The cable grip is an emergency condition
device used by personnel performing rescue
operations from a helicopter when the rescue
hoist has a malfunction which renders the hoist
inoperable. The cable grip is used for quick tem-
porary attachment to the hoist cable.
MAINTENANCE
The aircrewman's responsibility for
maintenance of the cable grip is limited to a
fresh water wash and to informing maintenance
control that it has been used. Repairs or other
actions required shall be performed by organiza-
tional level or above.
CALENDAR INSPECTION
All cable grips shall be subjected to a calen-
dar inspection upon issue and at intervals of 225
12-12
Chapter 12 HELICOPTER RESCUE DEVICES
days. To inspect the condition of the cable grip,
proceed as follows:
1. Inspect for missing, bent, fractured or
damaged components.
2. Check hardware for security of attach-
ment, corrosion, wear and ease of operation.
3. Check for sharp edges and projections.
CLEANING
Clean the cable grip every time it has been
immersed in salt water. To clean it, proceed as
follows:
1 . Clean devices with an acceptable cleaning
agent.
2. Remove all foreign objects with low-
pressure air.
3. Lubricate all movable parts of the cable
grip with Lubriplate. Wipe off excess Lubriplate
with clean, dry, lint- free cloth.
HAMMER HEAD'
VENT
BUTTON
TRIGGER
SAFETY CLIP
END CAP
PNEUMATIC RESCUE HAND TOOL
CONFIGURATION
The pneumatic rescue hand tool is a
cartridge-operated device. A chamber within the
handle secures a 3,000 psi nitrogen gas cylinder
which provides a very powerful force against the
cutting blade.
The case is made of nylon webbing 12 1/2
inches long and 5 3/4 inches wide at the top,
tapering to 3 1/4 inches wide at the bottom. A
46-inch lanyard and baby swivel hook, attached
to the upper grommet, are designed for attach-
ment to the pneumatic rescue hand tool. (See
figure 12-11.)
APPLICATION
The pneumatic rescue hand tool is designed
for helicopter rescue crewman to use during
air/sea rescue operations.
239.412
Figure 12-11. Pneumatic rescue hand tool.
The pneumatic rescue hand tool gives the
crewman a readily available cable cutter and
parachute harness webbing cutter. The tool can
cut single strands of stainless steel cable up to
7/32 inch in diameter as well as harness webbing
of thickness up to and including 1/4 inch and
widths up to 1 3/4 inch, in single cuts. The
pneumatic rescue hand tool, complete with case,
shall be readily available to the rescue crewman
during rescue operations.
MAINTENANCE
The aircrewman's maintenance of the
pneumatic rescue hand tool is limited to a fresh
water rinse. Repairs or other maintenance action
required are done by organizational level or
above.
12-13
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2, VOLUME 1
CALENDAR INSPECTION
The pneumatic rescue hand tool shall be in-
spected upon issue and every six months
thereafter. The six-month calendar inspection
consists of a visual inspection and a functional
test. To perform a visual inspection, proceed as
follows:
1. Inspect all parts for corrosion, cracks,
wear and any other defects.
2. Inspect blade for sharpness. Sharpen,
using an appropriate whetstone, or replace as
necessary.
3. Inspect the anvil for scored surface.
Functional Test
The functional test consists of the following
tasks:
1. Leakage test. To perform a leakage test,
proceed as follows:
a. Pressurize the hand tool to 3,000 psi.
b. Immerse the pressurized hand tool in
fresh water and rotate the tool in three
directions to eliminate any trapped air
in external pockets.
c. Any leakage after one minute indicates
a defective seal of the component
from which the gas is escaping.
Replace seals as necessary.
2. Trigger force test. To perform a trigger
force test, proceed as follows:
a. Mount the pressurized hand tool in an
appropriate fixture, cradle or V-block.
b. Using a push-pull scale, measure the
trigger force necessary to actuate the
blade on the first stroke. The force
shall be applied midway on the finger
area of the trigger. Two thickesses of
Type XIII, MIL-W-4088C webbing
should be cut. The trigger force shall
be between 5 and 20 pounds. Trigger
force outside this range indicates the
need for repair of the trigger (forward)
valve or the trigger assembly.
3. Performance. To conduct a performance
test, proceed as follows:
a. Cut a double thickness of webbing,
and with the trigger in the depressed
position, immerse the hand tool in
water.
b. Any leakage after one minute of
immersion indicates the piston seal
leaks or the exhaust (rear) valve
leaks.
c. Make ten additional double webbing
cuts. After the tenth cut, with the
trigger depressed, immerse the hand
tool in water.
d. Check for leakage during one minute
of immersion. Any leakage indicates
the trigger (forward) valve is faulty.
e. Make additional cuts of double
webbing until the hand tool fails to
cut through both thicknesses. The
total number of cuts should total 17 to
20 cuts.
f. Failure to make 17 cuts indicates
maintenance is required.
CLEANING
Clean the pneumatic rescue hand tool after
every immersion in salt water. To clean, proceed
as follows:
1. Rinse the hand tool thoroughly in fresh
water (preferably distilled), and air dry, using a
forced warm air source.
2. After cleaning the hand tool, lightly coat
the cutting edge of the blade with pneumatic
grease.
12-14
CHAPTER 13
CARBON DIOXIDE
Carbon dioxide is a colorless, tasteless gas
that has a pungent odor. The chemical symbol
for carbon dioxide is CO 2 . You will find that
most people use this symbol when referring to
carbon dioxide.
CO 2 doesn't burn and does not support com-
bustion. Therefore, it makes a fine firefighting
agent. And it is strongly recommended for elec-
trical fires. The servicing of firefighting equip-
ment is not part of the PR rate and so this text
does not cover fire extinguishers.
As a PR you deal with liferaft and life
preserver CO 2 cylinders, which you weigh,
recharge and repair.
Carbon dioxide is ordinarily procured from
local commercial sources. This CO 2 is stored in
standard supply cylinders which contain 50
pounds of carbon dioxide when full.
Before learning how to recharge CO 2 , you
should be familiar with the following informa-
tion:
In its gas form, carbon dioxide is 1.53 times
heavier than air. CO 2 gas can be converted into a
liquid by applying pressure to the gas. With as
little as 600 psi at a temperature below 88 F the
CO 2 gas can be converted into a liquid and
stored in that state until it is subjected to the out-
side atmosphere. By opening the cylinder valve
and letting the carbon dioxide escape into the
atmosphere, you cause a rapid drop in pressure.
As the CO 2 escapes through the small opening it
forms carbon dioxide snow. This snow, when
compressed into blocks or cubes, is what we
know as dry ice. At atmospheric pressure, dry
ice will remain at - 110F, directly evaporating
into CO 2 gas. CO 2 exists as a liquid only when
under pressure.
Whenever you are working with CO 2 in any
of its three stages gas, liquid, or dry ice, you
should be aware that small percentages of CO 2
in the air causes tiredness and perhaps
headaches. Experiments have shown that a three
percent concentration in the air doubles your
breathing effort, five percent causes panting,
eight percent causes marked distress, and 10 per-
cent causes unconsciousness very quickly.
Treatment of exposed personnel includes
removing them from the CO 2 -laden atmosphere,
artificial resuscitation, administering oxygen,
and keeping the patient warm.
CO 2 RECHARGE EQUIPMENT
Carbon dioxide recharge equipment is
manufactured for the Navy by several different
companies. The two most widely used units are
those manufactured by the C-O-TWO Company
of Newark, New Jersey. (Do not confuse this
company with the chemical symbol CO 2 ) and the
Walter Kidde Company of Belleville, New
Jersey.
A typical C-O-TWO recharge unit is shown
in figure 13-1 and consists of a supply cylinder
containing 50 pounds of CO 2 , a tilting rack for
inverting the supply cylinder, a motor-driven
pump, a rack for inverting the cylinder being
recharged, a scale for determining the weight of
the cylinder being recharged, and the necessary
high-pressure hoses, control valves, adapters,
etc., to properly hook up the equipment. The
two units are covered in detail in the PR 1 & C.
Before learning the operation of any specific
type of recharge equipment, you should be
familiar with the following general information,
which applies to all units.
13-1
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
PORTABLE CYLINDER
BEING RECHARGED
SCALES
MOTOR DRIVEN PUMP
239.39
Figure 13-1. C-O-TWO recharge or transfer unit (supply
cylinder without a syphon tube).
Carbon dioxide recharge equipment pumps
CO 2 in its liquid state only, and the amout of li-
quid CO 2 a cylinder contains varies witti the
temperature and pressure. For example, a stand-
ard 50-pound supply cylinder contains approxi-
mately 38 pounds of liquid CO 2 and 12 pounds
of gaseous CO 2 at a temperature of 70 F. It
follows, then, that the cooler the supply cylinder
and cylinder being recharged, the more efficient
the operation of the transfer equipment. For this
same reason, the time required to recharge an
empty cylinder increases with the temperature of
the cylinders.
When recharging a cylinder, it remains
cooler and may be filled faster if inverted, rather
than left in an upright position. Large cylinders,
which are impractical to invert, may be placed in
a horizontal position for charging.
Standard commercial supply cylinders in
50-pound sizes are obtained with or without a
syphon tube. When transferring from a cylinder
without a syphon tube, the cylinder must be
inverted. Supply cylinders with syphon tubes
should be maintained in an upright position, not
more than 60 degrees from vertical.
CO 2 SUPPLY CYLINDERS
Figure 13-2 illustrates the standard supply
cylinder used universally in recharging various
types of CO 2 cylinders. A cutaway view of the
cylinder valve is also shown. Table 13-1 lists
some of the most pertinent data concerning sup-
ply cylinders.
INSPECTING CO 2 CYLINDERS
AND RECHARGING
Cylinders, including some of those of new
manufacture, continue to bear ICC markings
and, until amendment to Department of Trans-
portation (DoT) regulations, such markings will
remain in use.
Compressed gas cylinders, including CO 2
cylinders must not be refilled if the hydrostatic
239.144
Figure 13-2. CO 2 supply cylinder.
13-2
Chapter 13 CARBON DIOXIDE
Table 13-1. Specifications on supply cylinders
Capacity at normal pressure
and temperature* 50 pounds
Working pressure 1,800 to 2,015
psi
ICC specification ICC3A
Dimensions (approx.) Diameter, 8 1/2
inches; length,
51 inches
Weight, empty 110-115 pounds
Outlet connection 3/4 inch
*Temperature of 68 - 70F and atmospheric pressure.
test date has expired. This date, expressed by
month-year, e.g., 6-70, is stamped on the
shoulder of the cylinder each time the cylinder is
retested. The hydrostatic test date is considered
as having expired if the latest date stamped on
the cylinder precedes the current date by more
than 5 years.
Cylinders that do not exceed 2 inches in out-
side diameter, and that are less than 2 feet long
are exempt from the hydrostatic retest.
The hydrostatic retest date applies to multi-
place liferaft cylinders; if the cylinder is due for
a test, discharge and disconnect the cylinder.
Obtain a new cylinder from supply as a replace-
ment and forward the old cylinder to an activity
capable of conducting a hydrostatic test.
Many nonshatterable cylinders are identified
by the words NONSHATTERABLE, NON-
SHAT, or SHATTERPROOF stamped (not
stenciled) on the shoulder or side of the cylinder.
Substitution of a "shatterable" for a "nonshat-
terable" cylinder is not authorized.
Personnel who handle compressed gas
cylinders must be familiar with the color coding
of cylinders. Color coding is provided as a
hazard warning, and should not be used by itself
to identify the contents of a cylinder. In the
event of conflict with other markings, or doubt
as to the contents, the cylinder should be re-
turned to the local supply activity, (non-RFI).
All carbon dioxide inflation cylinders must
be painted gray and markings must be in black
letters 1/4-inch high. The information must in-
clude gross weight, tare weight, weight of car-
bon dioxide, and date of latest recharge. Paint
and stencil the cylinder as required, insure that
all markings are included as necessary.
Insure that all carbon dioxide cylinders used
for liferaft inflation assemblies received from
supply, except those used on the one man rafts,
have syphon tubes installed.
Gently tap the inverted cylinder with a small
piece of wood. If any rust or other contamina-
tion falls from the cylinder, reject that cylinder,
and draw another cylinder from supply; repeat
the contamination check. Replace the stem in
the inflation assembly valve, install a new sealing
washer, and thread the inflation assembly valve
onto the cylinder and tighten.
Inspection for deterioration of the cylinder
will consist of a visual examination for the
defects listed below.
Cylinders with defects that approximate the
physical dimensions indicated in the following
list will be condemned and returned to supply.
1 . Corrosion pits in a general corrosion area
that exceed a depth of 1/32-inch, or isolated pits
not in a general corrosion area that exceed a
depth of 5/64-inch.
2. Dents that exceed a depth of 1/16-inch, or
whose major diameter is more than 32 times the
depth.
3. Cuts or gouges more than 1/16-inch, or
whose major diameter is more than 32 times the
depth.
4. Visible arc or torch burns.
5. Evidence that the cylinder has been in a
fire.
6. Discernible bulges.
Now that you have inspected the CO 2
cylinder, you are ready to recharge the bottle.
Figure 13-3 shows a recharging setup. Notice in
the figure that you need scales, a recharge pump,
a supply cylinder, and the necessary lines and
valves. Proceed as follows:
1. Place the CO 2 cylinder on the scales.
NOTE: An accurate scale with a capacity of
100 pounds is necessary. The scale should have
1/100 pound graduations.
13-3
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
SUPPLY VALVE
RELIEF VALVE
CARBON DIOXIDE
FILL LINE
SUPPLY VALVE
SCALE
SUPPLY
CYLINDER
(STRAIGHT SYPHON
TUBE INSTALLED)
CYLINDER
DAPTER
Figure 13-3. CO 2 recharging schematic.
239.359
Table 13-2. Carbon dioxide charge
Raft Type
Weight (in Lbs) of
Carbon Dioxide
LR-1
LRU-7/P
LRU-12/A
LRU-13/A
LRU-13/A
LRU-15/A
0.49 to 0.51
0.49 to 0.51
3.21 to 3.29
4.64 to 4.76
4.74 to 4.86
9.14 to 9.26
2. Weigh and record tare weight (empty
weight of cylinder, valve and cable assembly) of
the inflation assembly.
3. Install proper charging adapter on the
inflation assembly.
4. Secure the inflation assembly to the
weighing pan located on the scales before apply-
ing any pressure to the cylinder being recharged.
5. Open the supply cylinder valve, fill line
valve, and relief valve. This is done to purge (get
the air out of) the complete line. Once the line is
purged, close the fill line valve and the relief
valve. You must be careful when purging the
line; you are dealing with a high pressure. If you
do not secure the fill line before you apply
pressure, the line may start a whipping action
and damage anything or anyone that it hits.
6. After purging the line, connect the fill
line to the inflation assembly. Ensure that the
line is free from contact with any objects along
the entire distance from the compressor to the
charging adapter. If the line does not hang free,
accurate weight reading cannot be obtained. At
this time, you must zero your scales. By zeroing
the scales, you will be able to recharge the exact
amount of CO 2 into the inflation assembly (see
table 13-2 for carbon dioxide charges).
7. Ensure that the inflation assembly valve
is open. If it is closed you cannot recharge the
assembly.
8. Open the fill line valve slowly until you
hear CO 2 flowing through the line and into the
inflation assembly and the scale's indicator
shows the recharging cylinder is gaining weight.
9. Allow carbon dioxide to cascade (flow
freely) from the supply cylinder until the scales
13-4
Chapter 13 CARBON DIOXIDE
indicate that the cylinder being recharged isn't
receiving any more CO 2 . If you haven't reached
the gross weight required (tare weight plus
weight of charge) start the compressor and
complete charging. Stop the compressor upon
reaching the proper gross weight. At this time,
you have completed the recharging process and
you must secure the equipment.
10. To shut the equipment down, start by
securing the inflation assembly valve, and shut
off the compressor. Then secure the fill line
valve. Open the relief valve; this will relieve any
pressure you may have in the line between the fill
line valve and the inflation assembly. Disconnect
the fill line from the inflation assembly and
remove the charging adapter. To secure the rest
of the system, all you have to do is close the sup-
ply cylinder valve and bleed the system by open-
ing the fill line valve.
If, during the recharging process, the
cylinder being charged ceases to gain in weight,
there may be one of two things wrong:
1 . The supply cylinder may contain less than
10 pounds of carbon dioxide. In this case, a fully
charged supply cylinder should be used and the
partially charged cylinder reserved to start the
recharging of an empty cylinder.
2. The connecting lines may have become
stopped up with carbon dioxide snow. This may
be caused by water in the supply cylinder or too
small a valve passage (less than 1/8") in the sup-
ply cylinders. In this case, the disc assembly
(disc-type valve) or the cylinder valve (seat-type
valve) should be securely seated and the pump
shut off. The connections should be broken and
cleared of the carbon dioxide snow. The line will
actually clear itself if allowed to stand for some
length of time, but this can be hastened by
applying a flame or torch to the tubing. The line
should then be blown out with air to clear it of
water or foreign matter.
MAINTENANCE FOR THE
C-O-TWO TRANSFER UNIT
Once every month, inspect the level of the oil
in the crankcase and see that it is within the
limits specified.
Once every six months, lubricate the idler
shaft with two or three applications of light cup
grease; also, lubricate the gear teeth with a thin
coating of the same grease. With a small brush,
apply a light coating of vaseline to the piston
rod. To do this, dip the brush in vaseline and
hold the brush against the piston rod while
rotating the gears manually until the piston rod
has been coated completely. If necessary, tighten
the packing at the piston stem. A special wrench
is needed for this operation. Do not tighten ex-
cessively. Because of the design of the packing,
it is necessary to make only a snug adjustment in
order to have it hold tightly.
Keep the commutator or the motor clean.
Under normal operating conditions, the com-
mutator will require only occasional cleaning
with a dry piece of nonlinting cloth. Never
lubricate the commutator.
Drain and refill the crankcase at least once
every two years. The bearing housings of the
motor which also need attention at this time
should be cleaned and regreased by a qualified
electrician. Use table 13-3 for servicing
intervals.
Table 13-3. C-O-TWO unit servicing intervals
ITEM CHECKED OR SERVICED
MONTHS
1
6
24
CRANKCASE OIL LEVEL
X
IDLER SHAFT
X
GEAR TEETH
X
PISTON ROD
X
PISTON STEM PACKING
X
MOTOR COMMUTATOR
X
DRAIN AND REFILL CRANKCASE
X
MOTOR BEARING HOUSINGS
X
240.119
13-5
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
MAINTENANCE OF THE WALTER periodically and changing it as necessary. Here,
KIDDE TRANSFER UNIT experience with pumps dictates the time of
action. One can establish and maintain a
The instruction book on lubrication for the schedule compatible with the experience gained
Walter Kidde transfer unit simply recommends through operating the equipment. The plunger
inspecting the oil level in the crankcase packing needs no oil.
13-6
INDEX
Acceptance/calendar/phase inspection, 7-14
to 7-15
Aircrew Personal Protective Equipment
History Card, 5-2
Aircrew Personal Protective Equipment
Manual, NAVAIR 13-1-6.7, 5-2
Aircrew Survival Equipmentman (PR) rating,
2-1 to 2-9
enlisted rating structure, 2-2
leadership, 2-3
levels of maintenance, 2-8 to 2-9
intermediate level maintenance, 2-9
organizational level maintenance, 2-8
to 2-9
PR rating, 2-2 to 2-3
source of information, 2-3 to 2-4
work areas and conditions, 2-4 to 2-8
environmental conditions, 2-5 to 2-8
parachute loft layout, 2-4 to 2-5
AN/PRC-63, 11-1 to 11-3
AN/PRC-90, 11 -3 to 11-7
AN/PRT-5, 11-8 to 11-10
AN/URT-33A, 11-7 to 11-8
Anti-exposure assemblies, 7-1 to 7-17
commercial non-vented wet suit, 7-15
to 7-17
application, 7-15 to 7-16
maintenance, 7-16 to 7-17
CWU-21/P Anti-Exposure Assembly,
7-5 to 7-10
CWU-21/P Anti-exposure flying
coverall, 7-6
CWU-23/P liner, 7-6
Anti-exposure assemblies Continued
CWU-21/P Anti-Exposure Assembly-
Continued
donning, 7-8
fitting, 7-7 to 7-8
maintenance, 7-8 to 7-10
sizing, 7-6 to 7-7
SRU-25/P cotton-flocked rubber sock,
7-6
CWU-33/P Series Ventilated Anti-
Exposure Coverall Assemblies, 7-1 to 7-5
application, 7-2
function, 7-3 to 7-4
maintenance, 7-5
supplementary equipment, 7-2
Quick-Donning Anti-Exposure Coverall,
QD-1/CWU-16/P, 7-10 to 7-15
acceptance/calendar/phase inspection,
7-14 to 7-15
anti-exposure hood, 7-12
anti-exposure mittens, 7-12
donning, 7-12 to 7-13
function, 7-13
maintenance, 7-13 to 7-14
Anti-exposure hood, 7-12
Anti-exposure mittens, 7-12
Anti-g garments, 6-1 to 6-8
CSU-15/P anti-g garment, 6-6 to 6-8
configuration, 6-6 to 6-7
fitting, 6-7
maintenance, 6-8
Mk-2A Cutaway Anti-g Coverall, 6-1
to 6-6
configuration, 6-2
fitting, 6-2 to 6-5
maintenance, 6-5 to 6-6
Awl, 4-13
1-1
AIRCREW SURVIVAL EOUIPMENTMAN 3 & 2, VOLUME 1
B
Bayonet and receiver mechanism, attachment
of, 9-11 to 9-13
Bayonet receivers, adjustment of, 9-14
Beacons and survival radios, 11-1 to 11-10
D
Distress light (SDU-5/E), 10-3
Dry locker, 2-4 to 2-5
Dye marker, 10-1
Cable grip, 12-12 to 12-13
Canned drinking water, 10-5
Carbon dioxide, 13-1 to 13-6
CO 2 recharge equipment, 13-1 to 13-2
CO 2 supply cylinders, 13-2
inspecting CO 2 cylinders and recharging,
13-2 to 13-5
maintenance for the C-O-TWO transfer
unit, 13-5
maintenance of the Walter Kidde transfer
unit, 13-6
Class III sewing machines, 3-20 to 3-29
CO 2 cylinders, inspecting and recharging,
13-2 to 13-5
CO 2 recharge equipment, 13-1 to 13-2
CO 2 supply cylinders, 13-2
Cold Weather Flyer's Jackets, CWU-17/P and
CWU-45/P, 5-9 to 5-10
Cold Weather Underwear, CWU-43/P and
CWU-44/P, 5-10 to 5-12
Combination inhalation/exhalation valve, 9-10
Commercial non-vented wet suit, 7-15 to 7-17
CONSEW 99R and 99R-3 sewing machine,
3-38 to 3-40
Cords and threads, difference between, 4-4
to 4-5
C-O-TWO transfer unit, maintenance for the,
13-5
CSU-15/P anti-g garment, 6-6 to 6-8
Curtain fastener, 4-17
CWU-21/P Anti-Exposure Assembly, 7-5
to 7-10
CWU-21/P anti-exposure flying coverall, 7-6
CWU-23/P liner, 7-6
CWU-33/P Series Ventilated Anti-Exposure
Coverall Assemblies, 7-1 to 7-5
E
Enlisted rating structure, 2-2
Environmental conditions, 2-5 to 2-8
Fabrication and manufacture, 4-1 to 4-35
hardware, 4-13 to 4-23
curtain fastener, 4-17
glove fasteners, 4-15 to 4-17
grommets, 4-14 to 4-15
interlocking slide fasteners, 4-17
to 4-23
three-way locking fasteners, 4-17
three-way locking snaps, 4-17
seams and knots, 4-24 to 4-35
hand-sewn seams, 4-24 to 4-28
knots, 4-32 to 4-35
machine-sewn seams, 4-28 to 4-32
special hand tools, 4-10 to 4-13
awl, 4-13
foot-operated grommet press, 4-11
to 4-12
hand press, 4-12
knives, 4-12
measuring devices, 4-12 to 4-13
sailmaker's palm, 4-13
shears, 4-10 to 4-11
star punch, 4-13
textile materials terms and meanings,
4-1 to 4-10
construction features and uses of
various textile materials, 4-2 to 4-4
difference between threads and cords,
4-4 to 4-5
engineering requirements for fabrics,
4-6 to 4-10
fiber and filament, 4-1 to 4-2
storage of textile materials, 4-6
webbings and tapes, 4-4
1-2
INDEX
Fiber and filament, 4-1 to 4-2
Fire Resistant Flyer's Gloves, GS/FRP-2,
5-12 to 5-13
Flight clothing, 5-1 to 5-13
maintenance scheduling and records,
5-1 to 5-3
maintenance documents, 5-1 to 5-2
modifications, 5-2 to 5-3
types of flight clothing, 5-3 to 5-13
Cold Weather Flyer's Jackets,
CWU-17/P and CWU-45/P, 5-9
to 5-10
Cold Weather Underwear, CWU-43/P
and CWU-44/P, 5-10 to 5-12
Fire Resistant Flyer's Gloves,
GS/FRP-2, 5-12 to 5-13
general purpose flight clothing, 5-3
Intermediate Flyer's Coverall,
CWU-l/P, 5-4 to 5-5
Summer Flyer's Coverall, CWU-27/P,
5-3 to 5-4
Winter Flyer's Suit, 5-5 to 5-9
Flight clothing, general purpose, 5-3
Flight clothing, types of, 5-3 to 5-13
Flotation collar and forest penetrator, 12-4
to 12-6
Foot-operated grommet press, 4-11 to 4-12
Forest penetrator and flotation collar, 12-4
to 12-6
Glove fasteners, 4-15 to 4-17
Grommet press, foot-operated, 4-11 to 4-12
Grommets, 4-14 to 4-15
H
Hand press, 4-12
Hand-sewn seams, 4-24 to 4-28
Hand tools, special, 4-10 to 4-13
Hardware, 4-13 to 4-23
Helicopter rescue devices, 12-1 to 12-14
cable grip, 12-12 to 12-13
application, 12-12
calendar inspection, 12-12 to 12-13
cleaning, 12-13
configuration, 12-12
maintenance, 12-12
Helicopter rescue devices Continued
forest penetrator and flotation collar, 12-4
to 12-6
application, 12-4 to 12-5
cleaning, 12-6
configuration, 12-4
inspection, 12-5 to 12-6
maintenance, 12-5
hoist quick-splice plate, 12-11 to 12-12
application, 12-11
calendar inspection, 12-11
cleaning, 12-12
configuration, 12-11
maintenance, 12-11
pneumatic rescue hand tool, 12-13 to 12-14
application, 12-13
calendar inspection, 12-14
cleaning, 12-14
configuration, 12-13
maintenance, 12-13
rescue harness, 12-7 to 12-10
application, 12-9
calendar inspection, 12-9 to 12-10
cleaning, 12-10
configuration, 12-7 to 12-8
maintenance, 12-9
preflight inspection, 12-9
rescue hook, 12-10 to 12-11
application, 12-10
calendar inspection, 12-11
cleaning, 12-11
configuration, 12-10
maintenance, 12-10
rescue net, 12-6 to 12-7
application, 12-6
cleaning, 12-7
configuration, 12-6
inspection, 12-6
maintenance, 12-6
rescue seat, 12-3 to 12-4
application, 12-3 to 12-4
cleaning, 12-4
configuration, 12-3
inspection, 12-4
maintenance, 12-4
survivor's sling, 12-1 to 12-3
application, 12-1
calendar inspections, 12-2 to 12-3
configuration, 12-1
maintenance, 12-2
Helmet assemblies, major, 9-1 to 9-3
1-3
AIRCREW SURVIVAL EQUIPMENTMAN 3 & 2, VOLUME 1
Helmet components, major, 9-3 to 9-4
Helmet configuration buildup, 9-4
Helmets, 9-1 to 9-8
History of parachutes, 1-1 to 1-4
Hoist quick-splice plate, 12-11 to 12-12
O
Organizational level maintenance, 2-8 to 2-9
Oscillating, type sewing machines, 3-3 to 3-20
Oxygen masks, 9-8 to 9-16
I
Illumination signal kit, 10-2
Individual aircrewman's survival kit
(SRU-31/P), 10-3 to 10-4
Integrated torso harnesses, 8-1 to 8-7
description, 8-1
inspections, 8-6 to 8-7
sizing, 8-1 to 8-6
fitting, 8-4 to 8-6
lap belt and shoulder adjustments, 8-6
taking measurements, 8-1 to 8-4
Interlocking slide fasteners, 4-17 to 4-23
Intermediate Flyer's Coverall, CWU-l/P,
5-4 to 5-5
Intermediate level maintenance, 2-9
K
Knives, 4-12
Knots, 4-32 to 4-35
Leadership, 2-3
Levels of maintenance, 2-8 to 2-9
Parachute loft layout, 2-4 to 2-5
Parachutes, history of, 1-1 to 1-4
Pneumatic rescue hand tool, 12-13 to 12-14
PR rating, 2-2 to 2-3
Pressure-demand oxygen mask MBU-12/P, 9-8
to 9-10
Protective helmets and oxygen masks, 9-1 to
9-16
helmets, 9-1 to 9-8
helmet configuration buildup, 9-4
inspection, 9-4 to 9-6
maintenance, 9-4
maintenance procedures, 9-8
major helmet assemblies, 9-1 to 9-3
major helmet components, 9-3 to 9-4
sizing the PRK-37/P, 9-4
SPH-3B helmet, 9-6 to 9-8
oxygen masks, 9-8 to 9-16
adjustment of bayonet receivers, 9-14
attachment of bayonet and receiver
mechanism, 9-11 to 9-13
combination inhalation/exhalation
valve, 9-10
fitting, 9-13 to 9-14
maintenance, 9-14
preflight/post flight inspection, 9-14
to 9-16
pressure-demand oxygen mask
MBU-12/P, 9-8 to 9-10
sizing, 9-10 to 9- 11
M
Machine-sewn seams, 4-28 to 4-32
Maintenance, levels of, 2-8 to 2-9
Maintenance scheduling and records, 5-1 to 5-3
Measuring devices, 4-12 to 4-13
Medical packet, 10-4
Mk-2A Cutaway Anti-g Coverall, 6-1 to 6-6
Mk-13 MOD signal flare, 10-2 to 10-3
Mk-79 MOD illumination signal kit, 10-2
Quick-Donning Anti-Exposure Coverall,
QD-1/CWU-16/P, 7-10 to 7-15
R
Rations, 10-4
Rescue devices, helicopter, 12-1 to 12-14
1-4
INDEX
Rescue harness, 12-7 to 12-10
Rescue hook, 12-10 to 12-11
Rescue net, 12-6 to 12-7
Rescue seat, 12-3 to 12-4
Rotary type sewing machines, 3-20 to 3-44
Sailmaker's palm, 4-13
Seams and knots, 4-24 to 4-35
Sewing machines, 3-1 to 3-44
oscillating type sewing machines, 3-3 to 3-20
Singer sewing machine 7-33, 3-15
to 3-20
Singer sewing machine 31-15, 3-4
to 3-15
rotary type sewing machines, 3-20 to 3-44
adjustment of the thread take-up
spring, 3-44
centering the needle in the throat
(needle) plate, 3-41 to 3-42
class III sewing machines, 3-20 to 3-29
CONSEW 99R and 99R-3 sewing
machine, 3-38 to 3-40
setting the needle bar at the correct
height, 3-41
Singer sewing machine 143 W 2 and 3,
3-34 to 3-38
Singer sewing machine 211 W 151,
3-29 to 3-34
straight and zigzag sewing, 3-40 to 3-41
timing the feeding mechanism, 3-43
timing the movement of the needle
bar frame, 3-43
timing the sewing hook, 3-42
to raise or lower the feed dog,
3-43 to 3-44
to remove and replace the sewing
hook, 3-43
Shears, 4-10 to 4-11
Shop Process Cards (SPC), 5-2
Signal flare, 10-2 to 10-3
Signaling equipment and devices, 10-1 to 10-3
Signaling mirror, 10-1 to 10-2
Singer sewing machine 7-33, 3-15 to 3-20
Singer sewing machine 31-15, 3-4 to 3-15
Singer sewing machine 143 W 2 and 3,
3-34 to 3-38
Singer sewing machine 211 W 151, 3-29 to 3-34
SPH-3B helmet, 9-6 to 9-8
SRU-25/P cotton-flocked rubber sock, 7-6
Star punch, 4-13
Summer Flyer's Coverall, CWU-27/P, 5-3 to 5-4
Survival items, 10-1 to 10-5
canned drinking water, 10-5
inspection, 10-5
distress light (SDU-5/E), 10-3
individual aircrewman's survival kit
(SRU-31/P), 10-3 to 10-4
general packet, 10-4
inspection, 10-4
medical packet, 10-3 to 10-4
rations, 10-4
signaling equipment and devices, 10-1
to 10-3
dye marker, 10-1
Mk-13 MOD signal flare, 10-2
to 10-3
Mk-79 MOD illumination signal kit,
10-2
signaling mirror, 10-1 to 10-2
Survival kit (SRU-31/P), individual
aircrewman's, 10-3 to 10-4
Survival radios and beacons, 11-1 to 11-10
AN/PRC-63, 11-1 to 11-3
battery replacement, 11-3
function and use of operating controls,
11-2 to 11-3
general principles of operation, 11-2
inspections, 11-3
AN/PRC-90, 11-3 to 11-7
batteries, 11-5
operating procedure, 11-5 to 11-7
AN/PRT-5, 11-8 to 11-10
operation, 11-10
AN/URT-33A, 11 -7 to 11-8
Survivor's sling, 12-1 to 12-3
Tapes and webbings, 4-4
Textile materials, storage of, 4-6
1-5
, EOUIPMENTMAN 3 & 2. VOLUME 1
-1 W
A . Walter Kidde transfer unit, maintenance of the
4-4 13-6
Water, canned drinking, 10-5
Webbings and tapes, 4-4
Wet locker, 2-4
Winter Flyer's Suit, 5-5 to 5-9
Work areas and conditions, 2-4 to 2-8
1-6
AIRCREW SURVIVAL EQUIPMENTMAN
3 & 2, VOLUME 1
NAVEDTRA 10328-1
Prepared by the Naval Education and Training Program Management
Support Activity, Pensacola, Florida
Congratulations! By enrolling in this course, you have demonstrated
a desire to improve yourself and the Navy. Remember, however, this
self -study course is only one part of the total Navy training
program. Practical experience, schools, selected reading, and your
desire to succeed are also necessary to successfully round out a
fully meaningful training program. You have taken an important step
in self -improvement. Keep up the good work.
HOW TO COMPLETE THIS COURSE SUCCESSFULLY
ERRATA: If an errata comes with this course,
make all indicated changes or corrections before
you start any assignment. Do not change or
correct the Rate Training Manual (RTM) or
assignments in any other way.
TEXTBOOK ASSIGNMENTS: The RTM for this course
is Aircrew Survival Equipmentman 3&2, Volume 1,
NAVEDTRA 10328-1. The RTM pages that you are to
study are listed at the beginning of each
assignment. Study these pages carefully before
attempting to answer the questions in the
course. Pay close attention to tables and
illustrations because they contain information
that will help you understand the text. Read
the learning objectives provided at the
beginning of each chapter or topic in the text
and/or preceding each set of questions in the
course. Learning objectives state what you
should be able to do after studying the
material. Answering the questions correctly
helps you accomplish the objectives.
BLACK DOT INFORMATION: Black dots ( ) may be
used in the text and correspondence course to
emphasize important or supplemental information
and to highlight instructions for answering
certain questions. Read these black dot entries
carefully; they will help you answer the ques-
tions and understand the material.
SELECTING YOUR ANSWERS: After studying the
text, you should be ready to answer the ques-
tions in the assignment. Read each question
carefully, then select the BEST answer. Be sure
to select your answer from the subject matter in
the RTM. You may refer freely to the RTM and
seek advice and information from others on
problems that may arise in the course. However,
the answers must be the result of your own work
and decisions. You are prohibited from
referring to or copying the answers of others
and from giving answers to anyone else taking
the same course. Failure to follow these rules
can result in suspension from the course and
disciplinary action by the Commander, Naval
Military Personnel Command.
SUBMITTING COMPLETED ANSWER SHEETS:
It is
recommended that you complete all assignments as
quickly as practicable to derive maximum benefit
from the course. However, as a minimum, your
schedule should provide for the completion of at
least one assignment per month a requirement
established by the Chief of Naval Education and
Training. Failure to meet this requirement
could result in disenrollment from the course.
TYPES OF ANSWER SHEETS: If
you
receivec
Automatic Data Processing (ADP) answer sheets
with this course, the course is being admin-
istered by the Naval Education and Training
Program Management Support Activity (NETPMSA),
and you should follow the instructions in
paragraph A bellow. If you did NOT receive ADP
answer sheets with this course, you should use
the manually scored answer sheets attached at
the end of the course and follow the directions
contained in paragraph B below.
A. ADP Answer Sheets
All courses administered by the NETPMSA
include one blank ADP answer sheet for each
assignment. For proper computer processing,
use only the original ADP answer sheets.
Reproductions are not acceptable .
Recording Information on the ADP Answer
Sheets; Follow the "MARKING INSTRUCTIONS"
on the answer sheet. Be sure that blocks 1 ,
2, and 3 are filled in correctly. This
information is necessary for your course to
be properly processed and for you to receive
credit for your work.
As you work the course, be sure to mark
your answers in the course booklet because
your answer sheets will not be returned to
you. When you have completed an assignment,
transfer your answers from the course
booklet to the answer sheet.
Mailing the Completed ADP Answer Sheets:
As you complete each assignment, mail the
completed ADP answer sheet to:
Commanding Officer
Naval Education and Training
Program Management
Support Activity
Pensacola, FL 32559-5000
The answer sheets must be mailed in enve-
lopes, which you must either provide
yourself or get from the local Educational
Services Officer (ESO). You may enclose
more than one answer sheet in a single
envelope. Remember, regardless of how many
answer sheets you submit at a time, the
NETPMSA should receive at least one a month.
NOTE: DO NOT USE THE COURSE COMMENTS PAGE
AS AN ENVELOPE FOR RETURNING ANSWER SHEETS
OR OTHER COURSE MATERIALS.
Grading: The NETPMSA will grade your
answer sheets and notify you by letter of
any incorrect answers. The passing score
for each assignment is 3.2. Should you get
less than 3.2 on any assignment a blank ADP
answer sheet will be enclosed with the
letter listing the questions incorrectly
answered. You will be required to redo the
assignment and re submit a new completed
answer sheet. The maximum score that can
be given for a resubmitted assignment is
3.2.
Course Comple tion ; When you complete
the last assignment, fill out the "Course
Completion" form in the back of the course
and enclose it with your last answer sheet.
The NETPMSA will issue you a letter certi-
fying that you satisfactorily completed the
course. You should make sure that credit
for the course is recorded in your service
record.
Student Questions; Any questions con-
cerning this course should be referred to
the NETPMSA by mail using the address listed
above or by telephone: AUTOVON 922-1366,
FTS 948-1366, or commercial (904) 452-1366.
B. Manually Scored Answer Sheets
If you did not receive ADP answer
sheets with this course, it is being
administered by your local command and your
must use the answer sheets attached at the
end of the course booklet.
Recording Information on the Manually
Scored Answer Sheets; Fill in the appro-
priate blanks at the top of the answer
sheet. This information is necessary for
your course to be properly processed and for
you to receive credit for your work. As you
work the course, be sure to mark your
answers in the course booklet, because your
answer sheets will not be returned to you.
When you have completed an assignment,
transfer your answers from the course
booklet to the answer sheet.
Submitting the Completed Manually
Scored Answer Sheets: As you complete each
assignment, submit the completed answer
sheet to your ESO for grading. You may
submit more than one answer sheet at a time.
Remember, you must submit at least one
assignment a month.
Grading: Your ESO will grade the
answer sheets and notify you of any incor-
rect answers. The passing score for each
assignment is 3.2. Should you get less than
3.2 on any assignment, the ESO will not only
list the questions incorrectly answered but
will also give you a pink answer sheet
marked "RESUBMIT." You will be required to
redo the assignment and complete the
"RESQBMIT" answer sheet. The maximum score
that can be given for a resubmitted assign-
ment is 3.2.
Course Completion: After you have
submitted all the answer sheets and have
earned at least a 3.2 on each assignment,
your command will give you credit for this
course by making the appropriate entry on
Page 4 of your service record.
Student Questions: Any questions
concerning the administration of this course
should be referred to your ESO.
NAVAL RESERVE RETIREMENT CREDIT
This course is evaluated at 12 Naval Reserve
retirement points which will be credited upon
satisfactory completion of Assignments 1 through
7.
COURSE OBJECTIVE
By completing this course you will demon-
strate and exercise your understanding of the
history, development, and importance of para-
chutes, techniques for fabricating, modifying,
and repairing aviator's clothing and equipment,
and the method and requirements for testing and
inspecting aircrew safety and survival
equipment.
11
Naval courses may include a variety of questions multiple-choice, true-false, matching, etc.
The questions are not grouped by type; regardless of type, they are presented in the same general
sequence as the textbook material upon which they are based. This presentation is designed to pre-
serve continuity of thought, permitting step-by-step development of ideas. Some courses use many
types of questions, others only a few. The student can readily identify the type of each question
(and the action required) through inspection of the samples given below.
MULTIPLE-CHOICE QUESTIONS
Each question contains several alternatives, one of which provides the best answer to the
question. Select the best alternative, and blacken the appropriate box on the answer sheet.
Indicate in this way on the answer sheet:
SAMPLE
s-1. The first person to be appointed Secretary
of Defense under the National Security Act
of 1947 was
1. George Marshall
2. James Forrestal
3. Chester Nimitz
4. William Halsey
TRUE-FALSE QUESTIONS
Mark each statement true or false as indicated below. If any part of the statement is false
the statement is to be considered false. Make the decision, and blacken the appropriate box on the
answer sheet.
123
s-i ti n
4
n ___
SAMPLE
s-2. Any naval officer is authorized to corres-
pond officially with any systems command
of the Department of the Navy without his
commanding officer's endorsement.
Indicate in this way on the answer sheet:
i ^ ~r
D n
MATCHING QUESTIONS
Each set of questions consists of two columns, each listing words, phrases or sentences. 1
task is to select the item in column B which is the best match for the item in column A that i;
being considered. Items in column B may be used once, more than once, or not at all. Specific
instructions are given with each set of questions. Select the numbers identifying the answers <.
blacken the appropriate boxes on the answer sheet.
SAMPLE
In questions s-3 through s-6, match the name of the shipboard officer in column A by selectin
from column B the name of the department in which the officer functions.
A B
s-3. Damage Control Assistant 1. Operations Department
Indicate in this way on the answer shee*.
s-4. CIC Officer
s-5. Disbursing Officer
s-6. Communications Officer
2. Engineering Department
3. Supply Department
1
2
3
4
s-3
fi
.
D
n
s-4
n
n
n
s-5
D
n
a ___
s-6
n
n
n ___
iii
Assignment 1
Title: History and Description of the PR Rating
Text: Chapters 1 and 2
In this course you will demonstrate that learning has taken place by correctly answering
training items. The mere physical act of indicating a choice on an answer sheet is not in itself
important; it is the mental achievement, in whatever form it may take, prior to the physical act
that is important and toward which course learning objectives are directed. The selection of the
correct choice for a course training item indicates that you have fulfilled, at least in part,
the stated objective(s) .
The accomplishment of certain objectives, for example, a physical act such as drafting a
memo, cannot readily be determined by means of objective type course items; however, you can
demonstrate by means of answers to training items that you have acquired the requisite knowledge
to perform the physical act. The accomplishment of certain other learning objectives, for
example, the mental acts of comparing, recognizing, evaluating, choosing, selecting, etc., may
be readily demonstrated in a course by indicating the correct answers to training items.
The comprehensive objective for this course has already been given. It states the purpose
of the course in terms of what you will be able to do as you complete the course.
The detailed objectives in each assignment state what you should accomplish as you progress
through the course. They may appear singly or in clusters of closely related objectives, as
appropriate; they are followed by items which will enable you to indicate your accomplishment.
All objectives in this course are learning objectives and items are teaching items. They
point out important things, they assist in learning, and they should enable you to do a better
job for the Navy.
This self-study Bourse is only one part of the total Navy training program; by its very
nature it can take you only part of the way to a training goal. Practical experience, schools,
selected reading, and the desire to accomplish are also necessary to round out a fully meaningful
training program.
1-1,
Learning Objective: Identify
principal events and persons
related to the development of the
parachute as the principal item
of aviators personal survival
equipment .
The word "parare" in Italian means to
1 . protect or shield
2. to fall
3. to land safely
4. quick descend
1-2.
The French word "chute"
1 . quickly descend
2. Shield
3. protect
4. land safely
means to
1-3. Which of the following was the first to
sketch a parachute design?
1 . Pat Riggdon
2. Jodaki Kuparento
3. Martyn Montgolfier
4. Leonardo da Vinci
1-4. Who was the first balloonist to make a
parachute descent?
1 . Arnold Applely
2. Jodaki Kuparents
3. Andie- Jacques Garnerin
4. Carl Kirtley
1-5. Who was the first man to have his life
saved by a parachute?
1 . Jodaki Kuparento
2. Albert Berry
3. Floyd Smith
4. Ralph W. Bottreil
1-6. Who was the first man to successfully
jump from a bi -plane?
1 . James Higgins
2. James Russel
3. Albert Berry
4* Major Hoffman
1-7. Who was the first man to make a free fall 1-15.
parachute jump?
1 . Alva Starr
2. Major Hoffman
3. H. A. Harris 1-16.
4. Leslie Irvin
1-8. In what year did it become mandatory for
all Navy and Army aircrewmen to wear
parachutes?
1. 1908
2. 1922
3. 1924
4. 1944 1-17.
1-9. In what year was the PR rate established?
1. 1922
2. 1924
3. 1940
4. 1942
1-18.
Learning Objective: Describe the
PR rating and the requirements for
advancing in the rating.
1-10. The PR rating was established in 1942. 1-19.
The career progression was from striker
status through PRC.
1-11. Which of the following functions is/are
the primary mission(s) of the PR?
1 . To check and test parachutes
2. To check and test oxygen regulators
3. To maintain equipment which saves
lives under emergency conditions
4. To perform both 1 and 2 above
1-12. Qualifications for Aircrew Survival
Equipmentmen can be found in which of the
following publications?
1. NAVAIR 13-1 -6. 2 (Series) 1-20.
2. NAVAIR 4700 (Series)
3. OPNAV 4790. 2 (Series)
4. NAVPERS 18068(Series)
1-13. The PR rating is designated as which of
the following types of ratings?
1 . General
2. Service
3. Flight
1-14. At what level(s) within the rating 1-21.
structure can the requirement for
successful completion of the PR class "A"
school be met?
1 . AR
2. AA
3. AN
4. All of the above
Today, it is mandatory for the student to
complete one free fall parachute descent
before he can become a PR.
What is the minimum combined score of
Word Knowledge, Mechanical and Shop
Information tests for a PR candidate to
enter "A" school?
1. 105
2. 115
3. 125
4. 156
Some of the most important aspects for
Navy leadership are outlined in which of
the following publications?
1. NAVAIR 4790.2
2. OPNAV 4790.2
3. General Order 21
4. General Order 49
Which of the following requirements must
you meet to qualify for advancement?
1 Time in grade or service
2. Meet the occupational standards
3. Take and pass an advancement exam
4. All of the above
Which of the following manuals give(s)
information concerning technical subject
matter?
1. NAVAIR 13-1-6.2
2. NAVAIR 1 3-1-6.3
3. NAVEDTRA 92050
4. Both 1 and 2 above
Learning Objective: Describe the
layout and requirements of a
parachute loft.
The average packing table used in a
parachute loft is of what size?
1. 36" wide and 36" high and as long as
necessary to service the longest
parachute in service
2. 36" wide, 36" high and 45 feet long
3. Wide enough to use as a cutting table
4. Narrow enough to maintain the
prescribed width of the fold for the
people
The parachute loft should be located
centrally and at ground level so that it
is accessable to all organizations
services.
1-22. Hoist lines located in the wet and dry
locker shall be spaced at what minimum
distances?
1. 12 inches apart and 12 inches from
walls
2. 24 inches apart and 12 inches from
walls
3. 12 inches apart and 24 inches from
walls
1-23. There will be no windows nor sky lights
located in the dry locker. All lighting
will be incandescent.
1-24. If specified, a storage bin should be at
least how far from the wall and floor?
1. 12 inches from wall and 12 inches
from floor
2. 4 inches from wall and 12 inches from
floor
3. 4 inches from wall and 4 inches from
floor
4. Not specified
1-25. What is the ideal temperature for a
packing loft?
65 F
1 ,
2. 70
3. 75
4. 80
1-26. Relative humidity is the ratio between
the amount of water vapor in the air and
the amount the air could hold at a given
temperature.
1-27. What is the ideal humidity for a packing
loft?
1 . 20 percent
2. 40 percent
3. 60 percent
4. 75 percent
1-28. What is the ideal equipment for
regulation of the air temperature and
humidity?
1 . Dehumidifier
2. Air conditioner
3. Furnace with humidifier
4. Evaporator
1-29. Sunlight and some types of lights have
what effect, if any, on parachute
canopies?
1 . Deterioration of material
2. Production of static electricity
3. Prolongation of the material's
service life
4. None
1-30. What code is assigned to the Aviator's
Equipment Branch within in organizational
maintenance activity?
1. 13A
2. 13C
3. 12A
4. 12B
1-31. The testing of seat pans and oxygen
regulators will be conducted at which of
the following levels of maintenance?
1 . Intermediate
2. Organizational
3. Both 1 and 2
4. Depot
1-32. Maintenance requirement cards (MRC) are
used to perform which, if any, of the
following inspections?
1 . Repacking of parachutes
2. Repacking of a seat pan
3. Phase maintenance on an aircraft
4. None of the above
1-33. Which of the following information is
found on an MRC card?
1 . Clearances
2. Pressures
3. Tolerances
4. All of the above
1-34. Fluorescent lighting should be no closer
than how many feet from exposed
parachutes?
1. 1 ft
2. 5 ft
3. 10 ft
4. 25 ft
Learning Objective: Describe
the organization and responsi-
bilities of personnel and work
centers which maintain survival
equipment.
1-35. Only personnel of the PR rate shall be
permitted to service personnel
parachutes, however, any chief petty
officer can supervise this servicing.
1-36. How many levels of maintenance are
outlined in the OPNAV 4790.2 (Series)?
1 . One
2. Two
3. Three
4. Four
1-37. Under which, if any, of the following 1-39.
divisions does the organizational
Aviator's Equipment Branch come?
1 . Aircraft Division
2. Air Frame Division
3. Power Plants Division
4* None of the above
1-38. Work centers in AIMD's are assigned work 1-40.
center codes. The Regulator Shop is
assigned which of the following codes?
1 . 81A
2. 81B
3. 81C
4. 81D
If you were -assigned to work in work
center 81 B you would be working in which
work center?
1 . Parachute Loft
2. Survival Equipment
3. Fabrication Shop
4. Aviator's Equipment Branch Office
When a parachute is due for a calendar
inspection it would go to the AIMD for
inspection. Which of the following work
centers would preform the inspection?
1. 81 A
2. 81 B
3. 81C
4. 130
Assignment 2
Title: Sewing Machines
Text: Chapter 3
Learning Objective: Identify
types, operating characteristics,
components, and functions of
sewing machines used by the PR .
2-1 Sewing machines are classified as how
many basic types?
1 . One
2. Two
3 . Three
4 * Four
2-2. Which of the following parts of the sewing
machine form(s) the stitch?
1 Rotary hook
2. Oscillating shuttle
3. Thread take up lever
4. Both 1 and 2 ,
2-3. Which type of stitch is/are most commonly
used on sewing machines?
1 . Lock stitch
2. Chain stitch
3. Compound Stitch
4. Either 2 or 3
2-4. Sewing machines have how many basic parts?
1 . Two
2. Three
3 . Four
4. Five
2-5. Material being sewn on a sewing machine is
held in position by the
1 . needle bar only
2. pressure foot
3. feed dogs
4. pressure arm
2-6. Which of the following machines is
classified as an oscillating machine?
1. 211W151
2. 111W151
3. 111W155
4. 31-15
2-7. What is the recommended speed for the
31-1 5 machine?
1. 2200 stitches per min '
2. 2000 stitches per min
3. 1800 stitches per min
4. 1500 stitches per min
2-8. What is the stitch range for the 31-15?
1 . 3-15 spi
2. 7-32 spi
3. 5-32 spi
4. 51/2-32 spi
2-9. The 31-15 sewing machine can sew canvas up
to
1 . 2 oz
2. 4 02
3. 6 oz
4. 8 oz
2-10. How often should a machine that is being
used constantly be oiled?
1 . Once a day
2. Twice a day
3. Every time you change the bobbin
4. Every hour
2-11. What type oil is recommended for oiling a
sewing machine?
1. 10-10 oil
2. 3-in-one oil
3. Castor base oil
4. SAE 10
2-12. How much oil is used for each oiling
point on a 31-15?
1 . Until the oil starts to drip
2. One drop
3. Two drops
4. Three drops
2-13. What is the proper class and variety of
needle used in the 31-15?
1. 7x17
2. 17 x 7
3. 16 x 87
4. 87 x 16
2-14. A properly timed needle bar on the 31-15
sewing machine will have the needle bar
located so that the point of the shuttle
will be inch above the eye of the
needle on its up stroke.
1. 1/16
2. 1/32
3. 1/4
4. 1/2
2-15. Prior to making any adjustment to a
machine a good rule to follow is to
1 . set the stitches length to
2. check your trouble shooting chart
3. set the stitches length to 8 spi
4. call the chief for advice
2-21. What, if anything, is the purpose of the
grooves on both sides of a 1 6 x 87 sewing
machine needle?
1 They prevent the hook from striking
the needle
2. This will tell you the class and
variety of the needle
3. They serve no purpose
4. They allow the thread to fall back
into the needle when it enters the
material
2-22. LEAVE THE CORRESPONDING NUMBER BLANK ON
YOUR ANSWER SHEET.
2-16. When the point of the needle reaches the
material, the feed dogs should be
1 . on the down stroke and even with the
throat plate
2. one full tooth above the throat plate
3. even with throat plate on the up
stroke
2-17. When adjusting the feed eccentric on the
31-15, your stitch regulator should be
set at its lowest position. This is done
to have the machine
1 . form its longest stitch
2. form its shortest stitch
3. prevent any loose movement in the
feed eccentric
4. prevent the needle from hitting the
feed dogs
2-18. When sewing light weight material the
feed dogs should be adjusted so that they
are slightly
1. 1/4 of a tooth above the throat plate
2. 1/2 of a tooth above the throat plate
3. one tooth above the throat plate
4. even with the throat plate
2-19. When selecting a needle to be used on
cloth the point of the needle will have a
1 . round sharp point
2. triangle looking point
3. diamond looking point
2-20. Why wouldn't you use a cutting point
needle when sewing canopy fabric?
1 . It will break the top thread
2. It will break the bobbin thread
3. It will cut the warp and filler
threads
2-23. What determines the size of a needle?
1 . Diameter of the needle
2. Needle eye size
3. Size of the scarf
4. Both 1 and 2
2-24. What size of needle would you use if you
were going to sew 5 plies of rayon using
E" thread?
1. #20
2. #22
3. #24
4. #26
2-25. What size of needle would you use to sew
elastic webbing?
1. #18
2. #20
3. #22
4. #24
2-26. When you have a bobbin threaded into the
bobbin case, the bobbin will turn in
which direction when you pull on the
thread?
1 . From left to right
2. Counterclockwise
3. Clockwise
4. Away from the operator
2-27. To prevent the needle thread from fouling
when you start to sew, you should
1 . backstitch for 1/4 of an inch
2. hold both threads (needle and bobbin)
until you have made two or three
stitches
3. back stitch for 1/2 of an inch
4. back stitch for 1 inch
2-28. When regulating the pressure on the
tension disk you must remember that the
1 . needle bar must be all the way down
2. pressure foot must be up
3. needle bar must be all the way up
4. pressure foot must be down
2-29. A properly formed stitch will have the
threads locking
1 . in the bobbin ply of material
2. in the top ply of material
3. in the center of the thickness of
material
4. at any of the above locations
2-30. To regulate the pressure on the material
you would use the pressure regulating
1 . hex nut
2. thumbscrew
3. spring
2-31 . When removing material from your sewing
machine you should cut the thread close
to the material, leaving about
1 . 2 in.
2. 2 1/2 in.
3. 3 in.
4. 3 1/2 in.
2-32. The class 7-33 sewing machine is used for
what type work?
1 . Sewing medium canvas
2. Sewing heavy canvas
3. Sewing light to medium canvas
4. Sewing light canvas only
2-33. What is the difference between the 7-31
and the 7-33 sewinq machines?
1 . The 7-33 has a clutch on the balance
wheel
2. The 7-31 has a clutch on the wheel
3. The 7-31 makes ziq zaq stitjches
4. The 7-33 is a liqht weight machine
and the 7-31 is a medium machine
2-34. To remove the bobbin from the 7-33 sewinq
machine you must have the aid of a small
screw driver or a shuttle opening tool.
2-35. To replace the bobbin in the 7-33 sewinq
machine you should leave about how many
inches of thread hanging free from the
shuttle?
1 . 2
2. 21/2
3. 3
4. 4
2-36. The class III sewing machines are capable
of sewing up to how many stitches per
minute?
1. 2200
2. 2350
3. 2500
4. 3000
2-37. Which of the following machines would you
use to sew upholstery in an aircraft?
1. 31-15
2. 111W155
3. 7-31
4. SVW-1 5
2-38. What type of feeding action does the
11W151 have?
1 . Needle drop and alternating presser
foot
2. Needle drop
3. Compound feed alone
4. Alternating presser foot
2-39. What is the first step you should take
when you start to time a machine?
1. Set the "stitches" to spi
2. Set the "stitches" to 3 spi
3. Set the "stitches" to 5 spi
4. Set the "stitches" to 32 spi
2-40. To set a needle bar that has no timing
marks you should first set the machine
to sew how many stitches per inch?
1. 2
2. 4
3. 6
4. 8
2-41. How far should the needle bar raise after
it reaches its lowest point while a
setting procedure is being performed?
1 . 1/1 6 of an inch
2. 3/32 of an inch
3. 5/1 6 of an inch
4. 1/2 of an inch
2-42. A properly timed needle bar will hold the
eye of the needle of an inch
below the sewing hook.
1. 5/16
2. 3/32
3. 1/16
4. 1/8
2-43. To center the feeding action, the
distance between the needle bar and the
pressure bar shall be
1 . 5/16 in.
2. 3/32 in.
3. 7/32 in.
4. 17/32 in.
2-44.
2-45.
2-46.
2-47.
2-48.
2-49.
When setting the sewing hook on the
11W151 sewing machine, the hook should be
of an inch above the eye of the
needle, with the needle bar on its up
stroke.
1/4
1/16
1/8
3/32
LEAVE THE CORRESPONDING NUMBER BLANK ON
YOUR ANSWER SHEET.
The 11W154 sewing machine has a presser
foot lift of
1 . 1/2 in.
2. 5/8 in.
3. 3/4 in.
4. 1 in.
When lubricating the bobbin case on a
111W151 sewing machine, you can tell when
it needs oiling by checking the
1 . green felt pad
2. oil wick
3. yellow felt pad
What determines the size of thread that
you use with a sewing machine?
1 . How strong you want your stitch
2. The size of thread used in the bobbin
3. The size of needle being used
4. Both one and three above
How do you regulate the tension on the
bobbin thread?
1 . By a thumb screw on the bobbin case
2. By a small screw on the outside of
the bobbin case
3. By an adjustable nut on the bobbin
case
4. By a thumb screw on the feed
eccentric
2-50. What is the maximum speed of the 211W151?
1 . 3, 000 rpm
2. 3,500 rpm
3. 5,000 rpm
4. 4,000 rpm
2-51 . What feature does the 21 1W1 51 have that
will prevent damage to the sewing hook
from foreign matter?
1 . Safety clutch
2. Safety wheel
3. Gib
4. Automatic safety gib
2-52. What needle is used in the 211W151?
1. 135 x 7 or 135 x 17
2. 136 x 17
3. 16 x 87
4. Either one or two above
2-53. With a clearance of 1 /4 inch under the
pressure foot, what needle would you use
on the 211W151?
1. 135 x 22
2. 135 x 17
3. 135 x 7
4. 135 x 24
2-54. What needle would you use with a
clearance of 3/8 inch under the pressure
foot?
1. 135 x 22
2. 135 x, ( 7
3. 135 x 20
4. 135 x 17
2-55.
2-56.
2-57.
2-59.
2-60.
When setting the needle into the 211W151,
which direction should the long thread
groove face?
1. To the operator's right
2. To the operator's left
3. Toward the operator
4. Away from the operator
When you are setting the relative
positions of the needle bar and pressure
bar, you should insure that a clearance
of
1 .
2.
3.
4.
17/32
5/16
7/32
9/16
inch is present.
To adjust the feed eccentric, what would
you first adjust?
1 . Screw on the back of the drive gear
2. Feed dogs
3. Thread take up spring
4. Gib
2-58. How is the hook saddle lubricated?
1 . Through small oiling holes
2. By an oiling wick
3. By a oil reservoir
4. By any of the above
Which of the following sewing machines
makes a zig zag stitch?
1. 143W15
2. 143W2
3. 142W16
4. 31W15
What is the maximum throw of the 1 43W3
needle bar?
9/16 in.
5/16 in.
7/16 in.
1.
2.
3.
4.
3/16 in.
2-61. What is the maximum throw of the needle 2-63. The newest zigzag machine used in the
bar on the 143W2 sewing machine? Navy is a
1. 3/8 in. 1. 99R-3
2. 1/4 in. 2. 211W151
3. 5/16 in. 3. 211W155
4. 5/8 in. 4. 7-33A
2-62. Which direction does the long thread
groove face on the 143W2?
1 . Away from the operator
2. Toward the operator
3. Toward the left
4. Toward the right
Assignment 3
Title: Fabrication and Repair of Aircrew Clothing and Equipment
Text: Chapter 4
Learning Objective: Use correct
terminology when discussing yarns
and fabrics.
3-1 . What is the basic unit used in the
fabrication of textile yarns and fabrics?
1 . Staples
2. Fiber
3. Yarn
4. Fillers
3-2. The edge of material that has a woven
finish to prevent raveling is called the
1 . material edge
2. manufacturer's edge
3. selvage
4. finished edge
3-3. Threads that run lengthwise and parallel
to the selvage are called
1 . warp thread
2. filling threads
3. locking threads
4. basic threads
3-4. Another word used for filling threads
would be
1 . woof
2. weft
3. pick
4. any of the above
3-5. At what angle are bias cuts made?
1 . 25
2. 45
3. 90
4. 180
3-6. Why would you use a bias cut when making a
parachute?
1 . To save material
2. To prevent tearing between two sections
3. To provide elasticity
4. To do all of the above
3-7. The force required to break a material is
called
1 . breaking force
2. tensile strength
3. warp strength
4. filler force
3-8. The weight of cloth is determined by
weighing one
1 . running yard
2. square foot
3. square yard
4. running foot
3-9. When we say cloth, we are referring to a
fabric that is at least
1. 12 inches wide from selvage to selvage
2. 14 inches wide from selvage to selvage
3. 18 inches wide from selvage to selvage
4. 24 inches wide from selvage to selvage
3-10. Which of the following is/are a basic
weave?
1. Plain
2. Twill
3. Warp
4. Both one and two above
3-11. Which weave will give you a smooth finish
and is the easiest to make?
1 . Twill
2. Plan
3. Warp
4. Filling
3-12. Cotton is a natural plant fiber; it is
usually white, and the length of its
fibers is from
1 . 3/8 to 1 inch
2. one to 2 inches
3. one to 6 inches
4. 3/8 to 2 inches
3-13. Nomex fabric is a brand name for a cloth
that can resist heat as high as
1 . 700 to 800F
2. 500 to 700F
3. 300 to 800F
4. 400 to 1 ,000F
10
3-14. At 800F f Nomex fabric will
1 . start to burn
2. start to char
3. melt
4. be unaffected
3-15. To define the word "Duck", as in cotton
duck, you would be referring to a fabric
with a weight of
"I . 6 to 50 oz per sq yard
2. 6 to 20 oz per sq yard
3. 5 to 40 oz per sq yard
4. 5 to 50 oz per sq yard
3-1 6. Webbings are defined as material that is
less than
1 . 12 inches wide from selvage to selvage
2. 10 inches wide from selvage to selvage
3. 8 inches wide from selvage to selvage
4. 6 inches wide from selvage to selvage
3-17. Textile tapes can weigh up to how many
ounces per square yard?
1. 5
2. 1
3. 15
4. 20
3-18. The reason you use S, or right hand
twisted thread in a sewing machine is
because the left hand thread will break or
unravel .
Learninq Objective: Discuss
characteristics, specifications, and
care of fabrics used by the PR.
3-19. When storing textile material you should
have a storaqe area that is dry and free
from direct sunliqht, and with a
temperature of
1 . 60 F
2. 70 F
3. 80 F
4. 110 F
3-20. Which of the followinq would cause serious
damage to nylon?
1 . Exposure to freshwater
2. Exposure to saltwater
3. Exposure to sun's rays
4. Mildew
3-21. Air permeability is a term that refers to
the measured volume of air in cubic feet
that flows through one square foot of
cloth in one minute.
3-22. A piece of nylon cord that is 100 feet
long and has a elongation of 1 0% should be
able to stretch how far without breaking?
1. 90 ft
2. 100 ft
3. 105 ft
4. 110 ft
3-23. To test a fabric for elasticity, what
percent should you pull it to see if it
will return to its original shape?
1. 04%
2. 08%
3. 10%
4. 12%
3-24. Military specifications for parachute
materials require that, after 50 hours of
exposure to sunlight, parachute cloth
should not lose more than what percent of
its original strength?
1. 25%
2. 30%
3. 35%
4. 50%
3-25. Nylon can elongate how much without being
damaged?
1 . 5 to 25%
2. 10 to 20%
3. 1 5 to 30%
4. 18 to 40%
3-26. What is the percent of elasticity of
nylon?
1. 70%
2. 75%
3. 80%
4. 1 00%
3-27. Nylon fabric has a moisture reqain of what
percent?
1 . 2.5%
2. 3.2%
3. 4.2%
4. 5.5%
3-28. What is the meltinq point of nylon?
1 . 280 F
2. 382 F
3. 482 F
4. 600 F
Learning Objective: Install and
repair grommets and fasteners.
3-29. When installing the chuck and die into the
grommet setter the chuck is the top tool
and the die is the lower.
11
3-30. A properly set chuck and die will have a
clearance of
1. 1/8 inch
2. 1/32 inch
3. 1/2 inch
4. 3/4 inch
3-31. A carpenter's square has measurements of
1. 12 inches on one arm and 24 inches on
the other arm
2. 14 inches on one arm and 24 inches on
the other arm
3. 16 inches on one arm and 24 inches on
the other arm
4. 18 inches on one arm and 24 inches on
the other arm
3-32. Which of the following sizes of grommets
would be the smallest?
1. 1
2. 2
3. 3
4. 4
3-33. When setting a grommet by a grommet set
you should use a ______ ^_______
to set the grommet.
1 . ballpeen hammer
2. rawhide mallet
3. vise
4. regular hammer
3-34. If you do not have a grommet set a handy
way to install a grommet is to use
1 . a ballpeen hammer and a mallet
2. a vise
3. two ballpeen hammers and a mallet
4. vise grips
3-35. What is the most common fastener
used on clothing?
1 . Dura dot
2. Glove fastener
3. Three-way locking
4. Curtain fastener
type
3-38. How many sizes are available for the
curtain fasteners?
1 . Two
2. Three
3 . Four
4. Five
3-39. What is used to clean a slide fastener?
1 . Toluene
2. Stoddard solvent
3. Gas
4. Gas mixed with oil
3-40. If you do not have a good oil to apply to
a slide fastener for lubrication, graphite
is a good substitute.
3-41. What action should you take if you find
that the bead of a slide fastener is torn?
1. Replace the slide fastener
2. Repair the bead
3. Replace only the side that broke
Learning Objective: State the
numbers of sizes and varieties of
slide fasteners; select the correct
size of slide fastener.
3-42. To shorten an interlocking slide fastener,
the chain should be made how much smaller
than the opening in the garment?
1. 1/2 inch
2. 3/4 inch
3. 1 inch
4. 1 1/2 inch
3-43. How many types of slide fasteners are
there?
1 . One
2. Two
3. Three
4. Four
3-36. If you needed a snap fastener that would
not come apart accidentally you would use
a
1 . para dot
2. dura dot
3. glove fastener
4. three way locking
3-37. How many sizes are available for the 3-way
locking snap?
1 . One
2. Two
3 . Three
4. Five
3-44. How many sizes do slide fasteners come in?
1 . Five
2. Six
3. Seven
4. Eight
Learning Objective:
seams and stitches.
Hand sew basic
3-45. Why would you apply yellow beeswax to
hand sewing thread?
1 . To prevent fraying and untwisting
2. It contains no oil
3. To keep the thread from weakening
4. For both reasons 1 and 2
12
3-46. Which of the following stitches is used to
temporarily hold a seam together?
1 . Overthrow stitch
2. Baseball stitch
3. Running stitch
4. Basting
3-47. Which of these stitches would you use if
you didn't have access to a sewing
machine?
1 . Baseball stitch
2. Overthrow stitch
3. Running stitch
4. Lock stitch U.S. 301
3-48. To sew an eyelet onto a parachute
container you would use a/an
1 . baseball stitch
2. overthrow stitch
3. lock stitch
4. underthrow stitch
3-49. When neat appearance is necessary in a
repair made by hand sewing, which stitch
would you use?
1 . Hidden stitch jt
2. Machine stitch
3. Baseball stitch
4. U.S. 301 lock stitch
3-50. What type of a needle would you use to
make a hidden stitch?
1. 1 1/2-inch curved needle
2. 2 1/2-inch curved needle
3. 3 -inch straight needle
4. 2 1/2-inch straight needle
3-51. Which of the following stitches is a U.S.
standard lock stitch?
1. 301
2. 302
3. 303
4. 304
3-52. How many classes of seams are there?
1 . One
2. Two
3. Three
4. Four
3-53. If you laid two pieces of material on top
of each other and ran, a row of stitches
1/4 inch away from the edge you would be
making a /an
1. lap
2. superimposed seam
3. edge finishing
4. binding
3-54. If your thread breaks while sewing you
should start your sewing again
1.1/2 inch behind the break
2. 1/8 inch behind the break
3. 7/16 inch behind the break
4. one inch behind the break
Learning Objective: Select the
correct knot for various applications
in parachute rigging.
3-55. What is the most common knot used to join
two ropes together?
1 . Clove hitch
2. Bowline
3. Square knot
4. Half hitch
3-56. What knot would you use to tie a parachute
pilot chute onto a parachute?
1 . Square knot
2. Clove hitch
3. Half hitch
4. Bowline
3-57. Which of the following knots is used to
tie the suspension lines to the connector
links?
1 . Clove hitch
2. Half hitch
3. Overhand knot
4. Sheepshank
13
Assignment 4
Garments
,-iaintain,
..^j-^ , .... Jiorized
modifications to flight clothing.
4-1. What is/are the primary function(s) of
flight clothing?
1 . Protection
2. Comfort
3. Appearance
4. All of the above
4-2. What factor decides the difference between
protection and comfort?
1 . Design of the aircraft
2. Operational requirements
3. Size of the aircrewman
4. Type of material
4-3. Material that is used in the manufacture
of flight clothing is designed to
1 . lengthen service life
2. provide comfort
3. improve survival chances
4. provide a nice appearance
4-4. Planned maintenance for flight clothing is
performed at what level of maintenance?
1 . The level set by the OPNAVINST 4790
2. "0" level
3. "I" level
4. Depot level
4-5. Maintenance is divided into how many
categories?
1 . One
2. Two
3. Three
4. Four
4-6. As a PR you are instructed to clean a
protective helmet. What type of
maintenance would you perform?
1 . Calendar
2. Corrective
3. Phase
4. Preventive
4-7. Who schedules preventive maintenance for
all aircrew protective equipment within a
squadron?
1 . Maintenance/material officer
2. Production control petty officer
3. Shop chief
4* Quality Assurance
4-8. What is/are used to make entries on
maintenance documents?
1 . Blue pen
2. Black pen
3. Typewriter
4. All of the above
4-9. When signing your name to a maintenance
document you are required to
1 . print your name
2. sign your initials only
3. sign your full name
4. do any of the above
4-10. What document would you use to enter the
equipment assigned to an aircrewman?
1 . DD 1 348
2. Aircrew Personal Protective Equipment
History Card
3. NAVAIR 00-500
4. 4790/2B
4-11. The Aircrew Personal Protective Equipment
History card is divided into how many
sections?
1 . One
2. Two
3. Three
4. Four
4-12. The shop process cards (SPCs) provide the
maintenance man with which of the
following information?
1 . Illustration
2. Clearances and tolerances
3. Charts and part numbers
4. All of the above
14
4-13. When you are working with personal
protective equipment which of the
following NAVAIR manuals is most helpful?
1 . 13-1-6.7
2. 13-1-6.5
3. 13-1-6.4
4. 13-1-6.2
4-14. Who is the only authority that can
authorize a modification to survival
equipment?
1 . SUPERS
2. OPNAV
3. NAVAIRSYSCOM
4. The shop chief
4-15. When a modification is authorized for life
support equipment, the authorization will
come in the form of a/an
1 . CAMI
2. BACSEB
3. TIMI
4. Aircrew System Change
4-16. The field activity having cognizance over
most life support and survival equipment
is the Naval Air Development Center in San
Diego.
4-17. The field activity having cognizance over
parachutes, torso harness and related
hardware is Naval Weapons Center, (code
6412) China Lake, California
4-18. If you needed information about survival
radios and wanted to get in contact with
the CFA for radios you would contact
1. Naval Air Rework Facility, Pensacola
2. NATTC, Lakehurst, NJ
3. Naval Air Rework Facility, Washington,
D.C.
4. NAVAIRSYSCOM
4-19. If you are requested to sew a group of
patches on a flight jacket, you would be
allowed to sew up to how many square
inches of patches?
1 . Not to exceed SO square inches
2. Not to exceed 100 square inches
3. Not to exceed 150 square inches
4. There LS no limit
4-20. What i3 the largest patch that you are
authorized to sew on a piece of flight
clothing?
1 . 3 inches
2. 2 inches
3. 4 inches in any given direction
4. There is no limit
4-21 . The CWU-27/P is designed to be worn as an
1 . outer garment in warm weather
2. outer garment in winter weather
3. inner garment in warm weather
4. inner garment in winter weather
4-22. The CWU-27/P summer flight suit is made
from an aramid cloth. This cloth will
start to char at what temperature?
1 . 800 to 900 F
2. 300 to 400 F
3. 500 to 600 F
4. 700 to 800 F
4-23. When a shroud cutter is carried in the
CWU-27/P it should be stored in what
fashion?
1 . Stored into a sheath on the leg
2. Tied to the pocket with the hook closed
3. Tied to the pocket cord with the hook
blade open
4-24. When fitting an aircrewman for a flight
suit you should select a size that is
1 . one size larger than his/her suit size
2. the same as his/her suit size
3. one size smaller
4. two sizes larger than his/her suit
4-25. Who is responsible for cleaning the
CWU-27/P flight suit?
1 . The crewman
2. The parachute rigger
3. The AME
4. The AIMD laundry
4-26. The PR shall perform a general inspection
of the CWU-27/P flight suit every
1 . 30 days
2. 60 days
3. 91 days
4. 10 days
4-27. The CWU-27/P flight suits can stand up to
what temperatures when washing and drying
them?
1. 100 water and 120 drying temperature
2. 120 water and 160 drying temperature
3. 110 water and 140 drying temperature
4. 140 water and 180 drying temperature
4-28. The CWU-1/P is designed as a/an
1. lightweight flyer's coverall
2. intermediate weight flyer's coverall
3. heavyweight flyer's coverall
4. extra lightweight flyer's coverall
4-29. The lining of the CWU-1 /P is made of
1 . rayon and wool
2. cotton
3. silk
4* nylon and rayon
4-30. How many sizes are available for the
CWU-1/P?
1 . 8
2. 10
3. 12
4. 16
15
4-31 . The CWU-1 /P has openings behind the leg
pocket. It is permissible to sew these
openings closed if not used.
4-32. Which of the following flier coveralls can
be worn in lieu of the anti -exposure suit
when flying over land and the temperature
warrants anti -exposure garments?
1. Winter flyer's suit
2. CWU-1 7/P
3. CWU-1 6/P
4. Any of the above
4-33. What is the difference between the
CWU-1 7/P and the CWU-45/P jackets?
1. CWU-45/P has a built in hood
2. CWU-1 7/P has a detachable hood
3. CWU-45/P is made from leather
4. CWU-1 7/P is nylon
4-34. Which, if any, of the following effects
will hot water and hot dryers have on PVC
(araraid) underwear?
1 . PVC underwear will shrink
2. PVC underwear will fade
3. PVC underwear will lose its fire
protection
4. None of the above
4-35. Flight gloves come in what range of sizes?
1. 5 to 11
2. 3 to 10
3. 3 to 15
4. 3 to 20
Learning Objective: Maintain,
repair, and put anti-g garments
into service
4-36. How many "Gs" can an aircrewman endure
without the aid of an anti-G garment?
1. 4.5 to 5.5
2. 2.5 to 3.5
3. 3.5 to 6.0
4. 4 to 7
4-37. What "G" force would be equal to the
pressure supplied to the body by the
heart (blood pressure)?
1. 3 "Gs"
2. 4 "Gs"
3. 5 "Gs"
4. 1 "G"
4-38. An aircrewman having an applied force of 5
"Gs" would have how much weight forced on
his body?
1 . 3 times his weight
2. 4 times his weight
3. 6 times his weight
4. 5 times his weight
4-39. When wearing a properly fitted anti-G
suit, an aircrewman can withstand about
how many extra "Gs"?
1 . Five
2. Two
3. Three
4. Four
4-40. Which of the following "G" forces would
have the most harmful effect on your body?
1. 2 "Gs" for 1 minute
2. 3 "Gs" for 1 minute
3. 6 "Gs" for 5 minutes
4. 14 "Gs" for 1 second
4-41. Protection against which of the following
is NOT provided by wearing an MK 2A anti-G
suit?
1 . Blacking out
2. Loss of vision
3. Lowered mental efficiency
4. Heart attack
4-42. What part(s) of the body do/does the
anti-G suit protect?
1 . Abdomen
2. Thighs
3. Calves
4. All of the above
4-43. What length does the anti-G suit hose come
in?
1 . 2 feet
2. 4 feet
3. 6 feet
4.18 inches
4-44. Which tool would NOT be used to cut the
anti-G hose?
1 . Hack saw
2. Sharp knife
3. Razor blade
4. Wire cutters
4-45. Prior to inserting the portion of the
connector, the use of
will aid you to an easy installation.
1. oil
2. water
3. silicone (Mil-S-8660)
4. both 2 and 3
4-46. If undue difficulty is encountered when
inserting the connector, what action
should be taken?
1. Machine the nozzle to .50 inch
2. Machine the nozzle to .662 inch
3. Machine the nozzle to .050 inch
4. Machine the nozzle to .772 inch
4-47. How should the machined surface be treated
to prevent corrosion?
1 . ALODINE 21 2
2. Zink treated
3. ALODINE 12
16
4-48. Where installing clamps, to ensure the
clamps are tightened sufficiently, you
should
1. grab the hose and sharply jerk it
2. use a torque wrench
3. apply 1 to 20 pounds torque pressure
4. do both 2 and 3
4-49. What corrective action must be taken if
the clamps will not hold?
1 . Use 2 to 5 turns of electrical
insulation tape
2. Use 3 to 6 turns of electrical
insulation tape
3. Use a rubber gasket
4. Replace the clamp
4-50. When covering the clamp with electrical
insulation tape, how many turns are
applied?
1 . 1 turn
2. 2 turns
3. 3 turns
4. 4 turns
4-51 . Who is responsible for pre-f light
inspection of anti-G garments?
1 . The aircrewman
2. The plane captain
3. The PR
4. The AME
4-52. The interval between pre-flight
inspections shall "lot exceed
1 . 7 days
2. 1 days
3. 14 days
4. 30 days
4-53. Performing the calendar inspection for the
anti-G suit is the responsibility of the
1. aircrew survival equipmentman (PR)
2. AME
3. aircrewman
4-54. The calendar inspection shall be performed
every
1 . 30 days
2. 61 days
3. 91 days
4. 182 days
4-55. Which of the following is performed prior
to inspecting the anti-G suit?
1 . Remove the 3 turns of tape from the
clamps
2. Inflate to 2 psig
3. Inflate to 3 psig
4. Inflate to 5 psig
4-57. The anti-G suit bladder being tested shall
not loose more than how many psi in 30
seconds?
1. 1 psi
2. 2 psi
3. 3 psi
4. 4 psi
4-58.
4-59.
4-60,
4-61
4-62,
4-63,
4-64.
4-65,
4-56. When performing the leakage test,
the anti-G suit to
1.2 psig
2. 3 psig
3. 4 psig
4. 5 psig
inflate
How long is the service life of an MD-2A
cut-a-way anti-G coverall?
1 . 2 years from date of manufacture
2. 5 years from date of manufacture
3. 7 years from date of manufacture
4. Until it fails a leakage test
What is the final step when performing a
calendar inspection?
1. Sign off the history card
2. Reinstall 3 turns of electrical tape on
the clamps
3. Deflate the bladder
4. Lubricate all zippers
Which of the following repairs is NOT
authorized?
1 . Replacement of leg pockets
2. Replacement of adjustable laces
3. Replacement of air inlet port
4. Mending small holes
What size of electrical taps should be
used to cover the clamps?
1/2 inch
3/4 inch
1 .
2.
3.
inch
4. 1 1/4 inch
Anti-G coveralls should be cleaned by
1 . machine washing
2. dry cleaning
3. hand-washing in hot water
4. hand-washing in cold water
What type of detergent is used in washing
the MK-2 anti-G coverall?
1 . Mild bleach and water
2. Dry cleaning fluids only
3. Bacteriostat detergent
4. Any laundry detergent
When mixing the bacteriostat detergent,
what ratio is used?
1.1 cup detergent to 6 gallons water
2. 1 1/2 cup detergent to 3 gallons water
3. 1 cup detergent to 3 gallons water
4. 1 1/2 cup detergent to 6 gallons water
When laundering it, what is the prescribed
time for soaking the anti-G garment?
1 . 1 hour
2. 3 minutes
3. 4 minutes
4. 5 minutes
17
DU should 4-68. The CSU-1 5/P anti-G garment shall have a
calendar inspection every
ger 1 60 days
2. 31 days
3. 91 days
4. 182 days
ment, a
id be used. Do
.ight.
18
Assignment 5
Title: Anti-exposure Suits and Torso Harnesses
Text: Chapters 7 and 8
5-1,
5-2.
5-3.
5-4.
5-5.
5-6,
Learning objective: Identify require-
ments for wearing anti -exposure suits.
What water temperature requires that anti-
exposure suits be worn?
1 . 32 F or below
2. 40 F or below
3. 50 F or below
4. 65 F or below
What air temperature requires that anti-
exposure suits be worn?
1 . 32 F or below
2. 35 F or below
3. 40 F or below
4. 55 F or below
Learning objective: Identify the
characteristics of the CWU-33/P
anti-exposure suit.
The CWU-33/P anti-exposure suit is
designed to be a
1. continuous wear type
2. quick-donninq type
3. either 1 or 2 above
How many sizes does the CWU-33/P come in?
1 . 12
2. 16
3. 20
4. 14
As an initial guide, what sizing method
should be used to select a CWU-33/P anti-
exposure suit?
1. Select the man's suit size
2. Just take any size
3. Measure his waist to select his size
4. Measure his height to select his size
One of the things to look for in a
properly fitted CWU-33/P is that there
should not be excessive material around
1 . the arms
2. the legs
3. the crotch area
4. any of the above areas
5-7. To obtain the required protection, the
CWU-33/P should be worn with
1 . underwear
2. heavy socks
3. hood
4. all of the above
5-8. The CWU-33/P is fabricated from
1. 1/8-inch polychloroprene rubber
2. 1/4-inch polychloroprene rubber
3. 3/5-inch polychloroprene rubber
4. 1/2-inch polychloroprene rubber
5-9. Which of the following anti-G coveralls
is used with the CWU-33/P anti-exposure
suit?
1 . MK2A
2. MK3A
3. MK4A
4. MK4B
5-10. The CWU-33/P anti-exposure suit has a
check valve to prevent water from entering
the suit through the ventilation
connection.
5-11. Through what is the inflatable hood
inflated?
1 . CC>2 cartridge
2. Oral inflation valve
3. Both 1 and 2 above
4. None of the above
5-12. If you need information on sizing the
CWU-33/P, refer to
1 . NAVAIR 1 3-1-6.2
2. NAVAIR 13-1-6.4
3. NAVAIR 13-1-6.5
4. NAVAIR 1 3-1-6.7
How long can a CWU-33/P remain in storage
without an inspection?
1 . 1 year
2. 21/2 years
3. 3 years
4. 4 years
5-14. Repairs are not normally made to the
CWU-33/P after
1 , 2 years
2, 3 years
3. 5 years
4. 4 years
5-13,
19
5-15. The calendar inspection is performed 5-22.
every
1 . 30 days
2. 60 days
3. 91 days
4. 182 days
5-23.
Learning Objective: Identify the
characteristics of the CWU-21/P
coverall and the SRU 25 P socks.
5-16* How many sizes does the CWU-21/P liner
come in?
1 . 6
2. 8
3. 10
4. 12
5-17. The CWU-21/P has a liner manufactured 5-24.
from
1 . 70% wool
2. 90% cotton
3. 100% wool
4. 100% cotton
5-18. The outer liner of the CWU-21/P is made 5-25.
of
1 . polypropylene netting
2. cotton
3 . nylon
4. rubber and cotton
5-19. SRU 25 P rubber socks are supplied in how
many sizes? 5-26.
1 . Four
2. Six
3. Eight
4 . Twe 1 ve
5-20. SRU 25 P socks should be selected based
on the aircrewman's boot size. 5-27.
5-21 . CWU-21/P coveralls have a neck-seal
opening. This neck seal comfortably fits
a neck which is
1. 1 to 1 1/2 inches larger in
circumference than the opening 5-28.
2. 1 1/2 to 1 inch larger in
circumference than the opening
3. 1 to 2 inches larger in circumference 5-29.
than the opening
4. 2 to 4 inches larger in circumference
than the opening
Learning Objective: Use correct
procedures in making cemented repairs
to anti-exposure garments.
All final cemented seams shall dry
thoroughly for a minimum of
1 . 4 hours
2. 8 hours
3. 12 hours
4. 24 hours
All cemented areas shall have which of
the following applied to the seams?
1 . Talcum powder
2. Rubber lube
3. Silicone
4. Dow Corning 1 02
Learning Objective: Inspect, maintain,
and advise air crewmen in techniques
of donning anti-exposure garments.
Donning procedures for exposure suits are
outlined in
1 . NAVAIR 1 3-1 -1 2
2. NAVAIR 13-1-6.5
3. NAVAIR 13-1-14
4. NAVAIR 13-1-6.7
Calendar inspections procedures for the
CWU-21/P are performed at which, if any,
of the following levels of maintenance?
1 . Intermediate
2. Organizational
3. Depot
4. None of the above
The calendar inspection shall be performed
every
1 . 30 days
2. 61 days
3. 91 days
4. 182 days
The service life of the CWU-21/P shall be
1 . 3 years from date of manufacture
2. 5 years from date of manufacture
3. 7 years from date of manufacture
4. Until it is beyond economical repair
You should never launder the CWU-21/P
prior to placing it into storage.
If the CWU-21/P coverall has been immersed
in saltwater you should soak it in fresh
water for
1 . 30 minutes
2. 1 hour
3. 12 hours
4. 24 hours
20
5-30. LEAVE THE CORRESPONDING NUMBER BLANK ON
YOUR ANSWER SHEET.
5-40. You can repair tears up to a
inch rip on a quick donning suit.
1. 21/2
2. 3
3. 3 1/2
4. 4
5-31. To clean the CWU-23/P liner, use
1 . hand washing only
2. dry cleaning only
3. an automatic washer with a delicate
cycle or hand launder
5-32.
5-33.
5-34.
5-35.
5-36.
5-37.
5-38.
5-39.
Temperature ranges for storage of anti-
exposure suits are
40 to 90
60 to 70
1
2.
3.
4.
68 to 75
50 to 80
When patching an anti-exposure suit a
tear 4 inches long is considered
1 . repairable
2. non- repair able
3. "0" level maintenance only
4. depot maintenance repair
The most patches that can be applied to
each arm of an exposure suit is
1 . one
2. two
3. three
4. four
The CWU-16/P quick-donning exposure suit
supplied in how many sizes?
1 . One
2. Two
3 . Three
4 . Four
The mittens for the quick-donning suit
are manufactured from
1 . chloroprene-coated nylon
2. rubber-coated cotton
3. chloroprene-coated cotton
4. none of the above
The anti-exposure hood is normally stored
in the
1 . carry case
2. pilot's helmet bag
3. exposure suit pocket
The quick-donning suit should be worn
1 . over all flight gear
2. under all flight gear
3. over or under flight gear
4. instead of other flight gear
The inspection cycle for the quick-
donning suit should not exceed
1. 91 days
2. 60 days
3. 182 days
4. 225 days
5-41 . Packing instructions for the quick
donning suit can be found in
1. NAVAIR 13-1-6.2
2. NAVAIR 13-1-6.7
3. NAVAIR 13-1-6.8
4. NAVAIR 13-1-6.9
Learning Objective: Inspect and
maintain commercial wet suits.
5-42. How many sizes are available for the
commercial non- vented wet suit?
1 . One
2. Two
3. Three
4. Four
5-43. In general, the wet suit should be worn
when a combined air and water temperature
is below
1. 120 F
2. 125 F
3. 1 30 F
4. 135 F
5-44. What directive or manual can authorize
removal of the wet suit from service?
1. BACSEB's
2. OPNAV 4790. 2B
3. NAVAIR 13-1-6.7
4. OPNAV 13-1-6.2
5-45. The calendar inspection for wet suits
should be made how often?
1 . Every 30 days
2. Every 60 days
3. Every 91 days
4. Every 182 days
5-46. How often are special inspections
performed on a wet suit?
1 . Every 7 days
2. Every 1 days
3 . Every 1 4 days
4. Every 21 days
5-47. To prevent cracking of the wet suit
material while it is in storage, you
should use
1 . cellulosic material
2. cellulite
3. talcum powder
4. nap flacks
21
5-48.
5-49.
5-50.
5-51 ,
5-52.
5-53.
5-54.
Learning Objective: Inspect,
maintain, and fit integrated
torso harnesses to aircrew persons.
The MA-2 torso harness integrates the
air crewman's
1 . lap belt and seat pan only
2. parachute harness and lap belt only
3. parachute harness, lap belt, and
shoulder harness
4. lap and shoulder harness only
The MA-2 torso harness, when worn, is
closed together by
1 . velcro tape
2. zipper (slide fastener), hooks and
eyes
3 . snaps
4. snaps and hooks
How many adjustment points are on the
MA-2 torso harness?
1 . One
2. Two
3 . Three
4. Five
Where is the gated D-ring attached to
the MA-2 torso harness?
1 . Both right and left shoulder
2. Left shoulder
3. Right shoulder
4. Cross connector strap
To improve comfort while wearing the
MA-2 torso harness in warm weather, you
should
1 . cut away all nylon fabric from the
torso
2. wear light clothing under the torso
3. cut away all non-structural fabric
At whose discretion can an MA-2 torso
be modified to a cut-away?
1 . The aircrewman
2* The PR
3. The operations officer
4. The commanding officer
If, after selecting the proper size
torso harness, you find that the air-
crewman requires a smaller size than
the extra small, what action must be
taken?
1 . The aircrewman will have to quit
flying
2. The aircrewman will have to fly with
the extra small
3. A custom-made torso must be made
4. The aircrewman will have to fly helos
only
5-55. With whom would you consult to determine
if a custom made torso harness is
necessary?
1 . Senior PR
2. Physiology unit
3. AIMD Para Loft
4. Any of the above
5-56. When fitting the MA-2 torso harness the
ideal location for the male Koch fittings
should be
1 . in the hollow below the collar bone
standing
2. in the hollow below the collar bone
sitting
3. in the hollow below the collar bone
standing and sitting
4. 2 inches below the collar bone
5-57. When you are fitting the MA-2 torso
harness, the chest strap must not cross
the torso above the armpit or below the
breast of the female aircrewman.
5-58. When the aircrewman is suspended a few
inches above the desk using a riser
assembly the cross connector strap
should be how long?
1 . 12 inches
2. 14 inches
3. 18 inches
4. 20 inches
5-59. When you make the lap belt and shoulder
harness adjustment, the aircrewman must
be
1 . seated in an ejection seat
2. seated in the shop
3. standing
4. in any of the above positions
5-60. How many types of inspections are
performed on the MA-2 torso harness?
1 . One
2. Two
3. Three
4. Four
5-61 . The pref light inspection is performed
before each flight and at intervals not
exceeding
1 . 2 weeks between inspections
2. 10 days between inspections
3. 30 days between inspections
4. 91 days between inspections
5-62. The calendar inspection must be done how
often?
1 . Once a month
2. Every 182 days
3. Every 60 days
4. Each time the aircrewman 's protective
equipment is checked
22
5-63. What is the service life of the MA-2 5-65.
torso harness?
1 . 12 years from the date placed into
service
2. 10 years from the date placed into
service
3. 8 years from the date placed into
service 5-66.
4. 5 years from the date placed into
5-64. The date of manufacture of a torso
harness can be found on the
1 . inside of the right front leg strap
2. inside of the left front leg strap
3. cross connector strap
4. center of the back strap
Where can you find the placed-in-service
date on a torso harness?
1 . On the left leg strap
2. On the right leg strap
3. In the center of the lap belt strap
4. In the center of the back strap
Which of the following manuals covers
the MA-2 torso harness?
1. NAVAIR 13-1-6.1
2. NAVAIR 13-1-6.2
3. NAVAIR 13-1-6.3
4. NAVAIR 13-1-6.4
23
Assignment 6
Protective Helmets, Oxygen Masks, Survival Items and Radios
Text: Pages 9-1 through 11-3
6-7.
Learning Objective: Inspect,
maintain, and fit protective
helmets for aircrewmen.
6-1. Which of these factors will determine if
an aircrewman will be required to wear a
protective helmet?
1 . Designation of the aircraft
2. NAVAIR 13-1-6.7
3. OPNAV 4790. 2B
4. OPNAV 11-1 00-2
6-2. How many different configurations can be
made from the basic PRK-37/P helmet shell?
1. 3
2. 12
3. 14
4. 15
6-3. Which of the following helmets would you
use in an A-6 Target Range Acquisition
Multisensor (TRAM) aircraft?
1 . APH-6A
2. APH 5
3. APH-5
4. HGU-43/P
6-4. What helmet would be used as an interim
backup for the HGU-33/P?
1 . HGU 4/P
2. HGU 2/P
3. HGU 34/P
4. HGU 13-1
6-5. what helmet would you use if you were
going to fly in an AV 10 requiring the use
of an oxygen mask?
1 . HGU 32 A/P
2. HGU 45 A/P
3. HGU 49 A/P
4. HGU 57 A/P
6-6. How many sizes does the PRK 40/P helmet
shell liner assembly come in?
1. 1
2. 2
3. 3
4. 4
6-8.
6-9.
How thick is the polystyrene foam liner on
the PRK 40/P?
1. 1/2 inch
2. 3/4 inch
3. 1 inch
4. 1 1/4 inch
Which of the following microphones is a
boom mike?
1. AN/BMC-1
2. M-87/AIC
3. AN/BMC- 2
4. M-69/ATC
How many sizes of PRK-37/P helmet shells
are available?
1. 1
2. 2
3. 3
4. 4
6-10. When selecting a proper helmet shell, you
must first measure the
1 . diameter of the head
2. radius of the head
3. circumference of the head
6-11. Who is responsible for cleaning the
pilot's protective helmet?
1 . The aircrewman
2. The PR
3. The AME
4. The plane captain
6-12. How often is the fixed wing helmet
subjected to a calendar inspection?
1 . Every 61 days
2. Every 91 days
3. Every 182 days
4. Every 225 days
6-13. How often must the chin strap be replaced?
1 . Every 60 days
2. Every 90 days
3. Every 180 days
4. Every 225 days
24
I
6-14,
How often should the entire helmet be
cleaned?
1 . Every 60 days
2. Every 91 days
3. Every 1 80 days
4. Every 182 days
6-15.
be
With what should the visor lens
cleaned?
1 . Glass Plus
2. Windex
3. Mild soap and water
4. Any of the above
6-16. When applying reflective tape, what
percent of the helmet must you cover?
1. 40%
2. 50%
3. 80%
4. 100%
6-17. What are the two best colors of reflective
tape you can use on the helmet?
1. Orange and white
2. Blue and white
3. White and red
6-18. To apply reflective tape it is recommended
that you heat the tape and the helmet to
1. 100 F
2. 90 F
3. 80 F
4. 70 F
6-19. Which of the following helmets would you
issue an aircrewman who is flying in a
helicopter?
1 . HGU-34A/P
2. SPH-3B
3. HGU-43A/P
4. APH-5
6-20. How many sizes does the SPH 3R helmet come
in?
1 . Two
2. Three
3. Four
4. Six
6-21. How many sizes does the sizing liner come
in?
1 . One
2. Two
3. Three
4 . Four
6-22. The oxygen mask should be issued to the
pilot and it should remain his personal
equipment.
6-23. Who is responsible for cleaning the
mask? ^
1 . The PR
2. The aircrewman
3. The plane captain
4. Any of the above
6-24. The MBU-1 2/P oxygen mask is designed to
work at what depth of water?
1. 9 ft
2. 12 ft
3. 14 ft
4. 16 ft
6-25. How many different configurations can be
made from the MBU-1 2/P 2 mask?
1 . Four
2. Five
3. Six
4. Seven
6-26. Where can you find maintenance procedures
for the MBU-1 2/P 2 mask?
1 . NAVAIR 13-1-6.2
2. NAVAIR 13-1-6.5
3. NAVAIR 13-1-6.4
4. NAVAIR 13-1-6.7
6-27. When you insert the bayonet into the
receiver mechanism the first click you
will hear will be
1 . the safety lock
2. the locking point for adjustments
3. the bayonet entering the locking
mechanism.
4. a loose connector
6-28. The second click will be the
1 . first locking position
2. safety locking position
3. adjusting locking position
4. final locking position
6-29. The third click will be
1 . a defective coupling
2. the safety locking position
3. the adjusting locking position
4. the second locking position
6-30. The receiver assembly can rotate
degrees to allow it to be adjusted.
1 . 14
2. 15
3. 45
4. 180
6-31 . When adjusting the straps on the bayonets
you should tack them in place with
1 . two turns of "E" thread
2. one turn of "E" thread
3. two turns of "A" thread
4. one turn of "FF" thread
25
6-32. When making adjustments to the oxygen
mask, you should have the bayonet fittings
in which of the following disks?
1 . First
2 * Second
3. Third
4. Fourth
6-33. If leakage occurs around the mask and
you are using the proper size, you can
stop the leak by
1 . applying a leak seal
2. adjusting the bayonet receivers
3. applying a laminar seal
4. selecting a new mask
6-34. The preferred solution for cleaning the
oxygen mask is a mixture of 1/4 to 1 /2
ounce of cleaning compound added to
1 . one pint of water
2. two gallons of water
3* one gallon of water
4. 1/2 gallon of water
6-35. Calendar inspections are conducted by
"0" level maintenance activities once
every
1 . 30 days
2. 60 days
3. 90 days
4. 180 days
6-36. To clean the inhalation/exhalation valve
you should use
1 . benzalkonium chloride and distilled
water
2. distilled water
3. alcohol
4. Listerine
Learning Objective: Inspect
maintain, and advise aircrew
members on the use of survival
items.
6-37. Survival items may be carried in which of
the following places?
1 . Liferaf ts
2. Droppable kits
3. In the pockets of the aircrewman
4. All of the above
6-38. Which of the following manuals covers
survival items?
1 . NAVAIR 13-1-6.5
2. NAVAIR 13-1-6.1
3. NAVAIR 13-1-6.2
4. NAVAIR 13-1-6.4
6-39. The dye marker, when exposed to water,
will appear as which of the following
colors?
1 . Orange
2. Green
3. Either 1 or 2
4. Red
6-40. It takes approximately how long to exhaust
a dye marker?
1 . 20 to 30 minutes
2. 1 to 15 minutes
3. 5 to 30 minutes
4. 1 hour
6-41. How long will the dye remain a good
target?
1 . 30 minutes
2. 45 minutes
3. 1 hour
4. 2 hours
6-42. The dye marker, when exposed to water, can
be seen how far from an altitude of 3,000
feet?
1 . 2 miles
2. 5 miles
3. 7 miles
4. 1 miles
6-43. The signaling mirror will produce a light
the equivalent of how many candlepower?
1. 2,000,000
2. 1 ,000,000
3. 8,000,000
4. 100,000
6-44. On a bright sunny day the light from a
signal mirror can be seen how far?
1. 50 miles
2. 40 miles
3. 25 miles
4. 30 miles
6-45. The MK-79 Mod O Signal Kit comes supplied
with how many cartridges?
1 . 5
2. 6
3. 7
4. 12
6-46. When fired, each cartridge flare has a
minimum duration of
1.3 seconds
2. 2 seconds
3. 4 1/2 seconds
4. 5 seconds
6-47. When launched, the cartridge will reach
up to
1. 200 feet
2. 300 feet
3. 400 feet
4. 500 feet
26
6-48. The MK 13 Mod Signal Flare will burn
for approximately how long?
1 . 1 minute
2. 30 seconds
3* 40 seconds
4* 20 seconds
6-49. Any MK 13 Mod O Signal Flare manufactured
before which of the following dates must
be removed from service?
1. 1960
2. 1965
3. 1970
4. 1975
6-50. Which of the following lights is commonly
called a strobe light?
1 . STL-73E
2. LT-65
3. SL-5/E
4. SDU-5/E
6-51 . The SDU-5/E light requires an inspection
every
1 . 30 days
2. 60 days
3. 91 days
6-52. The SDU-5/E light is required to make how
many flashes every 2 minutes?
1 . 50 H^ 10
2. 40 -f 10
3. 30 +_ 10
4. 35
6-53. The SRU-31/P is supplied in how many
parts?
1 . 1
2. 2
3. 3
4. 4
6-54. Whenever you inspect the SRU-31/P, the
rations must be removed after
1 . 2 years from the manufacturing date
2. 5 1/2 years from the manufacturinq
date
3. 7 years from the manufacturing date
4. 6 1/2 years from the manufacturinq
date
6-55. A emergency drinking water can contains
how much water?
1 . 6 ounces
2. 10 ounces
3. 8 ounces
4. 12 ounces
6-56. When you perform a slap test on a can of
water you will hear a
1 . gurgle
2. muffled click
3. thud
4. sharp metallic click
Learning Objective: Test
and maintain survival radios.
6-57. How many modes of operation does the
AN/PRC-63 radio set have?
1. One
2. Two
3. Three
4. Four
6-58. Which of the following modes of operation
is NOT used in the operation of
AN/PRC-63?
1 . Beacon
2. Voice transmission
3. Voice reception
4. Automatic S.O.S.
6-59. What feature of the AN/PRC-63 radio will
let the air crewman know that his radio is
putting out a signal?
1 . A beacon confidence tone
2. A red light
3. A green light
4. A yellow light
6-60. The AN/PRC-63 radio has a voice
communications range up to
1 . 10 miles
2. 25 miles
3. 50 miles
4. 1 00 miles
6-61. A search aircraft flying at 10,000 feet
can locate a transmitting beacon up to
what distance?
1 . 25 miles
2. 70 miles
3. 80 miles
4. 1 20 miles
6-62. When tested, the lanyard attached to the
deployment device on the AN/PRC-63 radio
must withstand a pull of
1. 20 Ibs
2. 25 Ibs
3. 50 Ibs
4. 100 Ibs
6-63. When talking into the AN/PRG-63 radio the
radio must be held
1 . next to the lips and at a 45 angle
2. 2 inches form the lips at a 45 angle
3. next to the lips and upright
4. 1 to 2 inches from the lips and upright
27
increase the receiving sound on your 6-66. Before testing a radio, one step you must
/PRC-63 you would turn the perform is to
volume control clockwise 1 . inform flight operations that you are
volume counterclockwise testing
beacon selector to "loud" 2. test the battery separately
beacon selector to "loudest" 3. check the service life of the radio
ich of the following units is used to
st the operation of the AN/PRC-63?
AN/PRC-63T
AN/PRC-36T
AN/PRC-90
AN/PRM-32
28
Assignment 7
Survival Radio Inspections, Helicopter Rescue Equipment and Carbon Dioxide
Text: Pages 11-3 through 13-5
Learning Objective: Conduct
routine inspections of survival
radios*
7-1 . Who is responsible for the pref light
inspection on the survival radio?
1 . The PR
2. The AT
3. The air crewman
4. The plane captain "*
7-2. The 90 day inspection on survival radios
is performed by
1 . PRs
2. ATs
3. plane captains
4. aircrewmen
7-3. At what level of maintenance and by whom
is the 180 day inspection performed?
1. Organizational level, avionics rating
2. Intermediate level, avionics rating
3. Organizational level, PR rating
4. Intermediate level, PR rating
7-4. Where would you find information outlined
to perform the 180 day inspection on an
AN/PRC-90 radio?
1 . NAVAIR 13-1-6.7
2. NAVAIR 13-1-6.4
3. NAVAIR 16-30PRC-90-2
4. NAVAIR 16-3-PRC-63-1
7-5. When the AN/PRC-90 radio is operating in
a high temperature area, how often
should the Mallory battery be inspected?
1 . Every 1 days
2. Every 20 days
3. Every 30 days
4. Every 90 days
7-6. What is the shelf /service life of a
battery used in the AN/PRC-90 radio?
1.12 months from the date of manufacture
2. 24 months from the date of manufacture
3. 24 months from the date placed in
service
4. 36 months from the date of manufacture
7-7. Under ideal conditions, what is the voice
range of the AN/PRC-90 radio?
1 . 60 nautical miles
2. 75 nautical miles
3. 1 00 nautical miles
4. 250 nautical miles
7-8. The tone (code signal) on the AN/PRC-90
radio has a range of
1 . 50 nautical miles
2. 80 nautical miles
3. 90 nautical miles
4. 100 nautical miles
7-9. The shelf life of a battery is based on
storage temperature. What is this
temperature assumed to be?
1. 40 F
2. 50 F
3. 60 F
4. 70 F
Learning Objective: Identify
specifications and performance
capabailities of survival radios.
7-10. To place the AN/PRC-90 radio on a guard
channel .beacon operation, you would set
the function switch to
1. NBC 243.0
2. BCN 243.0
3. ABC 252.2
7-11. Which of the followingrradios is strictly
a beacon radio set?
1. AN/PRC-32
2. AN/PRC-63
3. AN/PRC-17
4. AN/URT 3 3- A
29
7-12. What is the storage life of a battery
used in the AN URT-33A?
1 24 months at 70 F from date of
manufacture
2. 24 months at 90 F from date of
manufacture
3. 36 months at 70 F from date of
manufacture
4. 36 months at 90 F from date of
manufacture
7-13. When the AN/PRT-5 is properly activated
it will send out signals on which of the
following frequencies?
1. 83*64 MHz
2. 8.364 MHz
3. 243.0 MHz
4. 8.364 and 243.0 MHz
7-14. At 77 F the battery pack for the
AN/PRT-5 is designed to give continuous
operation with at least 250 milliwatts
output for
1 . 72 hours
2. 60 hours
3. 48 hours
4. 24 hours
7-15. Which of the following radios has a
floatation collar?
1 . AN/PRC-63
2. AN/PRC-33
3. AN/PRT-5
4. AN/PRT-90
Learning Objective: Identify the
construction and characteristics of
helicopter rescue equipment such as
the survivor's sling and rescue seat.
7-16. For information on search and rescue
procedures you would refer to what
publication?
1 . NAVAIR 13-1-6.1
2. NAVAIR 13-1-6.2
3. NWP 37-1
4. OPNAV 4790.2
7-17. A survivor should never reach for a
rescue device until it has touched the
ground or water, because
1 . the device has to slow down
2. the device has to be grounded to
prevent electrical shock
3. this ensures the device will not
release unexpectedly
7-18. The survivor's sling is constructed with
1 . kapok filling
2. foam rubber filling
3. styrofoam filling
7-19. What color (s) is/are the survivor's sling?
1. Red
2. Orange
3. Yellow
4. Red and white
7-20. The rescue sling will carry how many
survivors at one time?
1 . One
2. Two
3. One survivor and a swimmer
7-21 . The calendar inspection is performed at
intervals not to exceed how many days?
1 . 60
2. 90
3. 120
4. 225
7-22. A preflight inspection must be performed
at least every
1. day
2. 7 days
3. 10 days
4. 14 days
7-23. When testing the survivor's sling on a
webbing tester, what load is placed on
the webbing?
1. 500 Ib
2. 600 Ib
3. 800 Ib
4. 1,000 Ib
7-24. The rescue seat has how many prongs and
how many degrees are they apart?
1. 2, 180
2. 3, 120
3. 4, 90
7-25,
The rescue seat's calendar inspection
shall be conducted every
1 . 30 days
2. 60 days
3. 182 days
4. 225 days
Learning Objective: Identify the
operational characteristics of the
forest penetrator and rescue net.
7-26. The forest penetrator is a compact device
weighing about
1 . 101/2 pounds
2. 12 pounds
3. 21 1/2 pounds
4. 25 pounds
30
7-27. The safety straps that hold the survivor
in place on the forest penetrator are how
long?
1. 4 feet 9 1/4 inches
2. 5 feet 6 inches
3. 6 feet
4. 9 feet
7-28. With the flotation collar installed, the
forest penetrator will float with its top
how far above the water?
1 . 2 inches
2. 4 inches
3. 6 inches
4. 8 inches
7-29. The forest penetrator is designed to
accommodate how many survivors at one
time?
1 . One
2. Two
3. Three
4. Four
7-30. All forest penetrators are subjected to a
calendar inspection every
1 . 60 days
2. 91 days
3. 182 days
4. 225 days
7-31 . The rescue net weighs approximately how
many pounds?
1 . 10 pounds
2. 12 pounds
3. 15 pounds
4. 20 pounds
7-32. The sea anchor used to stabilize the
rescue net has a retaining line that is
how long?
1 . 10 feet
2. 12 feet
3. 15 feet
4. 25 feet
7-33. During moderate seas the sea anchor should
be attached to the rescue net so that it
will extend
1 . 5 feet
2. 10 feet
3. 15 feet
4. 20 feet
Learning Objective: Conduct periodic
inspections and tests of rescue harnesses,
rescue hooks, and cable cutters.
7-34. The rescue harness shall be calendar-
inspected every
1 . 60 days
2. 91 days
3. 182 days
4. 225 days
7-35. The service life of the rescue harness
shall be 7 years from the date placed into
service but not to extend beyond
1 . 8 years from date of manufacture
2. 9 years from date of manufacture
3. 11 years from date of manufacture
4. 12 years from date of manufacture
7-36. If a service date cannot be determined,
the rescue harness must be removed from
service
1 . 5 years from the date of manufacture
2. 7 years from the date of manufacture
3. 8 years from the date of manufacture
4. 12 years from the date of manufacture
7-37. When you are cleaning the rescue harness,
the water must not exceed
1 . 90 F
2. 100 F
3. 120 F
4. 150 F
7-38. The large rescue hook will support how
much weight?
1 . 1 ,500 pounds
2. 2,000 pounds
3. 2,500 pounds
4. 3,000 pounds
7-39. The smaller hook will support
1 . 500 pounds
2. 700 pounds
3. 800 pounds
4. 1 ,000 pounds
7-40. The ring will support
1 . 500 pounds
2. 1 ,000 pounds
3. 1 ,500 pounds
4. 2,000 pounds
7-41. The cable grip will support how many
pounds?
1 . 1 ,000 pounds
2. 1 ,500 pounds
3. 2,000 pounds
4. 2,500 pounds
31
7-42. The pneumatic rescue hand tool can cut
stainless steel cable up to
1. 1/8 inch in diameter
2. 1/4 inch in diameter
3. 5/8 inch in diameter
4* 7/32 inch in diameter
2 pressure
7-50. Depending on pressure and temperature ,
CC>2 can have how many forms?
1* 1
2. 2
3. 3
4. 4
7-51 . Dry ice has a temperature of minus
1. 32 F
2. 95 F
3. 85 F
4. 110 F
-est, the hand
oe between
.ne ^performance test, a hand tool
ible to cut how many cuts of double
i
2.
3.
4.
I U CUtS
15 cuts
17 cuts
25 cuts
Learning Objective: Inspect
and recharge C0 2 cylinders
7-46. What color is C0 2 ?
1 . Light green
2. Colorless
3. Dark blue
4. Light pink
7-47. A standard supply cylinder will hold
1 . 1 5 Ibs of C0 2
2. 25 Ibs of C0 2
3. 50 Ibs of C0 2
4. 1 00 Ibs of C0 2
7-48. C0 2 gas is how many times heavier than
air?
1. 1 .53
2. 2.00
3. 1 .00
4. 1 .75
7-49. At a temperature of 88 F, C0 2 gas can be
converted to a liquid form by applying a
pressure of
1 . 400 psi
2. 500 psi
3. 600 psi
4. 700 psi
7-52. What effect on the body does 3% of CO 2 in
the atmosphere have?
1 . Causes panting
2. Causes blurred vision
3. Causes unconsciousness
4. Doubles breathing effort
7-53. What effect would 5% have?
1 . Causes panting
2. Causes hard breathing
3. Causes unconsciousness
4. Causes distorted vision
7-54. A C0 2 recharge unit will pump C0 2 in what
form?
1 . Liquid and gas
2. Liquid state only
3. Gas only
4. Only gas at a temperature of minus
110 F
7-55. A standard C0 2 supply cylinder will
contain approximately
1 . 38 pounds of liquid and 1 2 pounds of
gas
2. 40 pounds of liquid and 10 pounds of
gas
3. 45 pounds of liquid and 5 pounds of
gas
4. 50 pounds of liquid
7-56. It is recommended to invert the
CO 2 cylinder when recharging it because
1 . this will prevent the opening from
icing
2. it will remain cooler, allowing it to
fill faster
3. this allows the syphon to accept the
gas
7-57. What color are CO 2 cylinders painted?
1. Yellow
2. White
3. Green
4. Gray
7-58. All markings on C0 2 cylinders shall be
what color?
1 . Gray
2. White
3. Yellow
4. Black
32
7-59. A CO 2 cylinder that has a dent exceeding
1/16 inch in depth shall be
1 . rejected and returned to supply
2. used as is
3. repaired by the "0" level
4. used until the hydrostatic date
expires
7-60. A CO2 cylinder with a corrosion pit that
measures 1/32 of an inch should be
1 . repaired at the "0" level and
recharged
2. condemned and returned to supply
3. recharged and returned to RFI
4. returned to the manufacturer
7-61 . A hydrostatic test on a C0 2 supply
cylinder is good for
1 . 3 years
2. 5 years
3. 7 years
4. 10 years
7-62. Which of the following C0 2 cylinders does
NOT reguire a hydrostatic test?
1 . A cylinder that measures less than 2
inches outside diameter and less than
2 feet long
2. A cylinder that is more than 4 feet
long
3. A cylinder that is 4 inches in outside
diameter
7-63. All markings on CO 2 cylinders must be
painted black and the lettering must be
1.1/8 of an inch high
2. 1/16 of an inch high
3. 1/4 of an inch high
4. 1/2 of an inch high
7-64. To record the weight on a C0 2 cylinder
you must use a scale that reads in
1. 1/100 pound graduations
2. 1/1000 pound graduations
3. 1/100 ounce graduations
4. 1/1000 ounce graduations
7-65. What is the TARE weight of a C0 2
cylinder?
1 . Snpty weight with the valve and cable
assembly
2. Empty weight of just the cylinder
3. Full weight of just the cylinder
4. Full weight of the cylinder with the
valve and cable assembly
7-66. What is the weight of a CO 2 charge for an
LR-1 liferaft cylinder?
1. 0.25 Ibs
2. 0.50 Ibs
3. 0.75 Ibs
4. 1.00 Ibs
7-67. If the cylinder being recharged ceases to
gain weight, one of the reasons may be
the pressure in the supply cylinder is
below
1. 20 Ibs
2. 15 Ibs
3. 10 Ibs
Learning Objective: Maintain
the C0 2 transfer pump.
7-68. How often should the oil be checked in
the C0 2 transfer pump?
1 . Monthly
2. Daily
3. Weekly
4. Biweekly
7-69. How often should the idler shaft be
lubricated?
1 . Every 6 months
2. Once a month
3. Weekly
4. Biweekly
7-70. What lubricant should be used on the
irller shaft?
1 . Heavy cup grease
2. 1 0-10 oil
3. SAE 30 oil
4. Light cup grease
7-71 . The piston rod should be lubricated with
1 . SAE 40 oil
2. light cup grease
3. heavy cup grease
4. Vaseline
7-72. How often should the crankcase be drained
of oil?
1 . Every year
2. Every two years
3. Every three years
4. Every four years
33
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35
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Aircrew Survival
NAVEDTRA 10328-1
& 2, Volume 1
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Aircrew Survival Equipmentman 3 & 2, Volume 1
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Aircrew Survival Equipmentman 3 & 2, Volume 1
NAVEDTRA 10328-1
List Pint
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41
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43
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Aircrew Survival Equipmentman 3 & 2, Volume 1
NAVEDTRA 10328-1
AHHRESS
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Aircrew Survival Equipmentman 3 & 2, Volume 1
NAVEDTRA 10328-1
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NAMF
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Aircrew Survival Equipmentman 3 & 2, Volume 1
NAVEDTRA 10328-1
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Aircrew Survival Equipmentman 3 & 2, Volume 1
NAVEDTRA 10328-1
AnnRFSS
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51
PRINT OR TYPE
Aircrew Survival Equipmentman 3 & 2, Volume 1
NAVEDTRA 10328-1
NAME-
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Middle Street/Shlp/Unit/DivWon, etc.
'City or PP6
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53
PRINT OR TYPE
NAMF
Aircrew Survival Equipmentman 3 & 2, Volume 1
NAVEDTRA 10328-1
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Lut Pint
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