asfat · maintenance, sustainment and training areas with a solution partner approach, via aiming...

CONTENTS

ABOUT US 4

1st MAIN MAINTENANCE

FACTORY DIRECTORATE 5

2ND MAIN MAINTENANCE


4TH MAIN MAINTENANCE










ELECTRO-OPTICAL SYSTEMS MAIN

MAINTENANCE FACTORY DIRECTORATE 102

MINISTRY OF NATIONAL DEFENCE GENERAL

DIRECTORATE OF NAVAL SHIPYARDS 112

1st AIR MAINTENANCE


2ND AIR MAINTENANCE


3RD AIR MAINTENANCE


Army Sewing & Tailoring

WORKShops Directorate 191

NAVY Sewing & Tailoring


AIR Sewing & Tailoring


MOD PHARMACEUTICAL

PRODUCTION PLANT 203

ASFAT Inc., a fully government owned entity, was established on 12 January 2018 under the Ministry of National Defence in accordance with the supplementary article #12 enacted for Act#1325.

ASFAT Inc. utilizes over 30 years of experience in manufacturing, modernization, repair, maintenance and sustainment of 27 military factories and 3 naval shipyards with the qualified and expert labour force.

While performing its functions, ASFAT Inc. aims to improve operational excellence by developing facilities, capabilities and capacities of military factories and shipyards.

Being entitled to sign “Government-to-Government Agreements”, ASFAT Inc. plays an effective role to ease export processes of defence industry products.

It offers and provides innovative solutions to friendly and allied nations in design, manufacture, maintenance, sustainment and training areas with a solution partner approach, via aiming the launching of lifecycle management fundamentals with the synergy created by public-private partnership.

Thanks to the dynamism brought by its efficient organization and competent staff with international experience, ASFAT Inc. aims to contribute to the development of Turkish defence industry and thus export volume in the abovementioned core activities.

ABOUT US

MAIN MAINTENANCE

FACTORY DIRECTORATE

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1st MAIN MAINTENANCE FACTORY DIRECTORATE

MILITARY FACTORY AND SHIPYARD MANAGEMENT INC.

TECHNICAL FEATURES

GENERALCombat Weight : 47 tonsLength : 12 mWidth : 3.4 mHeight : 3.43 mCrew : 5Fire Control : AutomaticAmmunition Loading : AutomaticNight Vision : AvailableNBC Protection : Available

FIRE SYSTEMBarrel Diameter / Caliber : 155 mm, 52 cal.Fire Rate Burst Fire : 3 rounds/15 sec. Intense Fire : 6-8 rounds/3 min. Sustained Fire : 2 rounds/min.Barrel Movement Elevation : -2.5/700 Traverse : 3600Fire Range M107(HE) : 18 km M549A1/RAP(HE) : 30 km ERFB/BB(HE) : 40 +km

MOVEMENT CAPABILITYMax. Speed : 65 km/hGround Clearence : 0.42 mGradient : 60%Vertical Obstacle : 0.75 mTrench Crossing : 2.8 mFording : 1.5 mCruise Range : 360 – 400 km

POWER PACKEngine : 1000BG, MTU 881Transmission : x1100-5A3 (Automatic)

Power/Weight Ratio : 21 HP/tons

T-155 SP FIRTINA HOWITZER

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POYRAZ AMMUNITION RESUPPLY VEHICLE

TECHNICAL FEATURES

GENERALCombat Weight : 50 tons Crew : 3Length : 10.2 mWidth : 3.40 mHeight : 3.49 mNBC Protection : AvailableFuel Transfer System : Available

PERFORMANCEEngine : 750 BG (AVDS 1790)Transmission : CD 850 (Allison) Max. Speed : 50 km/hCruise Range : 360 kmPower/Weigth Ratio : 16 HP/tonsProjectile Storage : 96Charge Storage : 96Load/Transfer Speed : <20 dk (48 projectile) Projectile Transfer : AutomaticCharge Transfer : Semi Automatic

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OPTICAL DESIGN

Zoom : 7xObjective Diameter : 50 mmField of View : 7°30‘Field of View (1000 m) : 131 mImage Output Diameter : 7.14 mmLength : 186 mmWidth : 205 mmWeight : 1,25 kg

* Laser Filter (Optional)* Ergonomic Design* MultiLayer Coating (Transmitivity >99,5%)* Bak4 Prisms* Waterproof, N2 gas filled* Proper for Military Standards* Reticle (Optional)* Rubber coated body

TECHNICAL FEATURES

7x50 T 10 A2 BINOCULARS

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OPTICAL DESIGN

Model : T20A1Zoom : 20xObjective diameter : 120 mmField of View angle : 30 Body : AluminumTelescope Weight : 10,8 kgTripod Weight : 7,1 kg

* Available to mounting laser distance measurement aparture * New design, robust under all-field conditions tripod* Newly-designed Image Transfer Unit enabling usage at the back of the barricade* Night Vision Goggles usage by new design adaptor* Proper to Military Standarts

TECHNICAL FEATURES

20x120 T20A1 TELESCOPE, IMAGE TRANSFER UNIT AND TRIPOD

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OPTICAL DESIGN

CANON/MORTAR OPTICAL AIMING REFERENCEUsed to Orient the barrel of howitzers, cannons and mortars to the target in the shortest period of time.Eliminates the disadvantages of using an aiming post such as;- Finding a suitable ground to mount the aiming post,- Communication break offs among the crew while mounting the aiming post,- Deterioration of light discipline due to the illumination of the aiming post

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ZP17CL GLASS PERISCOPE

RPG-7 OPTICAL SIGHT* Designed for OG7V to fire anti-personel ammunition to more than 500 m.

Mica GlassNatural Light Transmitivity : % 92 %99,2Periscope Transmitivity : % 50 % 66Average Lifetime : 2,5 years 25 yearsLaser Filter : Unavailable Available

OPTICAL DESIGN

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OPTICAL DESIGN

LENSES

RETICLE

PRISM

HEAD UP DISPLAY WINDOWS

Spherical, aspherical lenses in conformance with the MIL-0-13830 and ISO-10110 standards are designed and manufactured with various dimensions.

* Light Weapon Snipper Telescope Reticles* Heavy Weapon Telescope Reticles (having ballistic features),* Binoculars and Telescopes Reticles* Fire Control System Reticles for height and angle measurement* Reticle Design for Night Vision Systems

* Plan surfaces and prisms with various angle and geometry are designed and manufactured in conformance with ISO 10110 standard.

HUDs: transparent display that presents data on usual viewpoint windows for aircrafts

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TRACKS

T 401 TRACK

1st Main Maintenance Factory Directorate has the ability of design, static and dynamic analysis, qualification field tests and manufacture of any type of tracks for all tracked vehicles.

For 3D modelling design stage “Pro-Engineer” and for analysis stage “Ansys” and “Adams” softwares are used.

With the wide product range, there are several kind of tracks for the vehicles up to 70 tons which are on serial production.

Type of Track : T 401 Vehicle : Leopard1 - FırtınaQuantity for 1 Vehicle : 166 for Leopard1 186 for FırtınaPitch : 160 mm Width : 543 mm Shoe Weight : 25 kg.

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T 601 G TRACK

T 602 TRACK

Type of Track : T 601 G Vehicle : M – 60T MBT Quantity for 1 Vehicle : 150 Pitch : 188,5 mm Width : 635 mm Shoe Weight : 31,5 Kg.

Type of Track : T 602 Vehicle : Leopard2A4 MBTQuantity for 1 Vehicle : 164Pitch : 183,5 mmWidth : 635 mmShoe Weight : 34 kg.

TRACKS

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T 701 TRACK

T 201 G TRACK

Type of Track : T 701 Vehicle : Altay MBTQuantity for 1 Vehicle : 164 Pitch : 186 mm Width : 635 mm Shoe Weight : 34,7 kg.

Type of Track : T 201 G Vehicle : M 113 APCQuantity for 1 Vehicle : 125 Pitch : 154,2 mm Width : 365 mm Shoe Weight : 13 kg.

TRACKS

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SPROCKETS AND ROADWHEELS

SPROCKET

ROADWHEEL

Sprocket Type Vehicle

T 517A Sprocket M 48-M 60 MBTT 601 Sprocket M 60 MBTT 401 Sprocket LEOPARD / FIRTINA HowitzerT 301 Sprocket M44-M52 TT 201 Sprocket M113-APC

Roadwheel design, manufacturing and overhauling for tracked vehicles.

Sprocket design and manufacturing for tracked vehicles.

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RESIN CASTING SAND MANUFACTURING

TRACK STEEL PARTS MANUFACTURING* Shell molding casting for track bodies* Capacity of 3 vehicle track every day corresponding 105,000 track body production annually * Any kinds of connectors, pins, and sprockets for track manufacturing

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SPARE PARTS

* 7x50 Binoculars mechanical parts production* Various vehicles and weapon spare parts * Parts for overhauling and modernization of vehicles * Parts for tracks manufacturing * Injection molding, casting molding

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MODERNIZATION OF SELF-PROPELLED HOWITZER

* Cruise Range : 400 km.* Max. Speed : 60 km/h* Main Gun : 155 mm.* Assistant Gun : 12.7 mm. * Engine Power : 450 HP* Transmission : CD-500-4* Fire Range : 24-30 km

TECHNICAL FEATURES (M52T)(After Modernization)

M52T (1994-2001)

- Power pack and hull- Fire Control System- Turret and Barrel18

MODERNIZATIONPROCESS

M44T HOWITZER

After Modernization

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MODERNIZATION OF TANKS

- Power pack and hull- Fire Control System- Turret and Barrel- NBC kit installation

MODERNIZATIONPROCESS

MODERNIZATION VERSIONS

* Cruise Range : 499 km.* Max. Speed : 30 mph* Main Gun : 105 mm.* Assistant Gun : 12.7 mm ve 7.62 mm. * Night Vision : TTS* Stabillization : Available* Engine Power : 750 HP* Transmission : CD-850-6A

TECHNICAL FEATURES (M48 A5T2)(After Modernization)

M48 T5 (1982-1984)M48 A5T1 (1984-1987)M48 A5T2 (1987-1990)

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LEOPARD 1 A1/A4 TANK

ABILITIES AFTER MODERNIZATION OF LEOPARD 1T TANKS;

This project was launched to increase Leopard 1A1/A4 battle tank’s possibility of hit with the first shot, bringing in night vision and ability of hit on the move, which is avaible in the inventory of TAF. It is projected that the battle tank’s depot-level maintanence will be made synchronously. The battle tank was called Leopard 1T that will be taken to the inventory.

* Direct optical, TV and thermal view for marksman; thermal and TV view for battle tank commander* Stabilization of line-of-sight * Free from line-of-sight stabilised firing line,* Optical primary directing system,* Higher precision firing calculation by considering the meteorological data (air temperature, latheral wind, athmosphere pressure and the temperature of ammunation) from the sensors,* Possibility for correction data (gradient of the battle tank, parallax, barrel reference and barrel abrasion) input and using that data in the ballistic computation,* Possibility for automatical adjusment of initial lead and additional elevation angle for barrel without making the line-of-sight off the target,* Automatical target tracking ability,* Coordination at the battlefield by providing the data about own position and position of the target,

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ENGINE – TRANSMISSION OVERHAULING

ENGINE

TRANSMISSION AND FINAL DRIVE

* M48, M60 and LEOPARD Tank,* M88, LEOPARD and TAMAY Recovery Vehicle* M44T and M52T SP Howitzer,* MLRS * GTYAS, M44T and M52T SP Howitzer

* M48, M60 and LEOPARD Tank final drives* M88, TAMAY and LEOPARD Recovery Vehicle transmissions* M44T and M52T SP Howitzer transmissions * FAUN, MERCEDES and VOLAT Tank Transporters

MAIN MAINTENANCE

FACTORY DIRECTORATE

2 nd

26

2ND MAIN MAINTENANCE FACTORY DIRECTORATE


DEPOT LEVEL MAINTENANCE ANDMODIFICATION (DLM) ACTIVITIES

2nd Main Maintenance Factory Directorate provides high quality, reliable, sustainable products and services to the defence industry.

• Disassembly and Sanding • Maintenance & Repair• Parts preparation• Spare part manufacturing• Hull and Sub-system installation• Painting• Test and Control

TECHNOLOGICALAPPLICATIONS

PRODUCT RANGE

M60T TANK

M48 A5T1/T2 TANK

RAPC/ACV

M113 SERIES

TAMAY

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ENGINE DEPOT LEVELMAINTENANCE

Renewal activities for 4-stroke and 2-stroke diesel engines of tracked vehicles in Turkish Armed Forces inventory are executed.

• Grinding and hard chrome plating activities for crankshaft and camshaft trunnions by using the chemical method • Grinding and repair activities for crankshaft trunnions with surface crack by using special welding method • Cycliner cap grinding activities • Valve grinding activities • Fuel pump adjustments• Adjustments and controls for engine electrical equipments• Cyclinder sleeve placement activities• Cyclinder honing activity


PRODUCT RANGE

AVDS 1790 2C/2CA

DETROIT DIESEL 6V53 DETROIT DIESEL 6V53T

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TRANSMISSION DEPOTLEVEL MAINTENANCE

• Renewal of transmission body • Renewal of transmission side cover• Renewal of torque converter • Differential renewal activities• Brain renewal activities• Gear renewal (grinding, bush installation and processing)


PRODUCT RANGE

ALLISON CD 850-6A TRANSMISSION

ALLISON X200-4 TRANSMISSION ALLISON TX 100-1 TRANSMISSION

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TEST BENCH UNIT

Engine test unit parameters for the engine being tested:• Power• Oil temperature and oil pressure• Air suction pressure• Fuel pressure• Exhaust gas temperature• Exhaust pressure• Turbo pressure• Turbo air inlet temperature

Engine test unit parameters for the transmission being tested: • Power transmission• Oil temperature and oil pressure• Right and left movement capability• Gear shifting ranges


Performance tests are applied for the engines and transmission that are renewed.

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RENEWAL OF ELECTRIC - HYDRAULIC EQUIPMENTS

Maintenance, repair and renewal activities for hydraulic and electric systems of tracked vehicles are executed.

Hydraulic• Hydraulic Cyclinder• Hydraulic Pump• Hydraulic Engine• Servovalves• Pressure Check Valves• Direction Check Valves• Proportional Valves

Electric• Electric Distribution Boxes• Electric Cable Tree• Electric Engines• Illumination-Warning Lights• Indication Panels• Heating Systems• Fire Extinguishing Systems• Command – control panels• Power Control Systems

Hydraulic• Pressure Test• Leak Test• Flow Test• Torque Test• Round Test

Electric• Rupture-Short circuit control• Precise soldering• Relay Contact-Switch• Maintenance/Repair

PRODUCT RANGE

TECHNOLOGICAPPLICATIONS

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RENEWAL, MAINTENANCE, REPAIR AND MANUFACTURE OF FIRE CONTROL DEVICES

Day Vision Periscope• M17 • M37• M27 • M45• M26 • M24• M336 • Gepanzert 2A4 Driver Periscope • M13 • Gepanzert 2A4 Gunner Periscope

Conventional Optical MaterialsM19 PeriscopeM24 PeriscopeM36 Light ArrayM120T TelescopeM20T Modificated PeriscopeM28E2 Side Direction DeviceM10A6 Ballistic SystemM105 Light ArrayM36 Light Array

Lamination ActivityThiakol Filling ActivityPolyurethane Sticking ActivityPrecision solderingPeriscope Vision TestPeriscope Leak Test

PRODUCT RANGE TECHNOLOGIC APPLICATIONS

Maintenance, repair and renewal for tracked vehicles vision units are executed

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MANUFACTURE

Spare parts within its capability and especially spare parts of the tracked vehicles are manufactured.

It can process the tank hull and tower.Machined manufacture activities required for spare parts manufacture are performed on a CNC stand having 5 axis, automatic tool changing capability, and having turning table.

Mold and part manufacture is performed on CNC Wire Erosion stand.

After the machined activities of the tanks and other tracked vehicles are completed, measurements of their sub-parts such as hull and other bridge launching systems are automatically performed 3D Coordinate Measurement Stand.

TECHNOLOGIC APPLICATIONS

MACHINED / UNMACHINED MANUFACTURE

CNC Horizontal Processing Center

CNC Wire Erosion Bench

CNC Perpendicular Processing

CMM Three Dimension Coordinate Measurement Stand

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MANUFACTURE

• Material analysis of the casted products are performed. • Sand, serter and resin are automatically mix each other in the casting unit. One-time casting capacity of molding shop :• 300 kg cast iron• 300 kg steel casting• 300 kg spheroid casting• 80 kg aluminum casting• 300 kg brass casting• 300 kg bronze casting


CASTING ACTIVITIES

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MANUFACTURE

TIG Weld: the parts for which leaktigthness is important this welding method is applied with less temperature.

MIG Weld: It is a welding method which is used for welding the aluminum parts.

MAG: It is a welding method which is used for welding the steel parts.

Manual Arc Welding: It is the welding method which provides opportunity to work in open areas.

Shielded Carbon Electrode Welding: It is the welding method which is used for repair of crankshafts.

Resistance Weld: It is the welding method which is used to make point welding with spot weld.

Acetylene Welding: It is the welding method which is used to repair small cracks on the material.


WELDING ACTIVITIES

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COATING AND PAINTING ACTIVITIES

Hard Chrome PlatingParts (various engine parts, shafts etc.) which are rusted and lost its standard dimension because of usage are returned to their standard dimensions and made stronger.

Manganese Phosphate CoatingThis activity is performed in order to protect steel and steel-alloy materials against corrosion and to prepare the surface for paint.

Aluminum ChromatizingThis activity is performed in order to protect aluminum parts against corrosion and to make preparations for painting.

Zinc CoatingThis activity is performed in order to protect steel and stell-alloy parts against corrosion and provide a nice appearance.

Silver CoatingThis activity is performed to increase electricity conductivity of the parts by using electrolysis method.

• Heat-controlled painting booth is used for hull and component painting. • Primer and finishing concealment paint is applied to the vehicle bodies. • Static Painting

Normalisation AgingStress Elimination CementationHardening AnnealingTempering



HEAT TREATMENT PROCESSES

COATING ACTIVITIES

PAINTING ACTIVITIES

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Silicone Manufacture It is resistant against water.Neoprene Rubber (EU) preparation It has high electricity isolation capability.Back Rubber (SBR) Preparation It is impact resistant.Nitrile Rubber (NBR) Preparation It is resistant against fuel and oil.


PRODUCT RANGE

RUBBER MANUFACTURE

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COMMUNICATION SYSTEMS• Antenna and Plate• Helmet, Micro telephone, Speaker, Temperature Detection, Control Unit• Filter, Power Supply, Multiplier, Amplifier

ELECTROPTIC/ SENSOR GROUP• E/O Sensor, Approach sensor, LN 270 INS• Mast and Mast Control Unit• Sensor Control Unit, Control Lever, Oedometer, Navigation Unit

ENERGY SYSTEMS • Power Distribution Unit• Auxiliary Power Unit (APU Unit)• APU Remote Control Unit, Accumulator charging unit, Inverter

DEVELOPED SYSTEMS

FIRE SUPPORT AUTOMATION PROJECT (ADOP)

MODERNIZATION PROJECTS

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• Additional reactive armours for hull• Additional reactive armours for tower• Fire Control System• Stabilisation System• Sprocket and Track• Final Drive• Engine (1000BG)• Transmission• Tower ring gear• 120 mm Gun

DEVELOPED SYSTEMS M60T PROJECT

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• Machined manufacture activities for hull,• Welding activities for hull,• Modification of elements,• Launching system parts; -Launching arm -Commander cupola -Back stationary and moving arm manufacture -Support blade welded manufacture -Welded manufacture for fork -Launching system machined manufacture activities -Launching sub-system assembly• Hull and bridge system assembly,• Vehicle test

TECHNOLOGICAPPLICATIONS BRIDGE LAUNCHING TANK

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QUALITY MANAGEMENTACTIVITIES

• AQAP 2110 Industrial Quality Assurance Level Certificate • ISO 14001:2015, Environmental Management System Certificate• OHSAS 18001:2014, OHS Management System Certificate• EFQM Excellence Level 3 Stars

QUALITY MANAGEMENT DIRECTORATE LABORATORIES

Physic - Chemistry Laboratory• Measurement of element values in the iron, aluminium and copper based materials with Optic Emission Spectrometer • Pull strenght tests of metal materials with pull and push device (up to 25 tons)• Pull tests for Rubber – Plastic Materials • Spring pull and push tests with spring tension device • Surface roughness determination of metal materials • Rockwell Hardness Measurements of metal materials with hardness measurement device • C and S analysis of casts having carbon rate above %5• Age method analysis in the chemistry laboratory.

Oil Analysis Laboratory• Analysis for metal increase in the engine and transmission oils with spectrometer device• Water, smut, oxidation, fuel, anti-freeze and nitration values analysis in oil with FT-IR Device• Viscosity Values Anaysis of oil with Viscosity Device

Optical Emission Spectrometer

Pull – Push Device

Atomic Emission Spectrometer

Viscosimeter FT-IR Spectrometer Device

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CALIBRATION LABORATORY

2nd Main Maintenance Factory Directorate renders internationally-traceable calibration and control services for the units with its Mechanical and Electronic Calibration Laboratory.

Electrical – Electronical

• Multimeters, Anolog & Digital (up to 7 1/2 Digits)• Oscilloscope, Anolog & Digital (up to 600 MHz)• Spectrum Analyzer (up to 2 GHz)• Frequency meters (up to 2 GHz)• LCR Meters• Clamp Ammeters (up to AC & DC 450 A) • AC & DC Power Supplies

Frequencymeters

• Calibration of frequencymeters are performed.

• Values measured up to 2 GHz by frequencymeters according to T.O. can be calibrated.

Oscilloscopes

• Digital and anolog oscilloscope calibration is performed.

• Values measured up to 600 MHz by oscilloscopes according to T.O. can be calibrated.

Multimeters

• Digital and anolog multimeters calibration is performed.

• Values measured by multimeters according to T.O. can be calibrated.

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CALIBRATION LABORATORY

DIMENSIONAL

• Micrometers • Callipers• Surface gages • Comparator/Dial Indictors• Protractors• Water balances

FORCE• Torque (0-2000Lbft)

TEMPERATURE• Thermometers and heat indicators • Humidity meters

PRESSURE

• Pneumatic Manometers (0-1000 Bar)

• Oil-filled Manometers (0-1200 Bar)

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DRIVE TEST CAPABILITIES

Within the scope of maintenance,repair, renewal and modernization activities of our factory final inspection and test activities are performed for all tracked vehicles.

Following tests are performed for the tracked vehciles in the tank test areas numbered 1 and 2:

• Road test, Brake and Acceleration,• %60-%45 Slope test,• %30 Side slope test• Water crossing• Verticle Obstacle

• Trench Crossing • Sinusoidal Motion Test• Fire Control System Test• Stabilisation Test

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NON-DESTRUCTIVE INSPECTION TEST AND CAPABILITIES

NDI activities are executed in compliance with the contracts signed between 2nd Main Maintenance Factory Directorate and customers.Magnetic Particle Control: With 6000 Ampere AC, DC and HWDC (Half-Wave Directed Current) stand, crack controls of ferromagnetic materials up to diameter of 30 cm and length of 2 m are performed.Penetrant Control: Crack control of all kind of metal and non-metallic materials (except wood and sponge type) is performed.X-ray Control: With 300 KWP stand, crack control of steel materials up to width of 5 cm is per-formed.Ultrasonic Control: Crack control of sound permeable metal and non-metallic materials up to width of 1 m is performed.

Penetrant Control Magnetic Particle Control

Ultrasonic Control X-Ray Control

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CERTIFICATES

• EFQM Excellence Level 3 Stars• ISO 14001:2015 Environmental Management System Certificate• AQAP 2110 Industrial Quality Level Certificate • OHSAS 18001:2014 OHS Management System Certificate

MAIN MAINTENANCE

FACTORY DIRECTORATE

4 th

47

4th MAIN MAINTENANCE FACTORY DIRECTORATE


SURVEY ACTIVITIES

For weapons, communication, electronic and information systems requirements in its field, 4th Main Maintenance Factory Directorate conducts engineering services, plans, controls, carries out and follows all the projects executed in 4th Main Maintenance Factory Directorate, takes precautions to simplify the production, determines needs to support the ordnance newly entered to the inventory and prepares project offers.

• Preparing technical drawings of main materials, spare parts, apparatus and tools to be manufactured in compliance with principles and procedures determined according to standards.• Supply scouting for main materials, spare parts, apparatus and tools to be manufactured to determine manufacture method and preparation of information package

Mechanical part designs required for integration and development projects by using Computer Aided Design – CAD) software

• Planning, controlling and following all executed projects by system engineers.• Executing comprehensive engineering services to develop maintenance, repair and manufacture possibilities and capabilities related to their specialty

FORMING AN INFORMATION PACKAGE:

MECHANICAL DESIGN

ACTIVITIES WITH PROJECT

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• MPT-76 National Infantry Rifle Rack Design• Machine Gun Stand Work• 20mm Oerlikon integration to armoured pick-up vehicles (Not used weapons in the Navy Inventory are transferred to the Land Forces in order that they are used in operations)• Weapon system with stand (Weapons in the Air Force Inventory becoming useless because of F4 and F5 aircrafts’ becoming scrap are transferred to the Land Forces to be used• Surveillance System design for old generation Cobra• Energy Bag Design

SYSTEM FOLLOWED• Weapon Systems• Radar Systems• Electronic Systems• Electronic Warfare Systems• Mine Detector Systems

EPOXY PRIMER• It is used for polyurethane paints application. • It is produced in compliance with MIL-PRF-23377J standard.

POLYURETHANE PAINT• It is produced in the colors of grey, white, red, bright white, black and according to MIL-PRF-85285 standard.

DESIGN ACTIVITIES

SURVEY ACTIVITIES

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MANUFACTURE ACTIVITIES

4th Main Maintenance Factory Directorate performs design and manufacture activities for light weapons, communication, electronic and information systems in its responsibility field.

Furthermore military paints which are used for painting military vehicles, equipment and weapons are manufactured.

• Part modeling and design with computer-aided Design (CAD).• CNC machine processing program with computer-aided manufacture (CAM)• Forming aluminium, steel sheet materials in molds with the pressing machine• Plastic parts manufactured by injection method• Rubber paste is molded in the pressing machines in order to obtain finished goods• Mold and part manufacture in CNC wire and immersion erosion machines• Spring winding up to 2,5 mm wire diameter in CNC machine• Writing on metal with laser stand• Dimension measurement activities with computerised 3D laser.

MACHININGFor various spare parts and electronic materials of light weapons:• Processing in 5 axis-CNC machine• Manufacture with turning, milling, drilling, bending and grinding methods• Welding activities for aluminum and steel materials with tig, mig, electrode and oxygen welding machine

HEAT TREATMENT PROCESSES• Normalisation

• Stress Elimination• Hardening• Tempering• Aging• Cementation• Annealing

COATING PROCESSES• Hard Chrome• Black Chrome• Nickel Sulphamate• Zinc Coating• Black Oxide• Manganese Phosphate• Copper• Sulphuric Acid Anodized• Silver

OTHER PROCESSES• First product manufacture with 3D printer• Electro static powder and lac-dying• Sanding with steel ball

PAINT MANUFACTURE

IR PAINT • Concealment against night vision devices • Appropriate for MIL-C-46168D standard• Manufactured as polyurethane resin-based and binary component.• Brown 383,30051• Green 383,34094• Black 37030


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• Earth Yellow 33245,• Skin 686,33440• Aircraft 36300 coloured IR paints are pro-duced.

ADVANTAGES • Resistance against atmospheric conditions (aerospace)• Chemical strength (alkaline, acid)• Light sensitivity• 5 (five) year service life after application

LABORATORY TESTS• Appearance• Thickness degree• Viscosity• Application• Covering Strength• Drying• Coating Strength• Sticking• Flexibility• Brightness

EPOXY PRIMER• It is used for polyurethane paint application.• It is produced in compliance with MIL-PRF-23377J standards.

POLYURETHANE PAINT• Its colors are gray, white, red, bright white, black and produced in compliance with MIL-PRF-85285 standard.

MANUFACTURE ACTIVITIES

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QUALITY MANAGEMENT ACTIVITIES

4th Main Maintenance Factory Directorate gives priority for customer satisfaction and the system certificates it has as follows;• AQAP 2110 NATO Quality Assurance Requirements for Design, Development and Manufacture

PHYSIC, CHEMISTRY AND METAL LABORATORYPAINT/PAINT RAW MATERIAL ANALYSIS• Covering/Coating strength, Brightness, Vol-atile Material Amount, Viscosity determination with Brookfield and Kreps Devices, Touch/ Dryness/Dust collection determination, densi-ty, pH analysis etc.

COATING CHEMICALS AND SOLVENTSANALYSIS• Density, melting, boiling point determina-tion specified in the national and international standards, pH Analysis etc.

PROCESS CONTROL TEST AND ANALYSIS• Chemical Coating Analysis (Phosphate, Chrome, Nickel, Anodized, Rust elimination and oil elimination and activation bath)

METAL/PLASTIC ANALYSIS• Spark-OES, Elemental analysis of steel, alu-minum and copper alloys with Carbon-Sulphur Device • According to TS EN ISO 6507-1-2-3 and TS EN ISO 6508-1 hardness analysis with Rockwell Hardness device and Vickers Micro-hardness device • According to TS EN ISO 6892-1-2, tensile & rupture strength of metal materials with 20 kN Tensile - Rupture Test Device• According to TS ISO 37, tensile & rupture strength of plastic materials with 1kN tensile – rupture test device• Shore A Hardness Analysis of Plastic Materials with Durometer

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REPAIR ACTIVITIES

4th Main Maintenance Factory Directorate performs design and manufacture activities for light weapons and communication, electronic, information systems within its responsibility field.

FREQUENCY MOD. RADIO REPAIR SK2 RADIO FAMILY (1ST GENERATION)

• 4014 / 4018 VHF / UHF Handheld Radio• 4411 / 4415 VHF /UHF Handheld Radio• 4024 / 4028 VHF / UHF Vehicle Radio• 4034 / 4038 VHF / UHF Base Radio Station• 4841 / 4845 VHF / UHF Relay + SK Card

SK2 RADIO FAMILY (2ND GENERATION)

• 4711 / 4715 VHF / UHF Handheld Radio• 4721 / 4725 VHF / UHF Vehicle Radio• 4731 / 4733 VHF Base Radio Station• 4735 / 4737 UHF Base Radio Station• 4441 / 4445 VHF / UHF Repeating Radio• 4741 Repeating Radio• 4742 VHF Mobile Repeating Radio• 5712 Squad Radio• 4900 EHHAS Handheld Radio• VRC 9611 5 Watt Vehicle Radio• VRC 9612 50 Watt Vehicle Radio• VRC 9613 5+5 Watt Vehicle Radio• VRC 9614 5+50 Watt Vehicle Radio• VRC 9615 50+50 Watt Vehicle Radio• VRC 9621 5 Watt Armoured Vehicle Radio• VRC 9622 50 Watt Armoured Vehicle Radio• VRC 9623 5+5 Watt Armoured Vehicle Radio• VRC 9624 5+50 Watt Armoured Vehicle Radio• VRC 9625 50+50 Watt Armoured Vehicle Radio• 9661 V/UHF Software-based manpack radio/Vehicle and Base Radio Station• 9651 Software-based Handheld Radio

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REPAIR ACTIVITIES

AMPLITUDE MOD.RADIO REPAIR

• MARCONI ans HARRIS series radios• They are used as vehicle radio and base radio. They can provide safe ground wave and skywave communication. • 9661 HF software based manpack/vehicle and Base Radio Stations.

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REPAIR ACTIVITIES

REPAIR OF MULTI-CHANNEL COMMUNICATION SYSTEMS

It is a mobile communication system was designed domestically to meet the voice, data and video communication need of the TAF users from the battalion levels to the army levels

• PRC 5114 personal communication switchboard (225-400 Mhz.)• Aselsan GRC 5520 micro wave receiver transmitter• TASMUS G+ magn mobile subscriber input switchboard• E-VOıP 2121 safe voıp telephone• VRC 5101 mat/M radio mobile subscriber terminal M radio (225-400 Mhz.)• VRC 9661 M radio• TASMUS (Tactical Field Communication Systems) MAGN switch

55



LIGHT WEAPONRENEWAL ACTIVITIES

4th Main Maintenance Factory Directorate performs renewal of light weapons in its responsibility area. Renewal activities includes; examination of weapons by disassembly of all parts even the smallest ones, making the failured parts operable or replace them with the new, renewed or repaired ones and then re-assembling such parts and comparing with the new ones.

RENEWED WEAPONS

Infantry Rifles• 7,62 mm G3A3/G3A4 Rifle• 7,62 mm AK-47 Kalashnikov Rifle• 5,56 mm HK33 Rifle

Machine Guns• 7,62 mm MG3 Machine Gun• 7,62 mm PKMS (BİXİ) Machine Gun• 7,62 mm FN Machine Gun• 12,7 mm Anti-aircraft Machine Gun• (M2,M3,M85)

Bomb Launchers• 40 mm MK19 Bomb launcher• 40 mm T40 Bomb launcher• 40 mm Drum bomb launcher

Sniper Rifles• 7,62 mm Dragunov Kannas Sniper Rifle• 8,59 mm Accuracy Sniper Rifle

Mortars• 60 mm Mortar• 81 mm Mortar• 106 mm Mortar• 120 mm Mortar

Roket Launcher• 40 mm RPG7 Rocket Launcher• 107 mm multi launcher rocket system

Pistol and Machine Pistol• 9 mm MP5A3 Machine Pistol• Various Pistols

56



• Adjusting line of fire with aiming sight• Changing barrel activities by using barrel pressing, fixing and drilling machines • Adjusting headspace process• Balancing weapons by balancing machine• Fixing front sight operation by front sight fixing machine• Oxygen and gas welding operations• Making weapons ready by sanding machine before phosphate coating and lac-dye painting process.• Phosphate coating and lac-dye painting process• In 25 mt polygon executing firing tests of rifles, machine guns and various pistols by fixing on gun rest. Like aircraft machines, machine guns etc.weapons firing tests are done in open shooting areas that Turkish Land Forces have.


LIGHT WEAPONRENEWAL ACTIVITIES

MAIN MAINTENANCE

FACTORY DIRECTORATE

5 th

58



DEPOT LEVEL MAINTENANCE AND REPAIR ACTIVITIES (DLM)

5th Main Maintenance Factory Directorate performs depot level maintenance/repair and overhaul activities for airframe engine and parts of aircrafts under its responsibility.


* Airframe overhaul & maintenance and repair of aircrafts* Modernization and R&D activities* Maintenance, repair and overhaul for engines, gear box, main/tail rotor blades, propellers and components* Avionic devices maintenance, mechanic and electronic calibration* Power train maintenance, repair and overhaul of accessories

* Manufacture* Paint removal (chemical, bead blasting)* Painting activities* Chemical activities* Surface activities* Nondestructive inspection* Machining and production activities* Laboratory activities* Technical support

ATAK T-129

PRODUCT RANGE

59



AH-1P COBRA

UH-1H B200

SIKORSKY S-70

60



MODERNIZATION PROGRAM

MODERNIZATION ACTIVITES* Helicopter obstacle avoiding system integration obstacle avoiding system includes - Tablet - Active obstacle avoiding system* Identification friend and foe systems (IFF MODE-5) integration* Helicopter electronic warfare systems (HEWS) integration

HEWS ACTIVITIES INCLUDE - infrared exhaust heat suppression systems (IRSS) - Infrared counter-measure systems (IRCM) - Counter-measure system (CMDS) - Missile Warning System (MWS) - Hews radar Warning Receiver System (RIAS) - Radar frequency jamming system (RFKS) - Laser Warning receiver system (LIAS) - Suit Central administration unit (SMYB) * Installation/integration of multi-band numerical joint radio (ÇBSMT)* Emergency positioning transmitter (ELT Device) integration* Satellite phone integration for search and rescue helicopters

WITHIN THE SCOPE OF AFOREMENTIONED ACTIVITIESS-70A-28DSAR Helicopters integrationAS-532USAR Helicopters integration

61



OVERHAUL / MAINTENANCE /REPAIR PROGRAM


HELICOPTERSAH-1P Attack Helikopter(Engine and accessories, power train, blade/propeller, hydraulic, airframe installation, structural repair, avionics)

AH-1W ATTACK HELIKOPTER(Engine and accessories, power train, blade/propeller, hydraulic, airframe installation, structural repair, avionics)

UH-1H&AB205 UTILITY HELIKOPTER(Engine and accessories, power train, blade/propeller, hydraulic, airframe installation, structural repair, avionics)

AB-212 UTILITY HELICOPTER(power train, blade/propeller, hydraulic, airframe installation, structural repair, avionics)

AB-412 UTILITY HELICOPTER(power train, blade/propeller, hydraulic, airframe installation, structural repair, avionics)

AS-532 UTILITY HELICOPTER(power train, blade/propeller, hydraulic, airframe installation, structural repair, avionics)

S70-A UTILITY HELICOPTER(Engine and accessories, power train, blade/propeller, hydraulic, airframe installation, structural repair, avionics)

S70-B UTILITY HELIKOPTER(Engine and accessories, blade/propeller, hydraulic, airframe installation, structural repair, avionics)

AB-206 TRAINING HELICOPTER(Engine and accessories, power train, blade/propeller, hydraulic, airframe installation, structural repair, avionics)

AIRCRAFTSB-200 Aircraft(accessories, blade/propeller, hydraulic, structural repair, avionics)

C-421B TRAINING AIRCRAFT(Engine and accessories, blade/propeller, airframe installation, Avionics)

T-182T TRAINING AIRCRAFT(Engine and accessories, blade/propeller, airframe installation, Avionics)

T-42A TRAINING AIRCRAFT(Engine and accessories, blade/propeller, airframe installation, Avionics)

62



DEPOT LEVEL MAINTENANCE OF HELICOPTER / AIRCRAFT ENGINES


ENGINES*T53-L13B, T53-L703 Engines(Depot level with full capacity)*T700-701A, T700-701C, T700-401 and T700-401C Engines(Improved field level maintenance, hot parts control, power turbine drive shaft replacement, overhaul of GG Rotor Assy, overhaul of accessory gear box, cold part maintenance and repair, overhaul of 1st stage nozzle assy, depot level engine test)

PRODUCT RANGE

*250-C20, 250-C20R4 Engines(Depot Level with full capability)*T62T-40-1 (APU) Engines(Depot Level with full capability)*PT6A-42, PT6T-3, -6, -9 Engines(hot section control)*Makila 1A1 Engines(Module replacement, periodical maintenance activities)*Piston EnginesIO-360-D, IO-470-L, IO-520-H, GTSIO-520-H(Depot Level with full capability)

GTSIO-520-H PISTON ENGINE T-53 SERIES TURBINE ENGINE

63



DEPOT LEVEL MAINTENANCE OF HELICOPTER / AIRCRAFT ENGINES

TURBINE ENGINES

ENGINE TYPE

T53-L13B

T53-L703

T700-701A

T700-701C

T700-401

T700-401C

250-C20, C20-R4

T62T-40-1 (APU)

PT6T-3, -6, -9

PT6A-42

Makila 1A-1

ENGINE TYPE

IO-360-D

IO-470-L

IO-520-H

GTSIO-520-H

AIRCRAFT IT BELONGS TO

UH-1H, AB205

AH-1P, UH-1H

S-70A-17

S-70A-28

AH-1W

S-70B

AB-206, OH-58

S-70A / B

AB-212, AB-412

B-200

AS-532

AIRCRAFT IT BELONGS TO

T-41D

T-42A

U-17B

C-421B

5th Main Maintenance Factory Directorate performs maintenance/repair and overhaul activities for aircrafts engines under its responsibility.

64



DEPOT LEVEL MAINTENANCEFOR AVIONIC UNITS

It performs depot level maintenance, repair and overhaul activities for electro-mechanic and warning systems, depot level maintenance and repair activities for communication systems, depot level maintenance and repair activities for available navigation systems and depot level maintenance and repair activities for available flight instruments of TAF aircrafts.

It also performs maintenance, repair, overhaul and test activities for available 20mm gun, M-65 tow missile system, helmet targeting system, TSU/NTS-LRF night vision binoculars and night aiming system, S-70 relay panels, laser pointers, mini UAVs night and day cameras.

TECHNOLOGIC APPLICATIONSCommunication and navigation systems applications:* Vhf/Am radios* Mxf radios* Intercom systems* Rpm systems* Positioning systems* IFF systems

* Autopilot systems* Navigation system* Radar altimeter* INS systems * Mini UAV Ground Control Unit

65



DEPOT LEVEL MAINTENANCEFOR AVIONIC UNITS

It provides technical supports for overhaul and modernization activities for aircrafts and acquires capabilities by manufacturing test devices under its responsibility fields and newly entered to inventory.


WEAPON ELECTROOPTIC AND ELECTRO PROTECTION SYSTEMS APPLICATIONS* M65 and Nts system* 29 Mm turret system* Hss system* Mini UAV camera system* Narcad system* Afcs* Cmds* Mws* Ircm* Glass cockpit system* Hews* Apr-39* Bdi control system* Engine control systems* Warning systems

SPECIAL TOOLS AND DEVICES* Electrical and hydraulic Crane* Linear actuators and servo* Power electronic device* Electronic warning device* Ac/dc engines* Ac/dc starters and generators* Electrical fuel pumps* Pitot static systems * Gyro systems* Oil pressure and heat indicators* Tachometer indicators* Engine transmission indicators* Pitot static test sets* Accelerometer systems

66



CALIBRATION ACTIVITIES

Our facility performs calibration of measurement devices belonging to electronic, mechanic and aviation systems under its responsibility in compliance with determined standards.


MECHANIC* Micrometers (inner/outer diameter)* Calipers* Comparators* Manometers* Angle gauge, set-square* Water balance* Torque devices* Balances, hand scale etc.* Torque meter, tensiometer etc.

ON-SITE CALIBRATED DEVICES* Trim actuator test device* Schenck balance test device* Bearing measurement test device* Mets (turbine engine test bench)* Starter generator Tc* Image console (hydraulic test stand)* Torque test device* Altimeter* Blade balance scales

ELECTRONIC AND AVIATION DEVICE* Vibrex* Jetcall* Stabilator SAS* APU-ESU* Ecu Box* Inspection Box* ITSGMS* VIDS-LINE Test Set* Balance kits* Multimeter* Thermometers (heat indicators etc.)

67



NONDESTRUCTIVE INSPECTION ACTIVITIES

Nondestructive inspection division performs NDI activities for parts and accessories of military and commercial airvehicles in its shops or in customer facilities with its mobile teams having portable devices.

Nondestructive inspection activities are performed by competent staff qualified and certified at level 2 in compliance with TS EN 4179 / NAS 410 standards.

Out factory directorate has the approval certificate awarded by Civil Aviation General Directorate for the belowmentioned nondestructive inspection methods within the scope of SHY-145 and it also a member of National Aviation Nondestructive Inspection Committee.

TECHNOLOGIC APPLICATIONS1. Fluid penetrant control management (PT)

2. Magnetic particle control management (MT)

3. Eddy current control management (ET)

a. Conventional techniques

b. Digital conductivity measurement technique

4. Ultrasonic control management (UT)

a. Conventional techniques

b. Improved ultrasonic phased array

technique

c. Bond test technique

5. Radiographic (X-ray) control method (RT)

a. Radiography technique

b. Radioscopy technique

68



NONDESTRUCTIVEINSPECTION ACTIVITIES


FLUORESCENT PENETRANT CONTROL MANAGEMENTWith the aim of determining the surface discontinues parts immersed into a chemical named fluorescent penetrant are controlled in a dark environment with black light (UV-A) after other chemicals are applied to them. All parts such as nonferrous, nonmagnetic, stainless steel, ceramic and glass are controlled.Magnetic particle control management:With the aim of determining surface and nearsurface discontinuties, it is aimed at creating a magnetic field around the part after the current is applied to the part or the part is exposed to magnetic field and occuring flux loss is controlled in a dark environment with black light in compliance with flux loss principle. All kinds of ferromagnetic parts are controlled.

EDDYCURRENT CONTROL MANAGEMENTWith the aim of determining surface and near surface discontinuties systems including special electronic devices and accesories and reference standards are used. Furthermore parts’ electrical conductivity values, heat treatment conditions, conductive/non-conductive coating thickness are determined. All kinds of parts having electrical conductivity are controlled.

69



MANUFACTURING ACTIVITIES

TECHNOLOGIC APPLICATIONSMANUFACTURING CAPABILITY* Manufacture and test for variously-diametered rubber and teflon based air vehicle hose* Manufacture and test for aluminum and stainless steel aircraft oil, fuel and hydraulic pipes up to 1 inch.* Machining of metal based materials,* Special tools manufacturing* Test device manufacturing* Harness manufacturing and continuity test* Metal plate forming and manufacturing* Aluminum and stainless steel welding* Composite material manufacturing* Flight control cable manufacturing* Various saddler materials manufacturing* Carpenter materials manufacturing* Serigraphy and printing manufacturing

BENCHES* CNC horizontal machining center with 5 axis* CNC verticle turning* CNC turning with C axis* Perpendicular processing center with 3 axis* Erosion and wire erosion* CNC cyclinderical grinding* Pantograph* Shotpeening activity* Cutting machine with laser* Bending bench* Mold bench (mechanical press)

5th Main Maintenance Factory Directorate performs manufacturing, repair and maintenance activities for structural parts, spare parts and special tools of aircrafts, helicopters, air and ground units and accessories under its responsibility.

70



QUALITY MANAGEMENT ACTIVITIES

Duties of the quality management of 5th Main Maintenance Factory Directorate are to improve quality assurance system, to enable corrective actions are made and make inhouse quality systems audits or enable that inhouse quality systems audits are made for determining the efficiency to enable that supply, maintenance and repair services army aviation units are performed in compliance with technical publications, regulations and maintenance manuals to make recommendation to the unit commanders to prevent accidents at the internal and outer unit relations in the army aviation maintenance and supply system of maintenance command and to prepare safety based quality policies and to take measures.

LABORATORY ACTIVITIESVarious chemical and physical test and experiments are made in the laboratory in order to ensure safety flights of airvehicles and to make the required analysis.

PERIODICAL OIL ANALYSIS PROGRAM* Spectrometrical oil analysis* Ferrograph analysis* Hydraulic contamination analysis* Water content determination

CHEMICAL ANALYSIS* Coating solutions analysis* Shelf life extension tests

METALLOGRAPHY TESTS* Hardness and micro-hardness measurement* Metallographic examinations

71



CERTIFICATES

SHY-145 AQAP-2310&AQAP-2110

TSE 18001

MAIN MAINTENANCE

FACTORY DIRECTORATE

6 th

73



DIRECTORATE MAIN MISSION

It includes the services of disassembly, repair and renewal of systems or materials which are in a defective state or that have a predetermined renewal time and it includes to make comparable to their new ones.

Maintenance, repair, renewal and test activities of engines, powertrain, generators, bomb disposal robot systems and line replaceable unit, which belong to Turkish Armed Forces inventory and in the 6th Main Maintenance Factory Directorate’s responsibility area are performed by using automated technology.

PRODUCT RANGE

74



ENGINE RENOVATION/OVERHAUL


MEASUREMENT• Nondestructive testing (magnetic, ultrasonic) operations for the crack inspection on cylinder head and engine block• Test, adjustment and troubleshooting operations with the fault detection and diagnostic devices used in new generation electronic controlled vehicle engines (ECU)• Computer controlled torqueing, matching with the barcode system,• Test operations of parts made of ferromagnetic materials such as iron, nickel, cobalt, and some alloys

CLEANING• Mechanical Cleaning/Surface Blasting-• Chemical Cleaning

CLASSICAL REPAIRING• Assembling and disassebling with sensored conveyor line• CNC Turning• CNC Milling• Welding• Assembling with computer controlled automation system• Vehicle with Electronic Control Unit (ECU);testing, adjusting and fault diagnosing FUNCTIONAL CONTROL• Engine test bench

75



GENERATOR RENEWAL

It includes the services of renewal, maintenance and tests, repair and modernization of various generators in diesel and gasoline-powered type whose powers range between 1 KVA and 1500 KVA, it also includes part repair and replacement services.

TECHNOLOGIC APPLICATIONS• Design and renewal of standardized control and power panels appropriate to generators’ power.• Performance test operations of overhauled generators with charge banks.• Project for dual generators, manufacturing and renewal operations

PRODUCT RANGE

DUAL GENERATORMANUAL

GENERATOR

76



MUNITON DISPOSAL ROBOT REPAIR AND RENEWAL

It includes the services of renewal, maintenance and tests, repair and modernization of bomb dis-posal robots on brand of TELEMAX and TEODOR.

PRODUCT RANGE

TELEMAXMUNITON DISPOSALROBOT

TEODORMUNITON DISPOSALROBOT

77



POWERTRAIN RENEWAL

It includes the services of renewal, maintenance and test, repair and modernization of Tactical Wheeled Vehicle and Tactical Wheeled Armored Vehicle as well as construction machine trans-missions, axle, transfer, cell connector.

PRODUCT RANGE

• Automatic Transmission• Mechanical Transmission• Axle• Transfer


• Disassembly, modernization and assembly operations on conveyor lines.• Test operations on modern test benches.• Test, adjustment and troubleshooting operations with the fault detection and diagnostic devices used in new generation electronic controlled vehicle transmissions.

78



LINE REPLACEABLE UNIT (SUBSYSTEMS) RENEWAL

AFTER RENOVATION OF LINE REPLACEABLE (SUBSYSTEMS) UNITS TESTING

It includes the services of renewal and test of line replaceable units (subsystems) which belong to tactical wheeled vehicle and tactical wheeled armored vehicle.

PRODUCT RANGE

• Alternator • Hub • Steering Pump• Torque Nonverter • Transmission Control Module• Parking Brake Unit

• Turbocharger• Oil Radiator• Oil Pump• Fuel Pump• Injector• Coolant Pump

79




It includes the operations of cutting, bending, plastering of spare parts used in either engine, powertrain and generator renewal activities or various vehicles, as well as mold manufacturing at 3 and 5 axis CNC and conventional machines.

TECHNOLOGIC APPLICATIONS• With Computer Aided Design (CAD) licensed 1 SOLIDSWORKS CAD software 3D parts modeling and design• Sensitive measurement control and re-engineering ability with 3D coordinate measurement (CMM) device• Turning in 5 and 3 axis CNC, milling, CNC plunge erosion, NC surface/cylinder grinding and leveling applications• Static and dynamic balance adjustment on rotary components like brake disc, pressure plate, involutes etc.

CASTING PROCESS• Cast iron, nodular cast iron, aluminum, bronze and brass casting ability• Monobloc (single piece) casting at the capacity of between 50 g and 850 kg• Metal melting with the system which has 500 kg and 350 kg crucible and 1350 kg melting capacity by 2 unrelated inductions

HEAT TREATMENT PROCESSES• Cementation• Stress Elimination• Hardening• Aging• Annealing

COATING PROCESSES• Mangan-Phosphate• Hard Chrome• Zinc Phosphate• Tamburlu Nikel?*• Brass• Zinc• Making Black

80



MECHANICAL AND ELECTRONICS MEASUREMENT EQUIPMENT CALIBRATION

It performs internationally-traceable calibration, control, maintenance and repair of precision measurement devices under 6th Main Maintenance Factory Directorate responsibility and outer units responsibilities in compliance with the determined standards.

• Mechanic Calibration Product Range and Technological Application

• Electronic Calibration Product Range and Technological Application

81



RESEARCH ANDDEVELOPMENT ACTIVITIES

Technical Project and Management Directorate performs renewal, test, manufacture, process con-trol design, software development and modernization activities in its responsibility area.


• PLC based process control system design,• Engine test cell design and manufacturing,• Transmission test cell design and manufacturing,• Welding robot design and manufacturing,• Turbocharge test bench design and manufacturing,• Transmission control module test bench design and manufacturing,• Viscose test bench design and manufacturing,• Oil pump test bench design and manufacturing,• Torque converter repair and test bench design and manufacturing,• Design and production of conveyor lines,• Design and production of Sandblasting Unit,• Design and production of Dismantling and Mounting of Run-Flat Tire Machine

82



LABORATORY ACTIVITIES

TECHNOLOGICAL APPLICATIONS

• Calibration possibility of Signal Sources, Multimeter, Signal Analyzers, Time and Frequency Counter, Oscilloscope Devices,• In situ hardness measurement by Rockwell-Brinell and Vickers hardness measurement devices in the laboratory,• Determination of chemical composition of steel, bronze, brass and aluminum alloys by Optical Emission Spectrometer Device,• Micro structure examination and determination of cementation thickness, grain size, graphite form and size in the image analysis device; taking photos of micro structure,• Surface roughness measurements,• Coating thickness measurement,• Determining AFS dimensions of casting sands,• Viscosity measurements of oils, density measurements of liquids, PH values measurement of solutions.

83



TEST ACTIVITIES


• All kinds of test software, test cell design and manufacturing.• Ability to simulate the disassembled and overhauled motor – powertrains – generator -line replaceable units at different revolutions and loads by automatic controlled computerized test benches.• Ability of monitoring 24 different parameters like revolution, torque and temperature of engines, cooling water temperature, lube oil temperature, fuel temperature and pressure, exhaust temperature, brake water temperature and pressure

84



CERTIFICATES

NATO QUALITY ASSURANCE REQUIREMENTS FOR DESIGN, DEVELOPMENT AND PRODUCTION

ENGINE DISASSEMBLE, RENOVATION AND ASSEMBLE FACILITY QUALIFICATION CERTIFICATE

MOTOR VEHICLE MAINTENANCE FACILITY QUALIFICATION CERTIFICATE

INDUSTRY REGISTRY CERTIFICATE

ISSUANCE DATE : 03.03.2016DUE DATE : 03.03.2019




AQAP-2110

TS - 11954

TS - 12047

SANSİC(B)-570049

MAIN MAINTENANCE

FACTORY DIRECTORATE

7 th

86



MOBILE FIELD UNITS MANUFACTURING ACTIVITIES

ON-VEHICLE MOUNTED UNIT

Between 1994 and 2008, a total of 1,897 units were produced and submitted to the Turkish Armed Forces (TAF) inventory (donated to 103 friendly and allied nations), 5 types of mobile unit are already in production capability and can be manufactured if requested.

Mobile Field Furnaces and Laundry Units can be used on various types of vehicles.

• Mobile Field Kitchen Units• Mobile Field Bath Units• Mobile Field Bakery Units• Mobile Field Laundry Units• Cold Air Cabinets with Trailer

• 10 Tons Tactical Wheeled Man Truck-Mounted Units• 25 Tons Mercedes Truck-Mounted Units• 5 Tons BMC Truck-Mounted Units• 25 Tons Ford Truck-Mounted Units

87



MOBILE FIELD UNITS FACTORY LEVEL REPAIR / MODIFICATION ACTIVITIES

MOBILE FIELD UNITS MODERNIZATION ACTIVITIES

The factory level repair and modification activities of the 5 main units in the inventory of Turkish Armed Forces have been carried out since 2003.

Units that are mounted on old generation vehicles which expire their economic and physical life and which cannot be used effectively in the field of operation are transferred to vehicles of a new generation with high mobility.

88



MOBILE FIELD UNITS DEVELOPMENT AND DESIGN ACTIVITIES

The design and development processes of container-mounted trailer and / or vehicle units are carried out as a continuous activity in order to make the field units suitable for today’s conditions and to use more effectively in accordance with the needs of the units in the operation areas.

Bathroom units that are developed for shower needs which are one of the important staff needs are improved by using different materials and in types according to the requirements of the mili-tary unit and the land conditions.

89



MOBILE FIELD UNITS DEVELOPMENT AND DESIGN ACTIVITIES

Container type oven unit is designed to be mounted on the vehicle with a hydraulic foot and can be installed on the vehicle in order to meet the bread needs of the field.

There is also a trailer mounted toilet / shower unit for meeting toilet and short shower needs, a single bathroom cabin that can be mounted externally to modular living room containers, and a single modular toilet cabinet that can be used around the living area.

90



DESIGN ACTIVITIES FOR OPERATIONS

OPERATIONS SUPPORTBASE AREA DESIGNS

Container protection cage and modular site materials designed for the safety needs of the troops in the operation area are being developed to provide protection against mortar attacks and gun fire.

In order to logistically support the participating troops and to ensure maintenance and repair of the vehicles, weapons and systems in an appropriate environment, Operations Support Base Areas designs consisting of containers are being made.

91



TAF CEREMONIAL SWORDS AND CADET RAPIERS PRODUCTIONS

Production activities of ceremonial swords given to the staff of the General Command of the Gen-darmerie and all the Forces’ Commands of the Turkish Army due to the ceremonies since 1991 and the production of the cadet rapiers manufactured for the use in the ceremonies of the students who have been studying at Naval and Military Academies since 2006 are performed at the 7th Main Maintenance Factory Directorate. The work load assigned varies from year to year, with an average of 3.000 to 4.500 swords and 300 to 1.200 pieces of rapier production.

Turkish Land Forces Ceremonial Sword

Turkish Air Forces Ceremonial Sword

TurkishNaval Forces Ceremonial Sword

Gendarmerie Forces Ceremonial Sword

92



SWORD MANUFACTURING / REPAIR ANDCEREMONY RIFLE / BAYONET REPAIR ACTIVITIES

The Sword Production Workshop is also responsible for repairing swords and rapiers that have been manufactured in the previous periods and deformed over time, as well as coating and renew-al of ceremonial firearms, various weapons and bayonets.

93



SWORD MANUFACTURING / REPAIR ANDCEREMONY RIFLE / BAYONET REPAIR ACTIVITIES

7th Main Maintenance Factory Directorate is responsible for meeting storage, heating, housing, kitchen, archiving, etc. needs of the units. It is capable of manufacturing various sheet materials which will be needed to be used in its existing facilities.

• Adjustable Rack Unit• Yukon Type Tent Stove• Food Hot Service Bank• Tent Metal Parts • Archieve Cabinet• Various Spare Parts and Mold• Mobile Carrier• 5-Tabletop Tray• Fixed Plant Oven

OTHER MANUFACTURING CAPABILITIES

94



PRODUCTION ACTIVITIES

It is aimed at increasing the product variety and increasing the quality to the highest level after the completion of the “Bench Modernization Project” which is carried out in the years 2018-2019 for the activities in the Manufacturing Workshop.

MAIN MAINTENANCE

FACTORY DIRECTORATE

8 th

8TH MAIN MAINTENANCE FACTORY DIRECTORATE

96 MILITARY FACTORY AND SHIPYARD MANAGEMENT INC.

DEPOT LEVEL MAINTENANCE & REPAIR (DLM) ACTIVITIES

Includes the services of maintenance, manufacture, modernization and test of ballistic protective products (helmet,vest,helicopter floor armor ect.) and renewal of inflatable boats under the re-sponsibilty of 8th Main Maintenance Factory Directorate.

TECHNOLOGIC APPLICATIONS• Ballistic Protective Composite Helmet Manufacturing / Repair• Ballistic Protective Vest (armor plate and vest) Manufacturing / Repair• Mine Protective Equipment Manufacturing / Repair• Helicopter Floor Armor Manufacturing / Repair• Inflatable Boat Manufacturing / Repair• Painting/Coating Activities

PRODUCT RANGE• Ballistic Protective Helmet• Ballistic Protective Vest• Helicopter Armour Plate


97MILITARY FACTORY AND SHIPYARD MANAGEMENT INC.

STRUCTURAL MODERNIZATION PROGRAMS

Ballistic Protective Composite Helmet: New type composite helmet is manufactured by using polyethylene armor fabric for lightness, accesory (night vision, ear protection accessories etc.) car-rier apparatus mounted on the polyethylene helmet.

Ballistic Protective Vest: New type commando vest is manufactured with the aim of increasing the mobility capabilities and possibilities of the personnel in operations.



MANUFACTURING CAPABILITIES

Includes the services of manufacture and test of ballistic protective products (helmet,vest,helicop-ter floor armor ect.) and Inflatable boats under the responsibility of 8th Main Maintenance Factory Directorate.

TECHNOLOGIC APPLICATIONS• 3D Modelling of parts and tool design by

CAD software program.• Special manufactured molds used for

manufacturing ballistic protection armour plates and helmets in composite workshop.

• Vest manufacturing and ballistic protective material assemby in vest workshop.

• Helmet accessory carrier apparatus and various plastic materials manufactured by plastic injection presses.

• Ballistic protection levels are tested at ballistic labrotary.

• Inflatable boats are manufactured in rubber boat shop.

• Helmets and armor plates are painted and coated in paint workshop with IRR paint.

• Marking on the product by laser.

MACHININGScrews, nuts and required spare parts having various size are produced.• Production with turning and milling

processes.




POLYETHYLENE COMPOSITE HELMETTECHNICAL FEATURESWeight : 1400-1600 gr.Armor Material : UHMW-PE / Aramid FabricBallistic Protection : NIJ Standard 0101.04 Level III-A

MODULAR COMMANDO VESTTECHNICAL FEATURESTotal Weight : 9320 ± 200 gr.Hard Armor Weight : max 7500 gr.Hard Armor Materials : Ceramic+UHMW-PEVest Weight : 1820 ± 80 gr.Ballistic Protection : NIJ Standard 0101.04 Level IV

G 470 COMBAT BOATTECHNICAL FEATURESCrew : 10 PersonPayload : 1250 kg.Number of Airtight Chambers : 5+2+1Material : NeoprenFloorboard : Roll-up (Aliminium)Weight (Empty) : 135 kgLenght : 470 cmWidth : 192 cm



MINE PROTECTION EQUIPMENTTECHNICAL FEATURES Total Weight : 14300 ± 200 gr. Suit Weight : 9450 gr. Helmet Weight (with vizör) : 2700 gr. Boot Weight : 2150 gr./ piece Suit Material : Nomex Fabric Armor Material : Aramid Fabric + UHMW-PE Ballistic Protection : A/P Mine protection (114 grams TNT eqt.) MIL SPEC 662-F (Frag.)

FLIGHT STAFF VESTTECHNICAL FEATURES Total Weight : 5050 ± 80 gr. Soft Armor Weight : 880 ± 20 gr. Hard Armor Weight : max 2600 gr. Soft Armor Materials : Aramid Fabric Hard Armor Materials : Ceramic+UHMW-PE Vest Weight : 1570 ± 20 gr. Ballistic Protection : NIJ Standard 0101.04 Level IV

S70 HELICOPTER FLOOR ARMORTECHNICAL FEATURES Total Weight : 160 kg. Armor Material : Polyethylene Armor Fabric Ballistic Protection : NIJ Standard 0101.04 Level III




TECHNOLOGY AND DEVELOPMENT ACTIVITIES

8th Main Maintenance Factory Directorate performs research and development projects required to increase economical use and efficiency of the products and carry out armoring and manufacturing activities.

MECHANICAL CAPABILITIES

MECHANICAL DESIGNMechanical parts designs required for the integration and development projects are performed by using Computer Aided Design (CAD).

RECENT PROJECTSOur recent projects are: EPP (expanded polyprophylene) shield design as ballistic inner parts development activity, IV level armor plate manufacturing for increasing the protection level, portable ballistic ear protector to protect ear part of the high helmets and Z type vest manufacturing to meet the needs of tank staff.

• EPP Shield Design• Level IV Armour Project• Ballistic Ear Protector Project



TEST ACTIVITIES

Quality Control Directorate performs all kind of test and process controls of the products under the responsibility of 8th Main Maintenance Directorate. Determination of the ballistic products ca-pabilities and ballistic test activities of other TAF/private sector institutions and organizations are also conducted. Test that are made includes: ballistic bullet tests as per NIJ 0101.04, NIJ 0101.06, NIJ 0108.01, TS EN 1063, STANAG 4569 and test of fragment as per MIL662F, TS-13349, STANAG 2920 standards are applied.

PRODUCT RANGE• Ballistic Protection Helmet • Ballistic Protection Vest • Mine Protection Equipment• Helicopter Floor Armor• Unproducted Equipment



QUALITY ASSURENCE ACTIVITIES

Activities of maintenance, manufacture, modernization and test of ballistic protective products quality controls are performed by Quality Management Directorate.

8th Main Maintenance Factory Directorate which gives priorty for personnel life security and customer satisfaction at overall activities has been awarded the certificates below:• AQAP-2120 , NATO Quality Assurance Requirements for Production Certificate. Expired in

September. • AQAP-2110 , NATO Quality Assurance Requirements for Design, Development and Production,

Certificate is in the process of application.

QUALITY ASSURENCE LABORATORIES

PHYSICAL LABORATORIES• Tensile Test• Climate conditioning devices • Water immersion conditioning• Test bullet preparing

BALLISTIC TEST LABORATORY1.Composite Helmet Tests• Bullet Test• V50 Fragment Test2.Composite Vest Tests• •Bullet Test • •V50 Fragment Test3.Unproduced ( Shield, glass, vehicle armor etc.) • •Bullet Test• •V50 Fragment Test

ELECTRO-OPTICAL SYSTEMS

MAIN MAINTENANCE FACTORY

DIRECTORATE

ELECTRO-OPTICAL SYSTEMS MAIN MAINTENANCE FACTORY DIRECTORATE


AIR DEFENCE MISSILE SYSTEMS MAINTENANCE AND REPAIR

Depot/company level maintenance and repair of Portable Stinger Training Aids and ATILGAN/ZIPKIN weapon systems of pedestal mounted stinger in TAF inventory (Land Forces, Air Forces ans Navy) are performed.

PORTABLE STINGER TRAINING AIDS• Repair/Maintenance of Gas Charging Unit(GCU)• Repair/Maintenance of Gas Pumping Unit (GPU)• Repair/Maintenance of power supply unit (PSU)• Repair/Maintenance of Gas Charging Unit(GCU)• Repair/Maintenence of M 160 Seeker Head training unit• Pedestal mounted Stinger (“Zıpkın”/ ”Atılgan”) subsystems Maintenance/Repair test

PRODUCT RANGE



MAINTENANCE AND REPAIR OF ARTILLERIES, MISSILES AND ROCKETS

Depot/company level maintenance and repair activities for 122mm SAKARYA, 302 mm KASIRGA multi-barrelled rocket launcher (ÇNRA) and 600mm YILDIRIM missile and weapon systems in Turk-ish Armed Forces inventory are performed.

SUBSYSTEMS UNDER OUR MAINTENANCE/REPAIR AND CALIBRATION RESPONSIBILITY• Repair/maintenance of fire control systems• Repair/maintenance of satellite and navigation systems• Repair/maintenance of ground metro?* measurement device• Repair/maintenance of automation control systems• Update and loading of computer and software• Repair/maintenance and test of missile/rocket fire systems

PRODUCT RANGE



REPAIR AND MAINTENANCE ACTIVITIES FOR BARRELED AIR DEFENCE WEAPON SYSTEMS

Depot/Company level maintenance and repair activities of 35mm Oerlikon Weapon Systems in Turkish Armed Forces inventory are conducted.

REPAIR & MAINTENANCE ACTIVITIES FOR 35 MM OERLIKON• Maintenance/Repair of weapon section• Maintenance/Repair of loader• Maintenance/RepairTest of Barrel• Maintenance/Repair of Electronic drawer• Maintenance/Repair of starter• Maintenance/RepairTest of Speed regulator• Maintenance/Repair of radar section• Maintenance/Repair of computer section• Maintenance/repair of tracking section

PRODUCT RANGE



MAINTENANCE/REPAIR OF BARRELED WEAPON, MISSILE AND ROCKET SYSTEMS

Maintenance/repair, test, modification, structural parts repair and replacement of anti-tank sys-tems, mechanical, electrical and electronic systems under electro-optical systems main mainte-nance factory directorate responsibility are performed.

TECHNOLOGIC APPLICATIONS• Test/repair and maintenance of night vision,weapon trigger system, missile guidance set,

training set, optic vision set of TOW weapon systems.• Side/elevation test, 2W1 cable test, training sets test and self-test of guidance electronic

system of TOW weapon system.• Maintenance, repair and tests of trigger systems,missile guidance sets, optical sights?*, night

vision and traning sets of MILAN, ERYX and KORNET-E Anti-tank systems • Maintenance, repair and tests of battery charger• Maintenance, repair, tests and modification of anti-tanks systems batteries and cables • Maintenance, repair and tests of mechanical systems of anti-tank systems.

PRODUCT RANGE



FIRE CONTROL SYSTEMS SHOP ACTIVITIES

Maintenance, repair, sustainment activities for electronic cards, mechanical parts, mechatronic and fire control systems of Leopard and M-Series Tanks, armoured combat vehicles towers, tactical wheeled armoured vehicle towers are performed during their life cycles.

FIRE CONTROL SYSTEMS• Leopard 2A4, Leopard 1T, M60T Main Combat tanks repairs and tests,

Repair and tests of• Armoured combat vehicles,• Tactical Wheeled Armoured Vehicles (KOBRA),• Electronic cards and gyroscope.



LASER INTEGRATED SYSTEMS SHOP ACTIVITIES

Maintenance, Repair and sustainment activities for on-vehicle/on-platform laser systems are per-formed during their life cycles.

LASER INTEGRATED SYSTEMS• Repair and test of target coordinate positioning systems,• Repair of laser distance measurement systems,• Repair of goniometer,• Repair of laser distance determination systems,• Repair of Laser target pointing system,• Repair and tests of optical sections and electronic cards.



VISION SYSTEMS ACTIVITIES

Depot/company level maintenance, repair, modernization and modification activities for surveil-lance systems, night vision goggles and their equipment are performed.

Not on-vehicle/on-platform vision systems shop

• M983 Night Vision Goggles• M972 Night Vision Goggles• AN/PVS-7B Night Vision Goggles• M929 Pilot Night Vision Goggles• AN/AVS-6 Pilot Night Vision Goggles• PUHU A-500 Pilot Night Vision Goggles• M930 Pilot Night Vision Goggles• Artillery Night Vision Binoculars M995• Light arm Night Vision Binoculars M993• M9865 Artillery Night Vision Binoculars• M9866 Light arm Night Vision Binoculars• M9885 Long distance Surveillance

Binoculars• M978 Night Vision Hand Binoculars• M1505 Night Vision Hand Binoculars



VISION SYSTEMS ACTIVITIES

on-vehicle/on-platform vision systems shop

• New generation stationary thermal camera.(Kerkenez)

• Thermal monitoring unit Coral • Thermal monitoring unit Gözcü • Baykuş Thermal camera • Hawk eye E/O reconnaissance and

surveillance system • Thermal camera system ASIR-SH2K • Hawk eye OD E/O system • M48A5T2 tank vision system • M60A3 Tank vision system • M60T 120 mm tank vision system • LEOPARD2A4 tank vision system• LEOPARD1T tank vision system• Armoured Combat Vehicle Vision system • Strengtened APC Vision system • TTZA COBRA Vision system



CALIBRATION ACTIVITIES

Electro-optical systems main maintenance factory directorate are performed in compliance with the determined standards.

ELECTRONIC CALIBRATION• AC/DC Voltage Calibration• AC/DC Current calibration• Resistance calibration• Inductance calibration• Capacitance calibration• Phase/Angle calibration• Digital/Analog Multimeter Calibration• Calibrator calibration• High Voltage calibration• Attenuator calibration• Low/High Level RF/Microwave Power

Calibration• Time/Frequency calibration• Spectrum Analyser calibration• Analog/Numerical oscilloscope calibration

MECHANICAL CALIBRATION• Pressure/Vacuum • Dimensional • Force • Angle • Temperature • Optic

MINISTRY OF NATIONAL

DEFENCE

GENERAL DIRECTORATE OF

NAVAL SHIPYARDS

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GENERAL DIRECTORATE OF NAVAL SHIPYARDS


MISSION AND RESPONSIBILITIES

In order to keep the operational readiness level of the Naval Forces Command at its highest, within the scope of maintenance; carrying out repair, construction, modification, modernization activities, planning the requirements for raw materials, spare parts, intermediate products, equipment, system and ensuring timely procurement of materials and services.

Managing and coordinating technical and administrative activities of the shipyards.

Carrying out the activities necessary for the indigenization of foreign materials / systems that are hard to find and critical for shipyard level maintenance and repair.

Managing and coordinating the activities to find out domestic sources for the materials used in the maintenance, repair and modernization processes

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GENERAL DIRECTORATE OFNAVAL SHIPYARDS

MISSIONTo be a center of knowledge and experience in all activities from design to construction of national naval platforms and to produce high value added products.

VISIONIn the naval defense industry, using the national technology and facilities to the maximum extent, it is to realize domestic production at high standards.

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GENERAL DIRECTORATE OFNAVAL SHIPYARDS

THE MISSION OF GÖLCÜK NAVAL SHIPYARD COMMAND

• Submarine construction, surface vessel and submarine repair and modernization,

• Maintenance and repairs of a total of 88 war ships, submarines and marine vessels and their 1,200 systems

THE MISSION OF İSTANBUL NAVAL SHIPYARD COMMAND

• Warship design, construction, repair and modernization,

• Maintenance and repairs of a total of 168 war ships and marine vessels and their 1,050 systems

THE MISSION OF IZMIR NAVAL SHIPYARD COMMAND• Maintenance/repair of naval land unit’s

weapons, electronic, communication systems.

• Maintenance and repair of a total of 79 war ships and marine vessels and their 710 systems

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THE IMPORTANCEOF SHIPYARDS

The most important element that enables our warships to perform their duties at the highest operational readiness level on world seas 7/24 is the technical capability in our shipyards.

TURKEYOne of the 10 countries that has the capability to construct warship in the world.

GÖLCÜK NAVAL SHIPYARD COMMANDOne of 10 shipyards in the world manufacturing submarine batteries.

İSTANBUL NAVAL SHIPYARD COMMANDOne of the 5 shipyards in the world capable of building mines and their modernization and maintenance with non-magnetisable materials

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THE IMPORTANCEOF SHIPYARDS

• 35 different branches/factories/workshops, 112 occupational branches with 6,000 staff for factory level maintenance and repairs.

• There is no other organization in Turkey that can provide such a wide range of maintenance, repair and technical support services.

• For this reason, our shipyards are compulsory factors for the Naval Forces’ sake.

Proactive approach to emergency situations and keep Naval Platforms always ready;• Repairment of TCG GİRESUN Frigate’s

propeller in Somali within 3 days• Repairment of mine hunting ship TCG

ALANYA’s Sonar, participation of the NATO operation in Italy in order to not to show vulnerability on behalf of our country

• Elimination of failures all of our components in place during the operation Deniz Kurdu 17 thanks to the support of Agile Repair Team

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ACCOMPLISHED ACTIVITIES

In addition to maintenance and modernization activities, Gölcük Naval Shipyard Command has succesfully completed 500 naval and marine vessels building activities in total including Meko Class Frigates, Type 209 submarines, logistic support vessels and dry-docks since 1937.

FRIGATES

LOGISTIC SUPPORT VESSELS

SUBMARINES

FLOATING DOCKS

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The frigates named TCG FATİH, TCG YILDIRIM, TCG ORUÇREİS and TCG KEMALREİS were designed by German Blohm und Voss, were built in Gölcük Naval Shipyard Command. Building and construction of each frigate took 3 years including the sea acceptance tests.

YAVUZ CLASS FRIGATES

BARBAROS CLASS FRIGATES

TCG FATİH 1988

TCG ORUÇREİS 1996

TCG YILDIRIM 1989

TCG KEMALREİS 2000

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The building of the first fast attack boat building started in İstanbul Naval Shipyard Command in 1975 and since then, 13 fast attack boats were built in totally. The last two boats of this project were built ın Gölcük Naval Shipyard Command starting from January 2006. The first boat was commisioned in January 2009 and the second boat was commisioned in April 2010 in Gölcük Naval Shipyard Command.

Gölcük Naval Shipyard Command has taken over the project of building 20 coast guard boats from İstanbul Naval Shipyard Command in 2005. Two of the boats were delivered to Northern Cyprus Turkish Republic. All of the boats have been in service since 2011.

Height : 40,75 m.Depls. : 195 tonsSpeed : 25 Kts.

FAST ATTACK BOATS

COAST GUARD BOATS

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Gölcük Naval Shipyard Command is one of the 16 shipyards in the world which can built submarines. With the association of German HDW Shipyard, 11 of TYPE 209 class submarine were built in Gölcük Naval Shipyard Command.

AY CLASS TCG YILDIRAY TCG DOĞANAY TCG DOLUNAY

PREVEZE CLASS TCG PREVEZE TCG SAKARYA TCG 18 MART TCG ANAFARTALAR

GÜR CLASS TCG GÜR TCG ÇANAKKALE TCG BURAKREİS TCG 1. İNÖNÜ

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İstanbul Naval Shipyard Command has accomplished building of 5 of AYDIN class Mine Hunter Cosstel vessel, 5 of KILIC Class Fast Attack Boats and 14 of 80-90 Class Coast Guard Boats.

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MILGEM (NATIONAL SHIP) PROJECT

It is the uniqe project that has been completed on aimed performance within planned budget and time among the other warship building projects in recent years.

The design of MILGEM is secured and patented by Ministry of National Defence.

NATIONAL DESIGN100 %

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MILGEM 1 – HEYBELİADA (F 511)

The first ship (TCG HEYBELİADA) was commisionned in 2011, the second ship (TCG BÜYÜKADA) in 2013 and the third ship ( TCG BURGAZADA) in 2018. The fourth ship (TCG KINALIADA) is nowadays on sea acceptance test (SAT).

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MILGEM 2 – BÜYÜKADA (F 512)

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MILGEM 3 – BURGAZADA (F 513)

The consruction of the BURGAZADA Corvette began on 17 December 2014 at İstanbul Naval Shipyard Command,

İt was launched upon its completion 3 months prior to the estimated date on the contrat in June 2016, The BURGAZADA corvette was delivered to Turkish Naval Forces in İstanbul Naval Shipyard Command on November 4, 2018.

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ON-GOING ACTIVITIES

MILGEM 4 – KINALIADA(F 514)

The fourth ship of the MILGEM Project KINALIADA Corvette’s consruction activities began in October 2015 at İstanbul Naval Shipyard Command.

It was launched about 6 months before the contrat schedule in June 2017,The fourth ship (TCG Kınalıada) is nowadays on sea acceptance test (SAT).

MILGEM 5 – İSTANBUL (F 515)

“I” class frigate (longer version of MİLGEM) İSTANBUL’s (F-515) first welding was carried out by Mr. President Recep Tayyip Erdoğan on 3rd of July 2017.

Project’s Main propulsion and weapon/sensor configuration studies are going on İSTANBUL Frigate to be commissioned in April 2021

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ON-GOING ACTIVITIES

NEW TYPE SUBMARINE PROJECT

The project for the supply of submarines with 6 individual air independent propulsion to be constructed in the Gölcük Naval Shipyard Command has been started on 22 june 2011 and the on-going activities of material flow and building infrastructure continues.Construction activities of the first submarine of the project,TCG PİRİREİS has started in 2015 and it is planned to launch the last submarine of the project in 20263. submarine MURATREİS’s first welding was conducted by Prime Minister in 25 February 2018 and 4. submarine AYDINREİS s first welding was conducted by Presedent in 4 November 2018.

REİS CLASS SUBMARINES

PİRİREİS (S-330)HIZIRREİS (S-331)MURATREİS (S-332)AYDINREİS (S-333)SEYDİALİREİS (S-334)SELMANREİS (S-335)

CONSTRUCTION START DATE: 2015PROJECT FINISH DATE : 2026

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PLANNED ACTIVITIES

MILGEM CORVETTE PROJECT FOR PAKISTAN NAVY

Project will be realized,conducted and finalised by ASFAT company of which its fund is directly under the control of the state and also ASFAT is the head company of military factory and military shipyards established under the Ministry of National Defence.

Turkey, with MILGEM Class corvette warship project has taken a quickstep in the international market. Turkey is at the stage of making such a great progress owing to this shining project right now. This Project is seen as a Project to further contribute to the development and enhancement of the subsequent projects.

Two of the corvettes will be built in İstanbul Naval Shipyard Command and other two in Karachi Shipyard, Pakistan.

AIR MAINTENANCE

FACTORY DIRECTORATE

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1ST AIR MAINTENANCE FACTORY DIRECTORATE


AIRCRAFT DEPOT LEVELMAINTENANCE, REPAIR ANDOVERHAUL (MRO&U) ACTIVITIESInclude the maintenance, repair, test and modification of hydraulic, pneumatic, mechanic, electrical and avionics systems along with repair / replacement of structural parts of aircrafts belong to 1st Air Maintenance Factory Directorate.


• Non-Destructive Control (X-Ray, Real Time X-Ray, FPI, MPI, ECI, Ultrasonic Control)

• Honeycomb Part Repair and Manufacturing• Harness and Panel Repair and Test• Paint Removal (Chemical, Bead-Blasting)• Painting Process• Canopy / Windshield Repair• Crew Escape System Overhaul • Weapon System Units Maintenance and

upgrade• External Fuel Tank Maintenance

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STRUCTURAL UPGRADE PROGRAM

33 key fuselage structural components manufactured and replacement capability gained within the scope of T-38 Fleet Pacer Classic III Structural Modification Program.

• Left/Right Dorsal Longeron• Left/Right Lip Ducts• Left/Right Dorsal Attach Angles• Left/Right Nacella Skin• FWD Center Fuel Cell Bottom Skin • FWD Skin of Windshield• F.S. 508 former• Left/Right Vertical Stabilizer Angles• Left/Right Upper/Lower Front Center

Longerons• Left/Right Bulkhead Stiffener (FS 388.75)• Left/Right F.S. 388.75 Bulkhead • F.S. 458.5 former• F.S. 464.5 former• F.S. 471 former• F.S. 479 former• F.S. 487 former • F.S. 487 support• Left/Right Inboard Lower Longerons• F.S. 505 former

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AIRCRAFT DEPOT LEVEL MAINTENANCE

• Coordinate Measurement Machine (CMM)Electronic positioning

• Magnetic Particle Inspection (MPI)• Electron Beam Welding (EBW)

PRODUCT RANGETURBOFAN ENGINES• F110-GE-100/100B/100C• F110-GE-129/129B• TF33-PW-100A

TURBOJET ENGINES• J79-GE-17C• J85-GE-5H• J85-GE-13• J85-CAN-15

TURBOPROP ENGINES• TYNE-MK-22• T56-A-15LFE • CT7-9C

TURBOSHAFT ENGINES• T700-701A/C• T700-401A/C• MAKİLA-1A1

GAS TURBINE COMPRESSORS• JFS• GTC 85-70/71• GTCP 85-160A/180/184

TECHNOLOGIC PROCESSES MEASUREMENT• Video Borescope • Fluorescent Penetrant Inspection (FPI) • Eddy Current Inspection (ECI)• Ultrasonic Inspection (UI)

CLEANING/STRIPPING• Mechanical Cleaning/Grit Blasting • Chemical Cleaning/Stripping

PAINTING• Dry Film Coating• Glyptal• Sermetal

BALANCE• Static• Dynamic

CONVENTIONAL REPAIRS• TIG Welding• Dabber TIG Welding• CNC Turning• CNC Milling• Electrochemical Grinding• Grinding• Blending• Lapping• EDM

FUNCTIONAL TESTS• Turbojet Test Cell• Turboprop Test Cell• JFS Test Cell• GTC Test Cell

HIGH TECHNOLOGY REPAIRS• Plasma Spray• Flame Spray• Vacuum Heat Treatment• Braze• Activated Diffusion Healing (ADH)• SWET Welding• Laser• CODEP Coating• Fluoride Ion Cleaning• Shot Peening • Induction Braze

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AIRCRAFT DEPOT LEVEL MAINTENANCE

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ACCESSORY DEPOT LEVEL MAINTENANCE

PRODUCT RANGE

HYDRAULIC AND LANDING GEAR SYSTEM ELEMENTS• Pumps and Motors• Servo and Solenoid Valves• Cylinders • Servo Actuators• Reservoirs• Filters• Dampers• Accumulators• Brake Elements• Rims• Struts / Cylinders

ELECTRICITY POWER SYSTEM ELEMENTS• AC/DC Generators• Control Panels• Illumination Elements• Regulators• Linear and Rotary Actuators• Pilot Control Elements (Throttle Quadrant /

Grip)• Starters

PNEUMATIC SISTEM ELEMENTS• Cooling Turbunes / Air Conditioning• Cabin Pressurizing Units and Safety Valves• Heat Exchangers / Seperators• Anti-Icing Valves• Oxygene Regulators/Convertors

ENGINE SYSTEM ELEMENTS (OIL, FUEL, MECHANIC)• Fuel Control Units• Pumps• Valves• Actuators• Fuel Nozzle / Spraying Units• Fuel/Oil Coolers• Gear Boxes / Constant Speed Drives

TECHNOLOGICAL APPLICATIONS• Ball Bearing Inspection / Repair• Bead Blast• Non-Destructive Inspections• Computer Controlled Profile Measurement• Surface Smoothness / Profile Test

Includes the services of maintenance, overhaul, repair, upgrade, and functional test of the accessories related to the aviation vehicles and ground support systems with their power plants under the responsibility of 1st Air Maintenance Factory Directorate.

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1st Air Maintenance Factory Directorate renders manufacturing, repair and control services for aircraft, helicopter and air and ground systems’ power plants and their structural parts, spare parts and special tools under its responsibility field.


TECHNOLOGICAL APPLICATIONS• 3D Modelling of parts and tool design by 13

licensed NX CAD software program• CNC machining program by 8 licensed NX

CAM software program.• Shaping of aluminium and steel sheets by

rubber diagram• Manufacturing honeycomp, sheet and

structural parts of cure parts such as rudder and wing by autoclave method.

• Tube manufacturing/bending/test processes and manufacturing of aluminium fuel and hidrolic tubes by CNC machines

• Manufacturing and test process of aircraft/motor hose assamblies

• Mold and part manufacturing with CNC wire cutting/EDM

• Aircraft control cable coating and test processes

• Vacuum plastic forming processes• NDI-MPI/FPI) processes• Laser cutting operations

MACHINING• Manufacturing of aircraft structural and

engine parts such as attach fitting, pylon rib, bulkhead, pin by;

• 5 Axis Machinining• C-Y Axis Turning/Milling• Grinding• Manufacturing various aircraft and fixture

by TIG-MIG and spot welding using aluminium and steel Heat Treating Process

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HEAT TREATING PROCESS• Normalization• Stress relief• Hardening• Tempering• Aging• Sementation• Solution Making• Annealing

COATING PROCESS• Borazon• Hard Chrome• Currentless, Nickel• Nickel Sulphamat• Cromic Acid Anodized• Black Oxide• Phosphate• Copper• Cadmium• Silver• Sulphiric Acid Anodized• Chemical abrasion

OTHER PROCESSES• Repairing and testing of aircraft fuel tank• Measuring by CMM and laser scanning

techonology• Laser scanning techonology• Forging steel and aluminium parts in 500

and 1000 tons press• Polyurethane and cellulosic painting.


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AVIONICS DEPOT LEVEL MAINTENANCE

PRODUCT RANGE

FLIGHT INSTRUMENTSFlight Command and Control System Elements• SAS Computer• AOA Transmitter• Sensor• CAD ComputerFire Control System Elements• Antenna• Transmitter• Control UnitNavigation/Communication System ElementsAircraft Engine Electronics System ElementsPrinted Circuit Boards

1st Air Maintenance Factory Directorate offers maintenance, repair, overhaul, upgrade and functional test services for air vehicles and their power plants avionic systems under its responsibility.


Test Program Software• Preparation / Control• TPS/ATE IntegrationPrecision SolderingAutomatic Test Analog/Digital Chassis Test

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PRECISION MEASUREMENT EQUIPMENT CALIBRATION

ELECTRICAL CALIBRATION• AC/DC Voltage Calibration• AC/DC Current Calibration• Resistance Calibration• Inductance Calibration• Capacitance Calibration• Phase/Angle Calibration• Digital/Analog Multimeter Calibration• Calibrator Calibration• High Voltage Calibration• Attennuator Calibration• Low/High Level RF/Microwave Power

Calibration• Time/Frequency Calibration• Spectrum Analyzer Calibration• Analog/Digital Oscilloscope Calibration• Vibration Transducer Calibration• Aircraft Test Set Calibration• VXI Calibration

ON-SITE CALIBRATION• Turboprob/Turbofan/Turbojet Engine Test

Cell Calibration of J79, J85, F110, CT7/T700, T56/TYNE22, PGB, GTC, JSF and ADG type engines

• Functional Check/Test Benches Calibration• Hydraulic Analysis Device Calibration• Oil Analysis Device Calibration• Liquid Flow Gage Device Calibration

- Turbine, Rotometer and Magnetic type meters - Liquids used for calibration; Fuel (MIL-PRF-7024), Oil(MIL-PRF-7808), Hydraulic (MIL-H- 5606) and Water

PHYSICAL/MECHANICAL CALIBRATION• Pressure/Vacuum• Dimension• Form• Angle• Temperature• Force• Torque• Flow (Gas/Liquid)• Mass/Balance

1st AMFD offers calibration, control, maintenance and repair services for Precision Measurement Equipment which are under the responsibility of 1st Air Maintenance Factory Directorate according to the standards traceable to International Metrology System.

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TECHNOLOGY AND WEAPON SYSTEM DEVELOPMENT

MECHANICAL CAPABILITIESMechanical Design: Mechanical parts are designed for integration and development projects. Computer Aided Design (CAD) tools are used for design work.

STRUCTURAL ANALYSISStructural analyses are performed for validation of strength properties in new designs and existing structures. ANSYS and MSC Software products are used for the analyses.

AERODYNAMIC ANALYSISComputational Fluid Dynamics (CFD) analyses are performed for flight performance, drag coefficients and safe separation characteristics. ANSYS Fluent software package is used for the analyses.

INTEGRATION AND CERTIFICATION ACTIVITIESCertification analyses and tests are carried out for integration of avionic systems and external stores (munition and pods). External stores certification and environmental conditions qualification activities are based on MIL-HDBK-1763 and MIL- STD-810 standards respectively.

Technology and Weapon Systems Development Directorate is responsible for integration and development projects that improve flight safety, economical usage and operational efficiency of aircraft under responsibility of 1st Air Maintenance Factory Directorate.

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AVIONICS INTEGRATION CAPABILITIESIn the scope of activities performed for avionics Integration of modern avionics and Weapon Systems on aircrafts in TurAF inventory:

• Electrical Group-A Design and Installation on Aircraft (MIL-W-5088),

• Pilot-Vehicle Interface Design,• Operational Flight Program Development

(AQAP-2210 and IEEE 12207),• System Integration Laboratory Tests,• Electrical Load Analysis (MIL-STD-704),• Aircraft Ground Testing (MIL-HDBK-1763)• Electro-magnetic Interference/

Compatibility Tests (MIL- STD-464),• Preparation of Technical Data Package for

mass Production.

FLIGHT TEST INSTRUMENTATION CAPABILITIES• On-board High Speed Camera Application

for Safe Separation of Munitions,• 1553 Mux-Bus Data Recording,• On-board Sensor application to collect data

(vibration, temperature, pressure etc.,• Analysis of Collected Data.

FLIGHT TEST CAPABILITIESDevelopment flight tests are performed by 401st Test Flight Squadron Command of 1st Main Jet Base in coordination with 1st Air Maintenance Factory Directorate.• Planning and execution of flight tests of the

modernization activities, avionic system integration and upgrade, and structural upgrade projects of jet aircraft

• Planning and execution of the flight tests related to determine the cause of an


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anomaly,• Real time data/image transmition, data

processing and evaluation in test flights,• Mobile Telemetry System,• Ability to follow and to direct the flights. • In the scope of external store certification,

planning and execution of the flight tests:• Flight Loads Test,• Flutter Test,• Environmental Tests,• Flying Qualities Test,• Performance and Drag Test,• Captive Flight Profile Tests,• Employment Tests,• Jettison Test,• Ballistics Tests according to MIL-HDBK-1763.

OUR RECENT PROJECTS• Stand Off Missile-B2 Project• Stand Off Missile for JSF Project• SOM Data Link Project• Laser Guided Kit-84 Project• Laser Guided Kit (TEBER) Project• Small Diameter Bomb Project• Air To Air Missile Project• F-16 Electronics Warfare Project


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TEST AND PRODUCTION SYSTEMS DEVELOPMENT ACTIVITIES

CAPABILITIES AND PRODUCTS• Turbojet/Turbofan Engine Test Benches• Turboprop/Turboshaft Engine Test Benches• Diesel Engine Test Benches• Piston Engine Test Benches • APU Engine Test Benches• Engine Accessories Test Systems• Aircraft Accessories Test Systems• Aircraft Electric Test Systems• F16 ISA (Integrated Servo Actuator) Test

System• F16 OBOGS (On Board Oxygen Generating

System) • CRU-120/A Test Stand• F16 REOS (Regulated Emergency Oxygen

System) Test Stand

• CT7 PGB (Propeller Gear Box) Test System Modernization.

• J-85 VEN (Variable Exhaust Nozzle) Test Stand

• Heat Treatment Workshop/Furnace Control System Design

• Tension-Compression Stand Design and Manufacture.

• PLC (Programmable Logic Controller) Based Process

• Control System Design• DAQ (Data Acquisition) System Design up to

1000 Channels• Mobile Test Systems Design• Fuel System Design• Sound-Proof Control Rooms Design and

Manufacture.

The design and manufacturing of the first and only national Turbojet-Turbofan engine test bench system; Atılım Test Cell has been carried out by this unit.

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F135 ENGINE EUROPEAN REGIONAL MAINTENANCE, REPAIR, OVERHAUL AND UPGRADE PROVIDER1st Air Maintenance Factory Directorate with the Vision of “being a logistics center contributing to Turkish Air Forces for being the most powerful aerospace force in the Region”, takes firm steps in meeting the F135 engines depot level maintenance requirements, not only for the Turkish Armed Forces but also for the European Countries.

From the year 2020; F135 engine depot level maintenance, repair, overhaul and upgrade activities of all F-35A aircraft, to be procured by the European Countries under the Joint Strike Fighter Program, will be performed at 1st Air Maintenance Factory Directorate plant.

1st Air Maintenance Factory Directorate takes pride in acquiring F135 Engine European Regional and Upgrade provider and competing with Norway and Holland.

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QUALITY MANAGEMENT ACTIVITES

Giving priority for fly safety and customer satisfaction at overall activities, 1st Air Maintenance Factory Directorate has awarded certificates. They are as follows;• AQAP-2310, NATO Industrial Quality

Assurance • AS 9100, Quality Management System (For

Aviation, Space and Defense Organizations)• AS 9110, Quality Management System (For

Aviation Maintenance Organizations)• TS-EN-ISO-9001:2015, Quality Management

System• TS-EN-ISO-14001:2015, Environmental

Management System• TS 18001 Occupational Health and Safety

Management System• NADCAP Non-Destructive Testing (X-Ray)• Certification *GE Company Quality

Compliance• TAI Company Quality Approval• THY Company Quality Approval• JOAP Oil Analysis Certification• ABO Oxygen Nitrogen Analysis Laboratory

Correlation • Turbomeca Fuel and Oil Analysis

Certification

QUALITY ASSURANCE LABORATORIES

CHEMISTRY LABORATORY• Aircraft Fluids Test and Analysis

Spectrometric Oil AnalysisJet Fuel Test and AnalysisHydraulic Particles AnalysisAviator’ Breathing Oxygen and Nitrogen Analysis

• Metal Analysis Elemental analysis of metal alloys by

ICP-OES, Spark-OES, Carbon-Sulfur Instruments

• Shelf Life Material Quality ControlFT-IR Spectrometer

• Process Control Test and AnalysisChemical Coating and Cleaning Baths, aircraft paint, penetrant.

• Fuel Dilution in Aircraft Oil Measurement by Fuel Sniffer

METALLURGICAL LABORATORY • Failure Analysis• Process Control Tests• Certification Tests• Metallurgical Investigation• Scanning Electron Microscope (SEM)• Elemental analysis of surfaces or cross

section of B5 to U92 materials• FOD (Foreign Object Damage) Investigation • Image AnalysisImage analysis is done to detect for the fractured section surface by using various magnifications. The cause of the damage is found by examining the traces of damage mechanisms in the structure.

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CERTIFICATES

• AS 9100D: Quality Management System Certification for Aviation, Space and Defense Organizations - for design, development, and production activities. (The First Military Institution In Turkey)

• AS 9110C: Quality Management System Certification for Aviation, Space and Defense Organizations - for maintenance and overhaul activities. (The First Military Institution In Europe)

• AQAP 2310/AQAP 2210: NATO Quality Management System / NATO Software Quality Assurance Requirements for Aviation, Space, and Defense Organizations

• THY Company Approval Certificate

• ISO 9001:2015: Quality Management System Certificate

• ISO 14001:2015, Environmental Management System Certificate

• NADCAP Non Destructive Testing(X-RAY) Certificate

• OHSAS 18001:2007, Occupational Health and Safety Management System Certificate

• AFMETCAL Conformity Certificate for Metrology and Calibration Laboratories by US Air Force

• TAI Company Approval Certificate

2nd

AIR MAINTENANCE

FACTORY DIRECTORATE

150

2nd AIR MAINTENANCE FACTORY DIRECTORATE


AIRCRAFT DEPOT LEVEL MAINTENANCE (DLM) & REPAIR ACTIVITIES

AIRCRAFT UNDER TECHNICAL MANAGEMENT RESPONSIBILITY AND HAVING DEPOT LEVEL MAINTENANCE CAPABILITY• C-160• C-130• CN-235• KC-135R• T-41D• SF-260D

TECHNOLOGICAL APPLICATIONS• Removal and installation procedures for the

different types of aircraft heater boots of various propellers

• Maintenance/repair procedures for propeller spinner and crescents

Includes maintenance/test, overhaul, modification and modernization of aircraft, hydraulic, pneumatic, electrical and avionic systems under the responsibility of 2nd Air Maintenance Factory Directorate (2nd AMFD) along with the repair and replacement of structural parts.

• Repair procedures for different types of aircraft radomes

• Inspection/repair and maintenance procedures for lifeboats and life vests

• Airframe sealing procedures for different types of aircraft

• Rebuilding damaged composite components (fiberglass and carbon composite laminates, honeycomb etc.) as similar to new ones.

• Performing inspection/repair, maintenance, and folding procedures on different types of aircraft liferafts

• Canopy installation.• Bladder type cell repair procedures.• Maintenance and inspection procedures for

aircraft tires.

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C LEVEL MAINTENANCE CAPABILITY OF A400M A/C (24 AND 48 MONTHS)• Ready for the acquiring the H level

maintenance capabilities as a result of its past experience

• AIRBUS DS recommended to accomplish modification activity onto A/C by 2’nd AMF Directorate as a result of its past experience and success.

AIRCRAFT UNDER TECHNICAL MANAGEMENT RESPONSIBILITY ONLY• E-7T• GÖZCÜ• GULF 550• GULF IV• CITATION VII• CITATION

AIRCRAFT DEPOT LEVEL MAINTENANCE (DLM) & REPAIR ACTIVITIES

152



AIRCRAFT ENGINES; DEPOT LEVEL MAINTENANCE & REPAIR


With the capability of 0.0005 inch volume accuracy soft-touch measurement of aircraft and engine parts in a 3-D environment;• Distance between two points• Distance between axes• Distance between two planes• Coordinates• Inner/outer diameter• Out of roundness• Inclination• Perpendicularity• Angle measurements of aircrafts, aircraft engines and accessories are performed accurately.

In the mechanical and chemical cleaning section, aircraft and engine parts are cleaned with;• Sandblasting• Glass powder

Engine overhaul shop, which performs depot level maintenance and repairs of aircraft piston en-gines and accessories, overhaul and maintenance activities for AEIO-540D4A5 engines used on SF-260D airplanes, IO-360D engines used on T-41D airplanes and Lycoming IO-540-C4D5D engines used on TB-20 airplanes, are performed.

Also, aircraft overhaul shop which possesses the certificate for overhaul and authority of aircraft piston engines up to 450 HP, has the capability for overhauling all engine series of Lycoming and Continental.

153



• Plastic media• Ultrasonic methodsTest bench procedures are performed by the aid of computer in Engine Test Cell which has the capability of testing the aircraft piston engines up to 750 HP.

In computer controlled test bench,• Oil pressure • Fuel pressure • Manifold pressure • Cylinder head temperature • Oil temperature • Fuel temperature • Engine RPM • Compression leakage control • Magneto rpm reduction • External leakage controls of SF-260D aircraft engines are carried out.

Precision (computer controlled) balancing processes are performed using the Hoffman horizontal and vertical balancing apparatus located in aircraft engine shop. On the vertical balancing appara-tus, balancing processes of material up to 153 cm diameter and 113.4 kg weight and on horizontal balancing apparatus, balancing processes of material up to 2.5 m length and 135 kg weight, can be performed accordingly.

AIRCRAFT ENGINES; DEPOT LEVEL MAINTENANCE & REPAIR

154



AVIONICS SYSTEMS; MAINTENANCE AND REPAIR

TECHNOLOGICAL APPLICATIONS & PRODUCT RANGEIn flight instruments shop having 300.000 class controlled environment conditions with an area of 700m2 • C-130, C-160 aircraft;

A/P (Autopilot Computers & Access) • KC-135R aircraft;

F/D (Flight Director Roll & Pitch Comput-ers)

• C-130, C-160, F-16 and F-4 aircraft; HSI (Horizontal Situation Indicator) ADI (Attitude Direction Indicator)

• CN-235, C-130, C-160, KC-135R aircraft; IAS (Indicated Airspeed)TAS (True Air Speed)RPM (Revolutions Per Minute)FTIT (Fan Turbine Inlet Temperature)ACC (Accelerometer)AOA (Angle Of Attack)RMI (Radio Magnetic Indicator)ALT (Altimeter)

PRESS (Indicators, Transmitters,) CLK (Clock)FQTY (Fuel Quantity Indicators & Control Amplifiers)

• CN-235 aircraft; Servoed Encoding Altimeter, CACP (Cabin Area Control Panel)

• SALT (Servo Altitude Indicator) of F-16, F-4, KC-135R aircraft

• ENCALT (Encoding Altitude Indicator) of CN-235, C-130, C-160 aircraft are performed.

• As the unique GYRO repair center of Turkey, in this shop repairs of all types of “Non-inertial”, “Vertical”, “Rate”, “Platform” and “Directional” Gyros are performed accurately. Within the scope of gyrobalancing capability, balancing of gyros up to 25.000 rpm is performed. In the GYRO shop which has a 100.000 class clean area of 200m2, repair processes of; DG (Directional Gyro) of CN-235, C-130, C-160, KC-135R, F-4, F-5, SF-260 aircraft, VG (Vertical Gyro) of CN-235, C-130, C-160, KC-135R, F-4, F-5, SF-260 aircraft and RATE Gyro of F-4, F-5 aircraft are carried out.

Maintenance, testing and repair activities of flight instruments, autopilot units, navigation instru-ments, aircraft engine instruments and general situation instruments of combat, transportation and training aircraft, are performed in this shop.

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ELECTRONIC SYSTEMS; MAINTENANCE AND REPAIR

COMMUNICATION (RADIO) SYSTEMS• C-130, C-160, UH-1H aircraft; HF (High

Frequency)• C-160, SF-260 aircraft; VHF (Very High

Frequency)• C-130, C-160, KC-135 R, F-4, F-5 aircraft; UHF

(Ultra High Frequency) • Transceiver control boxes are carried out

RADAR SYSTEMS• C-130, C-160, CN-235 aircraft; Air Radar units

and accessories• C-130, C-160 aircraft; Doppler Radar units

and accessories• F-16, F-4, C-130 aircraft; Altimeter Radar

units and accessories are carried out

NAVIGATION SYSTEMS• C-130, KC-135R, F-16, F-5 aircraft; TACAN

(Tactical Air Navigations)• CN-235, SF-260 aircraft; DME (Distance

Measuring Equipment)• CN-235, SF-260, C-130, T-41 aircraft; ADF

(Automatic Direction Finder)• CN-235, SF-260, C-130, C-160 aircraft; VOR

(VHF Omni-Range) units are carried out

In electronic systems shops which have 300.000 class controlled environment conditions and where repairs of systems of communication between aircraft and tower and navigation systems are performed, the testing, troubleshooting and repair activities of;

156



RADOME REPAIR AND TEST LABORATORY

The radome test laboratory facility, being the sole facility in its field in our country, can currently pursue very high technology such as test program software. The electromagnetic permeability tests of aircraft nose radomes are performed. The system which uses microwave technology, is controlled by a computer and the refraction angles caused by the tested Radome radar waves are measured. The system consists of a main building where receiver units, radome connection hardware, control console, system computer are located, and transmitter tower where X band transmitter, control console are located. Repair and testing activities for radomes of KC-135R, CN-235, RF-4E, F-4E 2020, F-16C/D, C-130B/E, C-160 aircraft and also radomes of civil aircraft, are performed.

TECHNOLOGICAL APPLICATIONS• RFO adjustment with mono pulse bridge • Testing without radome• Testing with radome• Evaluation of measurement results in the computer controlled environment

157



PROPELLER; MAINTENANCE, REPAIR AND OVERHAUL

In propeller maintenance/repair center, the sole facility in Turkey and Middle East, with two section having individually 420 m2 covered area, maintenance and repair processes of the propellers of piston and turboprop aircraft engines are performed. In propeller shop;• Maintenance and overhaul processes• Angle control• Altitude control• Balance control• Parts measurement control• Adjustment processes• Corrosion removal • Control and restoration activities for

propeller anti-ice systems are performed.

On hydraulic function test bench;• Angle Adaptation Control• Feather Angle Control• Small Pitch Angle Control• Brake (Reverse) Angle Control• Hydraulic Pitchlock Control• Mechanical Pitchlock Control• Internal and External Oil Leakage Control• Residual Oil Amount Control on Propellers

are performed.

Also, material structure and fatigue processes of C-130 aircraft propeller blades by MWM (Meandering Winding Magnetometry) and Sleeve and Spindle overhaul activities of Cougar helicopters, are performed.

158



AIRCRAFT OIL-FUEL ACCESSORIES; MAINTENANCE AND REPAIR

In oil-fuel shop, maintenance, repair and overhaul activities for fuel injectors, fuel tanks, fuel filters, oil pumps, oil cooler radiators of aircraft piston engines and oil cooler radiators, fuel level valves, oil and fuel cut-off valves, fuel filters, fuel tanks of Turboprop engines, are performed. Repair activities for:• C-130, KC-135R, SF-260, T-41 aircraft fuel tanks• C-130, SF-260, CN-235, F4E, UH-1H, T-41 aircraft fuel pumps• C-130, CN-235, KC-135R, SF-260, T-41, F-16, F-5, F-4 aircraft fuel shut-off valves• C-130, CN-235, KC-135R, F-5, F-4 aircraft control valves• F-16 aircraft; Fuel Transmitter, fuel flow proportioner• SF-260, TB-20 aircraft fuel injectors• C-130, CN-235, TB-20, SF-260, T-41 aircraft oil radiators are performed.On the system fuel flow test bench can give flow up to 100.000 PPH. Test processes of fuel transmitters, control valves, shut-off valves and fuel pumps are performed by high volume fuel flow bench which has a measurement capability of 0-120 PSI pressure +/- 0.05° with +/- 2.5 % accuracy.

159



HYDRAULIC SYSTEMS; MAINTENANCE AND REPAIR

PRODUCT RANGE• Brakes• Landing Gears• Accumulators• Valves• Governors• Hydraulic Pumps• Tire Rims• Pressure and flow Regulators• Shock Absorbers• Cooling Fans

160



ELECTRICAL SYSTEMS; MAINTENANCE AND REPAIR

A/C GENERATORS• Insulation• Current for revolution control• Voltage tests

WIRING HARNESS• KC-135R, C-130, CN-235 and F-16 aircraft

wiring repair• Refabricated, and reinstalled wiring on

aircraft • Wiring Production

Maintenance, repair and test activities for aircraft generators, voltage regulators, control panels, warning relays, alternators, starting motors, spark plugs, cable harnesses, electromechanical power converters, synchronized alternators, magnetos, DC and AC motors, Voltage/frequency converters, headlights, cranes and starter generators are performed.

GENERATOR CONTROL UNIT• Low voltage • High voltage• Frequency• Short circuit tests

MAGNETO• Insulation• Sparking plug ignition• Revolution control tests

161



AIRCRAFT RUBBER/PLASTICAND COMPOSITE SYSTEMS; MAINTENANCE AND REPAIR


• Propeller heater boots overhaul• Propeller spinners and crescents maintenance and repair• Aircraft nose radomes maintenance and repair• Liferafts and life vests maintenance and repair• Aircraft tires maintenance and repair are performed.• Canopy (windshield) mounting and sealing against to the pressuring on the body and repair of

fiberglass parts• Processes of humidifying, baking of radomes and rubber/plastic material• Repairs of fiberglass parts and revisions of spinners are performed.• Testing and repair of C-130 aircraft dinghies are carried out.

162



AIRCRAFT INSULATION AND FURNITURE; MAINTENANCE AND REPAIR


For all type aircrafts and helicopters repair and modification of• Sound insulation blankets• Pilot seats, cushions and pilot beds• Safety belts• Parachutist / passengers seats• VIP seats are carried out.

163



PRECISION MEASUREMENT EQUIPMENT CALIBRATION

MECHANICAL CALIBRATION CAPABILITES• Micrometers• Compass• Comparators• Digital and analog scales• Weights• Temperature and moisture meters• Thermocouples• RPM indicators• Precision surfaces• Measurement masters (gages)• Test adapters• Torquemeters

The calibration program of AFMETCAL, USAF is applied in PMEL, and the calibration procedures are performed IAW technical publications all of which are being updated continually. Environmen-tal conditions for temperature and humidity control, and also dust control (100.000 class for 60 m2, and 300.000 class for 256 m2 of total area) are obtained 24 hours/365 days in the PMEL which has a covered area of 482 m2. Mechanical and electronic calibration procedures are carried out in PMEL which has the certificate of superior success of AFMETCAL.

ELECTRONIC CALIBRATION CAPABILITES• Analog and digital multimeters• Microwave measurement apparatus• AC/DC power supplies• Electronic counters• Phase meters• Signal generators• Panel meters• Oscilloscopes• LCR meters• Special testing systems

164



NDI (NON-DESTRUCTIVEINSPECTION)

Cracks and folding, internal voids, all welding defects, corrosion, cold forge and casting defects, forging layers, tears, shrinkage, contraction and other linear defects, raw material and manufacturing defects can be detected during inspections. The personnel who have been certified internationally as LEVEL II carry out NDI (Non-Destructive Inspection) inspection in this shop.

NDI METHODS• Fluorescent Penetrant Inspection (MIL-STD-6866)• Magnetic Particle Inspection (ASTM-E-1444)• Eddy Current Inspection (ASTM-E-703 & ASTM-E-566)• Ultrasonic Inspection (ASTM-E-428)• Radiographic (X-ray) Inspection (MIL-STD-453)

NDI APPLICATIONS• Aircraft structural parts• Aircraft engines and accessories• Propellers and units• Hydraulic accessories

165




AIRCRAFT STRUCTURAL COMPONENTS MANUFACTURING• Radome manufacturing

RUBBER TECHNOLOGY• O-ring• V-ring• X-ring• T-ring • Bellows• Packing• Diaphragm

COMPOSITE TECHNOLOGY• Radome manufacturing for ground

equipment• Aircraft canopy manufacturing• Aircraft structural components

manufacturing• Pilot, parachutist and tank crew helmets

BALLISTIC PROTECTIVE VEST• Protection under combat conditions• Protection in case of armed attacks

UNDERWEAR VESTWeight : 3.000 gr.Ballistic Resistance(NIJ 0101.04) : IIProtective Material : UHMVV-PE fabricProtection Against : Handguns, MP-5 Automatic Handguns Automatic Handguns, Sten Automatic Handguns Trauma Depth : 30 mm max

SOLDIER VESTWeight : 6.900 gr.Ballistic Resistance(NIJ 0101.04) : IIIProtective Material : UHMVV-PE Fabric +UHMVV-PE PlateProtection Against : Handguns, Automatic Handguns, RiflesTrauma Depth : 30 mm Max

166



MACHINING TECHNOLOGY

• Milling• Electrical Discharge Machine• CNC Electrical Discharge Machine• Grinding• Honing• Computer Aided Design and Manufacture

(CAD/CAM)• Rubber Pad

Hot Technology• Forging• Casting• Welding• Head Treatment

Finishing Technology• Coating• Painting

167



MANUFACTURE

PARACHUTE MANUFACTURINGDetachment Landing Parachutes : T-10B ve T-16, T-10R Spare ParachutePilot Parachutes : F-16, F-4E/2020, SF-260, BA-22Seat Parachutes : F-4E/2020, F-16Speed Reduction Parachutes : F-16, NF-5 A/B, F-4E/2020 Brake ParachutesLoad Parachutes : G-12D, 28-15 Feet Load Parachute

BALLISTIC PROTECTIVE INFANTRY HELMETStructure : CompositeFiber Material : UHMW-PEMatrix Material : Phenolic ResinTotal Helmet Weight : 1,5 kgAverage Helmet Thickness : 9-10 mmSuspension System : Shock AbsorberResistance to Weapons : Resistance to pistols and Hand grenadesBallistic Performance : 550-620 m/secTrauma Depth : 25 mm

PROTECTIVE PILOT HELMETProtective flying helmet for pilots of aircrafts and helicopters. Communication system is weareable and night vision goggles system, oxygen mask attachable to the helmet with dark and transparent visor options.Protective material : Epoxy/fiberglass reinforced plasticWeight : 1050-1100 grImpact resistance : Shock absorbing polyurethane pads.

168



MANUFACTURE

ENGINE TRANSPORTATION STANDUsed to transport F-16 Engine through CN-235 A/C.Platform Width : 2135 mmPlatform Long : 3290 mmLoad Capacity : 2000 kgEmpty Weight : 1190 kg

GAS OXYGEN TRANSPORTATION TRAILERUsed to fill A/C oxygen cylinders.• 8 each cylinder• Each cylinde has 2800 Psi and 50 lt volume

SHEET METAL FORMING TECHNOLOGY• Pot die• Form Press• Punch Pres• Streching and Shrinking Bench• Router

HOSE/TUBE MANUFACTURINGManufacturing and testing procedures for tubes belonging to C-130, C-160, KC-135R, CN-235, SF-260D and T-41D are carried out.

169



GROUND SUPPORT EQUIPMENT; MANUFATURING AND OVERHAUL

BOMB LOADER VEHICLE (SEYİT ONBAŞI)The project for producing a bomb loader vehicle that shall cover also the JSF aircraft were initiated by TurAF in the year 2011, a prototype bomb loader was produced in 2013, and a decision was made to perform mass production as of the year 2014. A planning has been made for producing totally 70 Seyit Onbaşı bomb loaders until 2020.

Except the differential system, all other parts are domestic production and approximately 75 percent of domestic production parts have been manufactured by 2nd AMFD. It is capable of loading and unloading ammunition such as missiles, bombs and similar external loads on board of all fighters in TurAF inventory. In addition, thanks to the additional capability of the remote control system on the bomb loading vehicle Seyit Onbaşı, which its equivalent bomb loaders MJ-1 and MJ-1TR have no such a feature, Seyit Onbaşı provides safe, accurate, and easy loading/ unloading operations for its operators.

170



GROUND SUPPORT EQUIPMENT; MANUFATURING AND OVERHAUL

DIMENSIONS Length : 3850 mmWidth : 1250 mmHeight : 1070 mmWeight : 1800 kg

CAPACITY OF LIFTING On the Plate : 1360 kg (3000 lbs.)On the Fork : 1020 kg (2250 lbs.)

LOADING PERFORMANCE Minimum distance,platform to ground : 15,8 cm (6,25”)Maximum distance,platform to ground : 198 cm (78”)Minimum distance,fork to ground : 2,5 cm (1”)Maximum distance,fork to ground : 184 cm (72,5”)

VEHICLE MOBILITY Maximum Speed, Loaded : 16 km/h (10 mph)Breaking Distance,Loaded : 4,88 m (16 ft)Level of Gradeability,

Loaded : 10 % Level of Gradeability,Unloaded : 20 % Transmission System : Hydraulic

ENGINE Model No. : 9LD625-2Power : 28 HPNumber ofCylinder(s) : 2Cooling System : Air CooledFuel Type : DieselNoise Level : 84 db (A) maximum (unloaded 7m 1500 RPM)

STEERING SYSTEM AND WHEELSSteering System : HydraulicWheel Track (Thread) : Rear 107 cm Front 73 cmTires : 5.00-8, 8 plies pneumatics rubber tireDiameter of SteeringWheel : 35 cmTurning Radius : 3,3 m

171



GROUND SUPPORT EQUIPMENT AND LIGHT WEAPON; MAINTENANCE, REPAIR AND OVERHAUL• Repair and maintenance of air conditioning,

ventilation and firefighting systems• Repair, maintenance and refilling of the fire

extinguishers• Repair and maintenance of the mechanical

and electronic benches and equipments• Production, filling and testing processes for

the liquid oxygen and nitrogen• Maintenance and repair of A/C arrester

Hook, Net and Mobile barrier Systems• Aircraft Starters• lluminating Devices• Generators• Compressors• G-3 Machine Gun• MG-3 Machine Gun• Light Weapon Systems• Water Cannon

172



MOTOR VEHICLES AND WORKING MACHINES; MAINTENANCE, REPAIR AND OVERHAUL

Motor Vehicles, Working Machines• Aircraft fuel supply tanker• Aircraft towing vehicles• Aircraft anti-icing/de-icing units• Over-snow personnel carriers• Aircraft firefighting vehicles• Vacuumed runway sweepers• Snow plowing, sweeping and blowing

vehicles• Accident rescue cranes

173



PRODUCTION OF AIRCRAFT TOW TRACTOR, RAHVAN

A new project to produce Rahvan aircraft tow tractor which has economical sustainability, widely-available spare parts, is composed of domestic materials, provides a easy-operatable and standard structure, is appropriate for international standards, is rapidly returned to operable status and meets tow tractor needs within the national possibilities has been initiated in 2010 by 2nd AMFD. Then, mass production has been started in 2014 after prototype production.

TECHNICAL SPECIFICATIONSReverse sighting camera, automatic air conditioner, rear differential - steering wheel controlled standard closed cabin, 12V output for trailer, inner cabin controlled floodlight, clutch parking brake.

Engine : Tumosan, 4DT39, Turbo-Diesel Power : 95 HP @2500 RpmTorque, Maximum : 370 Nm @1500 RpmGear Case : Powershift, Full AutomaticDifferential Gear : Max-TrackBrake : 5 Pl. Oil Immersed HydraulicSteering Wheel : hydraulic, self-contained hyd. pumpThrust : 4 WdManoeuvre : 4 WsTurning Radius : 4400 mmSpeed : 32 km/H Max. (Forward/Reverse)Weight : 5250 kgLength : 4000 mmWidth : 2400 mmHeight : 2650 mm (without 2350 mm flash light)Height Above Ground : 330 mmAngle of Approach : 41°Angle of Departure : 28°Number of Occupants : 2+4

174



SERVICES OF THE QUALITY LABORATORY

Physics/Chemistry Laboratory• Shelf Life Item Inspection• Strength Tests (Pulling, pressing, cutting)• Chemical process control tests• Chemical material analyses• Hardness checks

Metallurgy Laboratory • Composition of metal materials• Damage mechanisms determination• Process control tests • Certification tests

Metallurgic inspections Oil/Fuel Laboratory• Water-methanol mixtures control• Contamination control for hydraulic fluids• Determining microorganisms in aircraft

fuels

Textiles Laboratory• Strength of Breaking, Tearing and Exploding• Air permeability• Determining Waterproofness• Determining burning level• Sensitivity to washing, dry-cleaning, friction,

and color photosensitivity• Determining filling-warp and weaving types• Material type identification

Rubber Laboratory• Vulcanization time testing• Low-temperature testing• Physical performance tests (hardness,

density, tensile strength)• Tests those applied after ageing in oil, fuel

and air• Purity tests for inhalation oxygen

175



QUALITY APPROVALSAND CERTIFICATES

• AS 9100 Aviation, Space and Defence Organizations Quality Management System Certificate• AS 9110 Aviation Maintenance Organizations Quality Management System Certificate• ISO 9001 Quality Management System Certificate• ISO 14001 Environmental Management System Certificate• AQAP 2110 Quality Assurance Level Certificate• SHY-145 Approval Certificate• OHSAS 18001 Occupational Health and Safety Management System Certificate• LM C-130 Authorized Service Center Certificate• AFMETCAL Calibration Compliance Certificate

3 rd

AIR MAINTENANCE

FACTORY DIRECTORATE

177

3rd AIR MAINTENANCE FACTORY DIRECTORATE


ELECTRIC SYSTEMS

PRODUCT RANGE Maintenance and Repair Capabilities• Electrical motors• Static and dynamic uninterrupted power

supplies• Static and dynamic frequency convertors• Invertors, redresors, voltage regulators• Airfield lighting with low and average

voltage underground cables failures• Airfield lighting systems• Disconnectors and circuit breakers• Low and average voltage transformer and

special type transformers

Manufacturing Capabilities• Automatic fire detection and warning

system panels• Constant Circuit Regulator• (It is a power supply enabling that the

airfield lighting unit comes on in five stages and with constant brightness.)

• Remote control board for the airfield lighting

• Internal and external main distribution, compensation and special type panels

178



ELECTRONIC/PRECISION SOLDERING LABORATORY

SOLDERING REQUIREMENTS FOR IPC J-STD-001 ELECTRICAL AND ELECTRONIC TOOLS

IPC Certified Technical Personnel (CIS) Training is offered to TurAF technical personnel in our Precision Soldering Laboratory established under our institution, by ICP Certified Instructors (CIT) as per recent technologies. Training demands of the Public and Private Sectors are met.

The training is offered in a 5-day period at our classroom having a 10-trainee capacity. IPC J-STD-001 training is valid for 2 years. Refresher trainings are also offered if demanded.

179



MECHANIC SYSTEMS


MACHINING• Triaxial Vertical Machining• Turning/Milling• Electro-Erosion• Grinding, Blending

Plastic FormingMetal Sheet Forming/Drilling/BendingWeldingPaintingMaintenance/Repair

VERTICAL PROCESS WORKBENCHHaving various alloys; brass, aluminum and steel materials can be processed with the sen-sitivity of ±0.01

PLASTIC INJECTION WORKBENCHAll types of plastic and thermoplastic items up to 225 gr can be pressed.

Designed and Manufactured Weapon Systems Onur Fuzes

180



MECHANIC SYSTEMS

Weapon Systems, Maintained And Repaired• D-VII B, L70 Air Defence Fire Control Radar

System• AGM-65A/B and TGM-65A/B MAVERICK Air

to Ground Missile Guidance Unit• GBU-10, GBU-12 (LGB) Air to Ground Laser

Guided Bomb, Computer and Control Section

• Rapier Low Level SAM System,2nd Line Level LRU, 3rd Line Level SRU Maintenance and Repair

• Rapier Low Level SAM System Tracker Radar• HAWK SAM System

Weapon Systems, Maintained and Repaired at Intermediate Level• AIM-120B ve AIM-120C7 AMRAAM AIR to AIR

Missile System

181



PRECISION MEASURUMENT EQUIPMENT CALIBRATION

Calibration service in 1000 m2 closed area with continuously controlled and monitored tempera¬ture, relative humidity, lighting, positive pressure and vibration.

In addition to this, on Site calibration service is provided with Transportable Field Calibration Unit (TFCU). Special designed for the subsys¬tems which are fixed or not transportable and have short calibration intervals.

Capable of 16.500 items calibration in a year with technical personnel, expert in their field.

Standard equipments are traceable to National Metrology Institute/Turkey (UME) and NIST/ USAQuality and Management System are performed in compliance with T.O. 00-20-14 U.S. Air Force Metrology and Calibration Program. The calibration service is evaluated & certified by Air Force Metrology and Calibration (AF M ETC AL/U SA) Program.

The Laboratory has Integrated Management System Documents TS EN ISO 9001:2008, TS EN ISO 14001, TS 18001 and AQAP 2110 NATO Quality System Document, AS 9110B and TS EN 9110:2010.

It has model certificate for quality guaranty implemented for maintenance institutions.

It renders services to public and private sector via its revolving fund system.

In addition, it offers consultancy services for establishing quality laboratories, determining device requirements and training.

182



PRECISION MEASURUMENT EQUIPMENT CALIBRATION

CALIBRATION CAPABILITIESMechanical Calibration • Pressure Calibration• Dimensional Calibration• Autocollimator, theodolites• Granite table surface with laser/planecator• Roundness• Parallelism and perpendicularity• Optical glass surface smoothness• Temperature Calibration• Force Calibration• Mass & Balance Calibration• Torque Calibration

ON-SITE CALIBRATION CAPABILITIESElectric/Electronics Calibration• AC/DC Voltage• AC/DC Current• Capacitance• Frequency• Oscilloscope• Microwave

Mechanical Calibration• Pressure• Torque• Temperature• Scale

Electronic Calibration • AC/DC Voltage Calibration• AC/DC Current Calibration• Resistance Calibration• Inductance Calibration• Capacitance Calibration• Phase Calibration• Attenuator Calibration• Low/High Level Powermeter Calibration• Frequency Calibration• Analog/digital oscilloscope calibration• Microwave Instruments Calibration

183



AVIONICS

We provide maintenance and repair services to the subsystems of all aircrafts and helicopters in TUAF inventory maintenance, repair and modernization of• All types of intercom and wireless

communication systems,• Inertial Navigation Systems,• IFF,

Depot level maintenance, repair, modification and modernization of• INS• TACAN• Auto pilot,• Radar warning receivers,• Air Combat Maneuvering Instrumentation

(ACMI) Pod,• Electronic Warfare Pod,

Maintenance and repairs of• Pilot Night Vision Goggles are executed.• In addition to this, circuit boards of these

avionic systems can be repaired, maintained and modernized and tested by automatic test stations.

184



ELECTRONIC WARFARE SYSTEMS

It performs depot level maintenance and repair of totally 120 units for the Electronic Warfare Systems of C-130, F-4 and F-16 Aircrafts.

PRODUCT RANGE• Analysis Processor • Processor, Radar Data• Superheterodyne Receiver• Superheterodyne Controller• Junction Box• C/D Receiver Assy• Display, Radar Set• Auxilary Sys.Con.• Prime Sys.Con.• Power Sup.• Power Amp.• Delay Line Unit• ECM Generator• Aft Repeater Assy• Cockpit Control Unit• Switching Group• Filter, Highly Permeable• Chaff-Flare Section, Munitions• Dispenser, General Purpose

185



AIRCRAFT RADIO AND IDENTIFICATION SYSTEMS

Maintenance and repair activities for radios, internal communication systems, IFF systems on fighter aircrafts, bombing aircrafts, transport aircrafts and training aircrafts in TurAF inventory and CSFDR system (Black Box), brake system, thermal camera and pilot night vision goggles on F-16 aircrafts in TurAF inventory are per-formed.

PRODUCT RANGE • External Communication Units• Panels• Internal Communication Units• Cards of Avionic units • IFF system units• Night vision googles• Anti / Skid system• Thermal camera system

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AIRCRAFT NAVIGATION SYSTEMS

Depot level maintenance and repair activities for Aircraft INS, TACAN, VOR/ILS, DME, AUTOPILOT, RADAR ALTIMETER, RELAY BOX, DED POWER SUPPLY, ANGLE OF ATTACK COMPUTER and ACMI POD flight systems in Turkish Armed Forces inventory are performed.

PRODUCT RANGE • Aircraft INS(LTN-92)• Aircraft TACAN(AN/ARN-153 and AN/ARN-

118)• VOR/ILS(KNR-634A)• Cards and chasis of avionic units • AUTOPILOT(APC-65F)• ACMI POD

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CONTROLLED CRYTOPRAGHIC ITEMS (CCI)

Distribution, accountancy, failure recording activities and failured items sending activities to foreign countries for 19 items of foreign Con-trolled Crytographic Items (CCI) are made in the CCI Workshop.

Failure detections of MIDS terminals (LVT-1, LVT-6, LVT-11) and their power supplies on Link-16 systems are performed by means of VLATS Test Station and LEGS program of the test station and the items are serviceably returned to service. Failured MIDS terminals are made serviceable in the CCI Workshop by ViaSAT Company Personnel within the scope of On site Engineering Contract. Terminals of which fail-ures cannot be eliminated are sent to ViaSAT/USA.

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RADAR AND NAVIGATION

• Transmitter and receiver units of Stationary and mobile radars which are one of the most important factor of air defense,

• Computer displays,• Circuit boards,• Tactical air navigation systems (TACAN,ILS)

units which can give directions to aircrafts in all weather conditions,

• Radar precision control and ground control approach (RAPCON-GCA),

• Identification of friend or foe systems can be maintained, repaired and modernized. In addition to that maintenance on site is carried out.

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COMMUNICATIONS

• Ground/ground, ground/air HF, UHF, VHF Have Quick radios• Communication systems in shelters, • Analog and digital switchboard, telephone, telem and voice recording systems• Air/air, air/ground target detection systems can be maintaned, repaired and modernized.• Production of various electronic cards and target detection systems

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ELECTRONIC POWER SUPPLIES

All types of power supplies of air and ground systems can be tested and repaired by using soft-wares and test devices produced by 3rd AMFD.

Because only a few centers have such capabilities in the world, we also provide services for NATO countries.

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GENERAL MATERIAL MAIN DEPOT AND PRODUCTION COMMAND

PRODUCT RANGE• Class A Uniform• Topcoat and coat• Battle Dress Uniform (BDU)• Flying Suits and Accessories• Band Costumes• Honor Ceremony Clothes• Ceremony Equipments• Worker & Airman Clothes• Producing and Maintaining of tents and

ceremony accessories• Work clothes.

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CERTIFICATES

• AQAP 2110 Industrial Quality Assurance Level Certificate• AS 9100 and AS 9110 Aerospace Quality Management System Certificate• ISO 9001: Quality Management System Certificate• ISO 14001: 2004 Environmental Management System Certificate• OHSAS 18001:2007 Occupational Health and Safety Management Certificate• AFMETCAL Certificate of Compliance

National Defence

Military

Army Sewing & Tailoring

WORKShops Directorate

Army Sewing & Tailoring WORKShops Directorate


ARMY SEWING & TAILORING

• Army Sewing & Tailoring Workshops Directorate carries out its activities in an area of 340.000 square meter in Maltepe / İstanbul.

• The aim of Army Sewing & Tailoring Workshops Directorate is making the planning, producing, maintaining and repairing activities timely, efficiently, economically to meet the needs of the staff of Land Forces.

• Technical Directorate affiliated to Army Sewing & Tailoring Workshops Directorate carries out its activities with the capacity of producing 356 different products and with an average of 1.200.000 pcs/suit per year.

• The user satisfaction is kept at highest level by workshop of special work contained within Technical Directorate by making private production for whom has non-standart body measurements.

• Rank, brevet (badge), epaulet etc. which are completing clothes produced by the Embroidary Workshop.

• Production Workshop has performed not only production and repairing of colors of Commandership of Land Forces but also all inneed of Turkish Armed Forces of colors.

• In the Product Development and Design Branch, we specify feature of confection, change of raw materials, make researches to increase efficiency and quality and prepare prototypes.

• All manifacturing activities are made pursuant to AQAP 2120 Quality Assurance System in the Army Sewing & Tailoring Workshops Directorate.



PRODUCT LIST OF CURRENT PRODUCTION1 Ceremony Uniform (summer / winter)

2 Mess dress Uniform

3 Harmonica Concert Uniform

4 Khaki Harmonica Ceremony Uniform (summer/winter) (for officers/NCOs)

5 Black Band Student Concert Uniform

6 Khaki Band Uniform (summer / winter)

7 Presidential Guard Regiment Band Ceremonial Uniform (jacket is blue and trousers are dark blue)

8 Khaki Coat Uniform (for NCOs)

9 Khaki Coat Uniform for Special Honor Troops (for officers/NCOs)

10 Coat Uniform for Presidental Guard Regiment (for officers/NCOs)

11 Khaki Coat Service Uniform (for officers/NCOs)

12 Khaki Overcoat (for female officers/NCOs)

13 Khaki Coat (with epaulette and without epaulette)

14 Khaki Trenchcoat (with epaulette and without epaulette)

15 Khaki Cloak for Band and Harmonica

16 Cloak for Mess dress Uniform

17 Cloak for Presidental Guard Regiment Band Ceremonial Uniform

18 Khaki Waistcoat (for officers/NCOs)

19 Shirt with Tie Collar (short sleeve/long sleeve) (for officers/NCOs)

20 Beige Shirt Short-sleeved for Summer (for officers/NCOs)

21 Combat Suit Uniform (for officers/NCOs)

22 Combat Coat Uniform (for officers/NCOs)

23 Dress Ceremony for Honor Troops (for officers/NCOs/Soldiers)

24 Coverall for Tank Staff (with epaulette and without epaulette)

25 Coverall for Land Aviation Technician

26 Coverall for Pilot (for flight)




CEREMONY UNIFORM (MAN)

COMBAT COAT UNIFORM WITH WINDBREAKER

COMBAT UNIFORM (FOR OFFICERS/NCOS) KHAKI WAISTCOAT

CEREMONY UNIFORM (WOMAN)

KHAKI COAT (WITH EPAULETTE AND WITHOUT EPAULETTE) KHAKI COAT


NATIONAL DEFENSE

MILITARY

NAVY SEWING & TAILORING

DIRECTORATE

199

NAVY SEWING & TAILORING DIRECTORATE



Navy sewing directorate is situated in the Cebeci neighborhood, Dikimevi district Çankaya covering an area of 26.905 m2. Closed area of the facility is 22.770 m2.

Navy sewing directorate covers one third of the field mentioned above.

200



RAW MATERIAL WAREHOUSE

• Warehouse number 1 has 4800 m3 volume.• Warehouse number 2 has 2700 m3 volume.• Warehouse number 3 has 3272 m3 volume.• Warehouse number 4 has 864 m3 volume.


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698 textile machines are available.

273 workers are available in navy sewing directorate.


202




CEREMONY UNIFORM (MAN)

SUMMER UNIFORM WITH LONG SLEEVE

(WOMAN)

CEREMONY UNIFORM(WOMAN)

SUMMER UNIFORM

WITH SHORT SLEEVE (MAN)

WINTER UNIFORM

WITH COAT (MAN)

SUMMER UNIFORM WITH SHORT SLEEVE

(WOMAN

WINTER UNIFORM

WITH COAT (WOMAN)

TRAINING UNIFORM

WITH SHORT SLEEVE (MAN)

SUMMER UNIFORM

WITH LONG SLEEVE (MAN)

TRAINING UNIFORM WITH SHORT SLEEVE

(WOMAN)

NATIONAL DEFENSE

MILITARY

AIR SEWING &

TAILORING WORKSHOP

DIRECTORATE

204

AIR SEWING & TAILORING WORKSHOPS DIRECTORATE


AIR SEWING & TAILORING

OFFICER’S EVERYDAY UNIFORM

SPECIALIZED ENLISTED MAN TRAINING UNIFORM MISSION UNIFORM

WOMAN OFFICER’S DAILY UNIFORM

WOMAN OFFICER’S DAILY UNIFORM EXCLUDING NCO

MOD PHARMACEUTICAL

PRODUCTION PLANT

206

MOD PHARMACEUTICAL PRODUCTION PLANT


HISTORY

There were only surgeons in the medical staff of Ottoman army until the mid 19th century. Physicians who were also pharmacists at the same time in those days were only taken into the army as time-of-flight agreements. Military hospitals and infirmaries have been established from the period of sultan Mahmut II, then physicians and pharmacists have been started to be taken into the army permanently. Gümüşsuyu, Kuleli, Davutpaşa, Cebehane, Maltepe, Tophane, Leventçiftliği, Topçular, Askeri Hassa, and Mabeyin hospitals were examples of military hospitals which were established at that period. To provide medical supplies of those military hospitals Pharmaceutical Warehouse Directorate (Askeri Eczane-i Amire) was founded in 1835.

In Turkish army, the production of pharmaceutical and medicinal material which was started in Askeri Eczahane-i Amire, was continued between 1853-1856 during the Crimean war. First patent medicine production facility was located in Gülhane Military Hospital at Sarayburnu-İstanbul. The facility was called Malzeme-i Sıhhıye-i Askeriye İmalatanesi (Military Medical Materials Facility) which pharmaceuticals (injectable solutions, quinine etc.), medical materials, medical dressing materials, gauze and first aid kits were produced. Pharmaceutical and medical materials were produced both at İstanbul and Sille district of Konya at First World War period.

Facilities located at İstanbul and Sille were merged into a single unit called Pharmaceutical Factory that part of Main Medical Warehouse at Ankara Etlik. The Pharmaceutical Factory served as a part of Land Forces Command until 1953 and then united to Ministry of Defence (MOD). Today’s MOD Pharmaceutical Production Plant was planned to build in 1960, became operational in 1964. MOD Pharmaceutical Production Plant still continues pharmaceuitcal production at the same location.

MOD Pharmaceutical Production Plant produces Nuclear Biological and Chemical (NBC) exposure antidotes which is critical and strategical, pharmaceuticals, gauzes and first aid kits (primarly NBC antidotes) and develops brand new formulations.

DRUG PRODUCTIONBRIGADIER GENERAL ŞÜKRÜ SÜER

INSPECTING PRODUCTION LINE

207



HISTORY

EXPERIMENTS ON DRUG MATERIALSTODAY’S MOD PHARMACEUTICAL

PRODUCTION PLANT

208



PRODUCTION DEPARTMENTS

• Tablet, Capsule Production and Blister Packaging Department • Injections Department• Solution Department• Pomade and Powder Department• Bandage and Dressing Materials Department

AMPOULE STERILISATION SOLUTION FILLING LINE

AMPOULE SEALING

209




TABLET, CAPSULE AND BLISTER PACKAGING DEPARTMENTNBC antidotes and antiflu capsules are manufactured.

AMPOULE PRODUCTION DEPARTMENT Ampoules of NBC antidotes and atropine autoinjectors are manufactured.

CAPSULE LINE

AMPOULE STERISATION

TABLET PRODUCTION

AMPOULE SEALING

210



BANDAGE AND DRESSING MATERIALS DEPARTMENTDifferent sizes of sterile/nonsterile gauze, compression bandages and personal first aid kits are manufactured.

SOLUTION DEPARTMENTDifferent sizes of sterile/nonsterile gauze, compression bandages and personal first aid kits are manufactured.

DRESSINGS DEPARTMENT

SOLUTION FILLING STATION

PACKET VACUUM

SOLUTION DEPARTMENT


211



POMADE AND POWDER DEPARTMENTAntimicrobial pharmaceutical preparation for topical use and concealing skin paint are manufactured.

POMADE TANK

POWDER FILLING


212



OTHER DEPARTMENTS

• Packaging• Inspection and Control Section• Warehouse• Water Facility

PACKAGINGThe finished products are packaged in tubes, bottle or blister with two different external packing forms as pharmacy and hospital.

PACKAGING

ANALYTICALY TESTS IN QCL

BLISTERING

MICROBIOLOGICAL TESTS IN QCL

INSPECTION AND CONTROL SECTIONAll the physical, chemical and microbiological tests for the final product, bulk product, raw material and packaging materials are performed in Quality Control Laboratory (QCL).

213



OTHER DEPARTMENTS

WAREHOUSERaw materials, consumables, bulk and final products are stored in a controlled environment. And also includes special areas like raw materials, quarantine, final product, flamable materials and cold storage.

WATER FACILITYWater is very important to ensure the high standarts in pharmaceutical production. The water system of our facilities consist of softened water unit, purified water and water for injection units.

DISTILATE WATER PRODUCTION DISTILATE WATER TANKS

214



PRODUCTS

NBC ANTIDOTES

PRODUCT NAME PACKAGING ACTIVE INGREDIENT INTENDED TO USE

Atropine suphate ampoule (0,5 mg) 1 mL

1 ml / 1 Ampoule Atropine suphateAntidote against organophosphate gases

Atropine suphate ampoule (1 mg) 1 mL

1 ml / 1 Ampoule Atropine suphateAntidote against organophosphate gases

Automatic Atropine İnjector 2 mL

2 ml / 1 AutoinjectorAtropine suphate, Obidoxime HCl

Antidote against organophosphate gases

Sodium Nitrite ampoule 10 mL

10 ml / 1 Ampoule Sodium NitriteAntidote against cyanide gases

Sodyum Thiosulphate ampoule l 10 mL

10 ml / 1 AmpouleSodyum Thiosulphate

Antidote against cyanide gases

Potassium Iodide Tablet

10 Tablet Potassium IodideAgainst nuclear accidents and weapons

Prydostigmine Bromide Tablet

21 TabletPrydostigmine Bromide

Antidote against organophosphate gases

Dekontaminasyon Tozu 50 g

50 g Tüp Alüminium SilicateUsed externally agianst chemical gases

CAMPAING AND TRAINING EQUIPMENTS

PRODUCT NAME PACKAGING ACTIVE INGREDIENT INTENDED TO USE

Concealing Paint20 g

20 g BottleActivated Coal, Vaseline

Camouflage

Halazone Tablet 25 Tablet Halazone Water disinfectant

Sodium Chloride Tablet

10 Tablet Sodium ChlorideKeeping electrolite balance

215



PRODUCTS

BANDAGE AND DRESSING MATERIALSPRODUCT NAME PACKAGING INTENDED TO USE

Sterile Wound Dressing (20x20 cm) 1 Item Dressing

Sterile Wound Dressing (30x30 cm) 1 Item Dressing

Non-sterile Wound Dressing (20x20 cm) 1 Item Dressing



Bandage (3x0,05 m) 1 Item Dressing and stabilizing

Bandage (3x0,1 m) 1 Item Dressing and stabilizing

First Aid Kit 1 Item Stabilizing and antibleeding

GENERAL USEPRODUCT NAME PACKAGING ACTIVE INGREDIENT INTENDED TO USE

Orgripal Capsule 16 Capsule

Paracetamole

AntigribalOxolamine Citrate

Chlorpheniramine Maleic

Orpermanganat Tablet 20 Tablet Potassium Permanganate Antiseptic

Ortikon Solution (Plastic Bottle) 1000 mL

1000 mL Bottle Polyvinyl Pyrrolidone iode Antiseptic





Hydrogen peroxide100 mL 100 mL Bottle Hyrogen Peroxide Antiseptic

Benzalkonium Solution 100 mL

100 mL Bottle Benzalkonium Chloride Disinfectant

Ayko Talk Powder50 g

50 g Bottle

Salicylic acid

AntimycoticBoric acid

Undecylenic acid

216



TABLETS

ORPERMANGANAT TABLET

CAPSULES

ORGRIPAL CAPSULE

PRODUCTS

217



SOLUTIONS

BENZALKONIUM SOLUTION 100 ML HYDROGEN PEROXIDE 100 ML

ORTIKON SOLUTION (PLASTIC BOTTLE) 1000 ML, 100 ML AND 50 ML

PRODUCTS

218



POWDER

AYKO TALK POWDER 50 G

CAMPAING AND TRAINING EQUIPMENTS

CONCEALING PAINT 20 G

HALAZONE TABLET

SODIUM CHLORIDE TABLET

PRODUCTS

219



NBC ANTIDOTES

ATROPINE AUTOINJECTOR 2 ML• SODIUM NITRITE AMPOULE 10 ML• SODIUM THIOSULPHATE AMPOULE 10 ML

DECONTAMINATION POWDER 50 GATROPINE SULPHATE 0.5 MG AND1 MG AMPOULE 1ML

PRODUCTS

220



POTASSIUM IODIDE TABLET

CONCEALING PAINT 20 G

PRODUCTS

221



BANDAGE AND DRESSING MATERIALS

STERILE WOUND DRESSING(20X20 CM AND 30X30 CM)

FIRST AID KIT NON-STERILE WOUND DRESSING

BANDAGE(3X0,05 M AND 3X0,1 M)

PRODUCTS