AIRCRAFT JACKING PROCEDURE

THEORY:

For maintenance activities such as rigging, levelling, retraction test, wheel brake
assembly change and major component change the aircraft must be jacked up
properly. The jacking up can be done by using single point lifting by bottle jack or
three point lifting by tripod jack. The jacks may be hydraulic or screw type as
supplied by the manufacturer apart from this required the additional tail jacks or
trestles may be used in accordance with the maintenance manual or the type of
activities.
PREFERENCE:
It is always recommended to refer the respective aircraft maintenance manual
before attempting to perform jacking up operation.
AIM:
To lift the aircraft by using jacks.
REQUIREMENT:
Man hours -3
Man power-3+1
Document-aircraft maintenance manual
.Equipment-bottle jack, wheel chocks, aircraft ladder
PRECAUTIONS:
 Refer aircraft manual before jacking up the aircraft to know the correct
method /procedure, sequence of operation and requirement of equipment.
 Ensure the lifting capacity of the jack and the jacks are fully serviceable.
 If necessary fit the jack pads on the aircraft structure.
 Avoid aircraft jacking up operation in open area.
 Find out the weather status from the ATC/MET department.
 Select the hard and level ground.
 If required keep trestles ready for use. Do not jack up the aircraft before
ensuring that the C.G and gross weight are within safety limits.
 Do not attempt to jack up the aircraft by the main gear shock strut.
 Ensure that the nose landing gear upper and lower torque links are
connected prior to jacking.
 Maintain the communication between the crews.
 Ensure all ground support units are clear of the aircraft.
 Place caution boards/sign boards on the ground near the nose, wing tip and
tail of the aircraft.
 Keep the safety lines around the aircraft.

PROCEDURE:
 The procedure of as per type of the aircraft and a per manufacturer
instruction.
  Ensure the ground is hard and without slipping.
 Remove the chokes from the wheels
 Place the trestles wherever it is applicable.
 Place all the jacks at specified jacking points.
 Deploy one person at each jacking joints.
 Ensure that the jacks are properly placed.
 Raise the jacks slowly till the contact of the aircraft jacking point is at
contact place slightly way out of jack and align it.
 First raise the nose slightly then simultaneously all the jacks till the wheel
or gear from 1 inch from the ground.
 Engage the lock mechanism and lock the jack to prevent sudden collapse
due to hydraulic leakage of jack.
 If the aircraft is slightly to be jacked more than 24 hours or overnight, it is
recommended to adjust the trestles at all specified station to support the
aircraft weight.
 Place a display board (aircraft on jacks) in front of the aircraft.
 While lowering the aircraft from the jack ensure the parking brakes are in
OFF position.
 No loose items should be available in and around the aircraft while lowering
the aircraft and obstruction if any to be clear before lowering.

RESULT:

Thus the aircraft is jacked up safely without any damage to men, material
and equipment.
 AIRCRAFT LEVELING PROCEDURE
AIM:

To place the aircraft level with the ground by using strain gauge and spirit level
method (aircraft type light weight).
THEORY:

Levelling of an aircraft is the procedure of placing an aircraft in its rigging position

by means of lifting the aircraft by hydraulic jacks so as to enable the rigging check
on newly assembled aircraft or replacement/renewal of any major component of the
aircraft in order to ensure the correct fitting and alignment of aircraft.
The rigging position is the position of the aircraft at which longitudinal and lateral
axis are parallel to the ground (Straight level position).It can be done by three
different methods on the aircraft type as follows.
1. Straight gauge and spirit level (Light aircraft)
2. Plumb bob method (large wide body)
3. Engineers steeper method for supersonic aircraft.
NOTE:
As the procedure differs always. Therefore always refer the instruction specified by
manufacturer for the correct procedure of rigging and instructions required.
OCCASIONS:
1. on replacement/renewal of major components.
2. during rigging check.
3. during symmetry check.
4. As required by manufacturers and competent authority.
REQUIREMENT:
1. Man hours-3
2. Man power-3+1

3. Document- aircraft maintenance manual, aircraft forms, aircraft rigging

charts.

4. Equipment-Tripod jack (hydraulic/screw), aircraft ladder, leveling board,

spirit level, tail trestles.

PRECAUTIONS:

 Observe all the precautions while jacking up the aircraft.

 Check accuracy of spirit level.
PROCEDURE:

 Ensure that the aircraft is jacked up properly and place the trestles wherever
it is required.
 Place the longitudinal leveling board at port side.
 Place the spirit level over the longitudinal board.
 Adjust the tail trestle till the bubble of the spirit level brought in center.
 Repeat the same operation.
 Place the spirit level after checking the accuracy.
 Adjust the main jacks till the double of the spirit level in brought to the
centre.
 Recheck the lateral level as well as longitudinal level.

CAUTION:
Always finish the levelling procedure by checking the longitudinal level without any
adjustments.

RESULT:
The aircraft is level and ready for further checks.
 AIRCRAFT SYMMETRY CHECK PROCEDURE
AIM:

From time to time it is necessary and advisable to check the alignment of fully
assembled aircraft.
TOOLS REQUIRED:

Aircraft jacks ,pliers ,spirit level/plumb bob ,measuring tape ,drawing of the aircraft
,marker pens, aircraft maintenance manual, aircraft servicing ladder.
SAFETY PRECAUTIONS:

All precautions as that of jacking and levelling of an aircraft. Do not step on control
surface or composite part while taking measurement.
GENERAL INFORMATION:
Symmetry checks will normally be made after any major structural repair or after
the aircraft has been subjected to severe condition such as heavy loading extremes
turbines, violent manoeuvres.

 Symmetry should also be done if any of the following conditions are observed.
 Wrinkled or buckled skin
 Area of loose or sheared rivets
 Area of badly fitting panels or inspection plates

If a pilot process the flight characteristics that cannot be corrected by remission

of control, it is that fuselage and wings are out of alignment.
PROCEDURE:
 Level the aircraft.
 Fix the reference point along the axis of the symmetry.
 Measure the distance from the reference points on the adjustable component
role down the value of drawing.
 If all measurements at which the tolerance give the maintanence manual, the
aircraft is in correct alignment.
 If any of the measurement or not with tolerance, the alignment must be
adjusted as specified in maintenance.
 Check the vertical symmetry of the aircraft in a like manner by the use of
measuring type of check the distance between a tip of the vertical stabilizer
and the horizontal stabilizer.

DOCUMENTATION:

 Enter the maintenance activity carried out aircraft servicing form.

 Enter the measurement valid on the drawing of the aircraft.
 Enter the adjustment carried out if any of aircraft servicing form.

RESULT:
Aircraft symmetry check procedure is practiced with an understanding of
safety precautions.
 CONTROL SYSTEMS RIGGING PROCEDURE
AIM:

To understand the underlying principle of operating procedure for aircraft control

system rigging as the method of checking the relative alignment and adjustment of
an aircraft main structural component.
GENERAL:
Aircraft structure must be rigged for alignment of all fixed component where major
component are aligned with each other.
Alignment of control surfaces and control that move the surface (i.e. adjustment of
cable, length, cable tension).Angular deflection of control surfaces must be
measured.
GUIDING PRINCIPLE:

Control surface should move a certain in either direction from the neutral position.
These movement of the cockpit control. The flight with the movement of the cockpit
control. The flight control system must be adjusted to obtain the requirement.
TOOLS REQUIRED:

Tensiometer, cable rigging tension chart, protractor, rigging fixtures, contour

templates, rulers, hydraulic tools, sow spirit levels.
SAFETY PRECAUTIONS:
No damage should occur to control surface during control rigging.
PROCEDURE:

 Positioning of flight control surface system in neutral and temporarily locking

it with rig pins or blocks.
 Adjusting surface travel, system cable tension, linkages and adjustable stops
to the aircraft manufacturer specification.
 Keep the flight control system in neutral positioning the external control
surfaces lock(i.e.) the form of channel wooden blocks) in place by sliding these
into opening between the ends of the cable movable surface and to aircraft
structures.

SURFACE TRAVEL MEASUREMENTS:

 The tool for measuring surface travel primarily include protractors, rigging
fixtures, containers, templates and rulers.
 Various types of protractors are used for determining the flight control
surfaces one protractors that can be measured ailerons, elevators or wing
flaps travels in a propeller protractors.
 This protractor is made up of frame disk, a ring and two spirit levels.
CONTROL RIGGING PROCEDURE:

 Lock the cockpit control bell crank and the control surface in the neutral
position.
 Adjust the cable position, maintaining the rudder elevator or ailerons in the
neutral position.
 Adjust the controls stops to limit the control surface travel to the dimensions
given for aircraft being rigged check the range of movement of the control and
the control surface in both direction from neutral.
 Pins, usually called rig pins are something used to simply the setting or
pulling, levels in their neutral position.

DOCUMENTATIONS:
Enter the maintenance operation done in the aircraft servicing team.

RESULT:
Thus the control rigging procedure is performed using safety precautions.
 FLOW TEST TO ASSESS FILTER ELEMENT CLOGGING
AIM:

Whenever it is suspected that the hydraulic system has become contaminated (or)
the system has been operated at temperature in excess of the specified maximum,
check of the system should be made. The Filter in most hydraulic system are
designed to remove most foreign particles that are visible to the naked eye,
therefore clogging test on filter element would indicate health of the hydraulic
system free from suspended particles and absence of excessive wear and tear.
Those will also reveal if the system is free from contamination.
TOOLS REQUIRED:
 Hydraulic pump to build up working pressure
 Hydraulic flow meter
 Hydraulic pressure gauge
 Fire extinguisher
 Stop watch
 Ultrasonic filter.
SAFETY PRECAUTIONS:
Since hydraulic fluid is highly inflammable adequate and relevant fire extinguisher
should be available.
PROCEDURE:
 Run the motor pump and build up the pressure.
 Measure the amount of fluid flow per minute with the help of stop watch.
 Read the pressure differential across the filter from the pressure gauge.
 Check the recorded figure of the flow rate and the pressure differential
between the outlet and inlet of the filter against the value given in the
maintenance manual.
 If the rate of flow is more than that given in the maintenance manual, stop
the test and remove the filter and put it through ultrasonic cleaning machine
if it is a metallic filter or else replace the filter.
 If the metallic particles are detected on filter establish the root cause.
 If the pressure differential across the filter is beyond the limits given in the
maintenance manual
i. A low differential will indicate filter rupture.
ii. A higher differential would indicate clogging.
 Take corrective actions as outlined above.
DOCUMENTATION:
Make relevant entries in aircraft service as the maintenance intervention.

RESULT:
Thus the flow test to the air filter element clogging practiced with an understanding
of mandatory safety precautions.
PRESSURE TEST TO ASSESS HYDRAULIC EXTERNAL & INTERNAL LEAKAGE
AIM:

To assess the internal and external leakage in a high pressure hydraulic

system since such a leakage would lead to catastrophic consequences in flight if
not checked on ground
TOOLS REQUIRED:
 Test equipment to generate hydraulic pressure
 Pressure gauge
 Flow heater
 Stopwatch
 Magnifying lens
 Inspection lamp
 Die penetrated test kit for leakage test
 Maintenance manual
 Fire extinguisher
SAFETY PRECAUTION:

Since hydraulic fluid operations at very high pressure level is very hot and highly
inflammable, adequate and appropriate firefighting equipment should be available
ready on hand
EXTERNAL LEAKAGE TEST:
External leakage would occur on joints due to inadequate lightness, inefficiency of
rubber gasket, seals (or) due to cracks in hoses or pipelines
PROCEDURE:
 Generate pressure in the system to normally operating level
 Carefully examine whether the flow is flowing smooth or with fluctuation
indicting leakage
 Similarly check-up the reading on the pressure gauge for fluctuation.
Fluctuation indicates leakage.
 Check the level of hydraulic reservoir. If the level drops constantly, it also
indicates external leakage.
 Systematically check all joints, starting from the reservoir on all pressure
pipes and return pipe up to reservoir.
 If there is a leakage detected by tightening a joint; if it holds rubber gasket
or seal, switch the pump change the gasket with a serviceable (or) tighten
the joints, run the pump and check the leakage.
 If crack in a pipeline is suspected apply a dye-penetrant in pipe length and
carry.
INTERNAL LEAKAGE TEST:

Internal leakage could occur due to internal malfunction of hydraulic components

such as hydraulic boosters, hydraulic actuators, accumulators etc.
PROCEDURE:

 Run the hydraulic pump and build a pressure in the system.

 Start the stopwatch and switch off the pump
 Constantly monitor the readings of the hydraulic pressure gauge
 Do not operate any controls
 Stop the stop watch when pressure drops to the level specified in the
maintenance manual e.g. from 280 bar – 150 bar; 280 bar – 100 bar.
 Record these timings and check against the allowable time levels in the
maintenance manual. If the time taken for the drop is less than that
specified, it indicates internal leakages level higher than the acceptable level
due to wear and tear.
 Individual components contribution to higher internal leakage rates tend to
be identified and replaced as per maintenance manual.

RESULT:
Thus the pressure test to assess hydraulic internal and external leakages is done
using the mandatory procedures.
 FUNCTIONAL TEST TO ADJUST OPERATING PRESSURE
AIM:

Pump output pressure to determine the smoothness and efficiency of operation of

service operator by the hydraulic system. Its pressure output is controlled by a
combination of pressure relief valve, pressure regulator and pressure gauge. The
aim is to understand the procedure to adjust the operating pressure of the
hydraulic system.
TOOLS REQUIRED:

 Hydraulic pressure generation kit

 Combination of pressure relief valves
 Pressure regulator
 Pressure gauge
 Fire extinguisher
PROCEDURE:

 Make sure that all safety precautions are ready

 Run the pump at minimum rpm, read the pressure gauge.
 Build-up the pump rpm until it reads fuel pressure.
 Note down the pressure on the pressure gauge
 Adjust the pressure using the pressure regulator.
 Check for any leakage in the hydraulic tubes
 If yes, replace the hydraulic tubes
 Check for proper retraction of landing gear.

RESULT:

Thus the functional test to adjust operating pressure is performed with necessary
safety precautions.
 PRESSURE TEST PROCEDURE ON FUEL SYSTEM COMPONENTS
AIM:

Aircraft fuel system depends on pressurization of its fuel tanks to differential level
to achieve the sequence of consumption, ensures movement of CG and hence
longitudinal stability within the design value.

This experiment would allow an understanding of various components active in the

fuel system pressurization and consumption process.
TOOLS REQUIRED:
 Fuel system set-up
 Pressure gauge
 Fuel system
 Pressurization unit
 Compressed air cylinder with regulator and safety valves.
 Electrical power supply.
 28 V DC
 Fuel flow meter
 Fuel level indicator
 Failure warning panel
 Fire extinguisher
SAFETY PRECAUTIONS:
 Fuel is highly combustible hence no flame in the vicinity.
 Suitable fire extinguisher and fire safety precautions.
PROCEDURE:
 Connect the fire compressed air cylinder to the pressurization unit.
 Open the air flow slowly
 Observe the pressure values at different tanks or measure from the
individual pressure gauges connected to various tanks
 Run the booster pump; observe the sequence fuel flow as per level of
pressurization in tanks.
 Cut off pressurization air to one tank and observe “tank feeding” light
coming on its failure warning panel of fuel.
 Note down the pressurization level of different tanks
 Stop the test
DOCUMENTATION:
Record the maintenance operations carried out on an aircraft servicing form.

RESULT:

Thus the pressure test on fuel system components is done using mandatory
procedures.
 BRAKE TORQUE LOAD TEST ON WHEEL BRAKE UNITS
AIM:
To study the brake torque load test on wheel brake units.
OCCASION:

When an aircraft brakes are damaged, the brake torque load test on wheel brake
units is required.
PROCEDURE:

 Brake torque load test is normally a simple test driven model, brake torque
is a function of brake pressure and aircraft velocity as wheel speed.
 Basically aircraft tyres are designed for intermittent usage at much higher
loads than automobile tyres.
 Brake torque load test equipment basically consists of
i. Electric power motor
ii. Wheel
iii. Fulcrum support
iv. Brake pedal
v. Open belt assembly
vi. Rpm indicators
vii. Loads
 With this components we can measure torque of aircraft wheels on various
load condition.

𝑉𝑥 − 𝑊𝑥 𝑅
𝑆𝑙𝑖𝑝 𝑟𝑎𝑡𝑖𝑜 =
𝑉𝑥
Where,

Vx = angular velocity
Wx= angular velocity
R = Rolling radius

 Assuming the operating conditions for the equipment are constant, a brake
having a retarding torque equal to the full load torque of the motor to which
it is applied is usually satisfactory.
 The torque can be determined by the brake units,

𝑆𝐹
𝑇 = 5250 ∗ 𝐻𝑃 ∗
𝑅𝑃𝑀

Where,
T = Brake Torque
HP= Horse Power
5250 = Constant
SF = application service factor
 Wheel brake procedure function at the wheel is to slow (or) stop the rotation
of the wheel light aircraft use a single disc type brake but large transport
aircraft require multiple disc to deal with forces generated.

RESULT:
Thus the brake torque load test on brake units is studied.
 MAINTENANCE & RECTIFICATION OF SNAGS IN HYDRAULIC & FUEL
SYSTEM
AIM:
To understand the essentials of maintenance and up-keep of hydraulic and fuel
system components. To understand the logical sequence of troubleshooting with
reference to rectification of hydraulic and fuel system.
TOOLS REQUIRED:
HYDRAULIC SYSTEM:
Hydraulic pressure gauge to read up to 300 bar pressure, common tool bar,
hydraulic system diagram up to component level, multipurpose patch test kit,
clean glass bottle of some capacity and waste cloth.
FUEL SYSTEM:

Pressure gauge to read up to 5 bar pressure , common tool bar, fuel system
diagram up to component level, water detecting capsules, clear glass jar of 5
litre capacity, waste cloth and drip tray.
SAFETY PRECAUTIONS:

 Since hydraulic fluid and fuel are both highly combustible all fire precaution
availability of fire extinguisher for liquid fire are mandatory.
 Waste cloth and drip tray must be available readily to avoid spillage of
hydraulic oil (or) fuel on the ground.
 Avoid to prevent jamming and cracking.
MAINTENANCE PROCEDURE:

 Systematically start from one end of the aircraft and reach ground in a
clockwise direction till for you reach the same.
 For convenience, the whole aircraft is divided into 8 parts. Checks are
carried out in system components including pipelines.
 Level of air reservoir (or) fuel in tanks as seen from built in indicator.
 Free movement of control surfaces.
 Check for undercarriage bay and aircraft components.
 Serviceability of cockpit indicator and failure warning panel.
RECTIFICATION OF SNAGS:
HYDRAULIC SYSTEMS:
 They may be broadly divided into four parts.
 Those related to pressure generations and distribution system.
 Those related to component malfunctioning.
 Leakage
 Indication system electrical failure.
SNAGS RELATED TO PRESSURE GENERATION AND DISTRIBUTION SYSTEM:
Pumps Not Building Pressure:
  Ensure level in the reservoir in between the minimum and maximum level
marked.
 Run the pump on the aircraft on their stand and measure pressure output.
 Adjust pressure regulator if necessary.
 Ensure no abnormal pressure rise when pump runs.
 Check drive shaft conditions.
 Check operations of safety valve at correct pressure.
 Ensure system isolation solenoid valve is not closed.
 If all else fails, replace the pump.
SNAGS RELATED TO COMPONENT MALFUNCTIONING:
Malfunctioning of Servo Actuators:
 Check the pressure input to the servo actuators.
 Check the availability of electrical power to the servo control unit of the
servo actuators.
 Check for quality of hydraulic fluid, free from impurities which could block
the servo control mechanism.
 Check the free movement of servo actuator jacks.
 If any of the above failures, replace the servo actuators.
RECTIFICATION OF LEAKAGES:
 Check if the leak is from the joint of two pipelines, if yes open and ensure
presence of serviceable gasket seal at joint.
 If the check is from the body of the pipeline, check for cracks.
 If the leakage is from the body of the component replace the component.
RECTIFICATION OF INDICATION SYSTEMS ELECTRICAL FAILURE:
If the check indicates proper functioning of component build-up and the
leakage indicator in cockpit show malfunctioning then
 Check the electrical input of the cockpit.
 Check the serviceability of in final warning panel.
 Check output from pressure transmitter if all else is ok replace hydraulic
pressure indicator.
FUEL SYSTEM:
Here again snags may be classified into

 Those related to failure of feed from tank.

 Those related to malfunctioning of components.
 Leakages
 Indication supplier electrical failure.
SNAGS RELATED TO FAILURE OF FEED FROM TANK:
Feed failure could be due to,

 Lack of pressurization in the tank.

 Check fuel level and top it when low.
 If input to unit shows zero pressure, trace the line backward up to the
reduced level and correct the fault.
 If the input is OK and the output is faulty replace the pressurization unit.
DOCUMENTATION:

Enter the maintenance work and rectification work carried out in the
appropriate columns of the aircraft servicing form.

RESULT:

Maintenance and rectification of snags in the hydraulic and fuel system studied
in depth to develop diagnostic skill based on full understanding of the aircraft
systems.