Professional Documents
Culture Documents
VII Aircraft-Systems-Lab-Manual
VII Aircraft-Systems-Lab-Manual
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:
PRECAUTIONS:
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
DOCUMENTATION:
RESULT:
Aircraft symmetry check procedure is practiced with an understanding of
safety precautions.
CONTROL SYSTEMS RIGGING PROCEDURE
AIM:
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:
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:
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:
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:
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.
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
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.