Aircraft Systems Lab Manual by Gp

8/11/2019 Aircraft Systems Lab Manual by Gp

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PARISUTHAM INSTITUTE TECHNOLOGY & SCIENCE

THANJAVUR

AE-2405 AIRCRAFT SYSTEMS LABORATORY MANUAL

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AE-2405 AIRCRAFT SYSTEMS LABORATORY

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LIST OF E,PERIMENTS

S$N*$ Nae *+ 'e E.per(e) Pa/e N*

1. Aircraft Jacking Up procedure 9

2. Aircraft Leveling procedure 15

3. Control S!te" #igging c$eck procedure 1%

&. Aircraft S""etr C$eck procedure 22

5. 'lo( te!t to a!!e!! of filter ele"ent clogging 25

). *re!!ure +e!t +o a!!e!! $draulic ,-ternal/nternal Leakage 20

0. 'unctional +e!t to adu!t operating pre!!ure 3

%. *re!!ure +e!t procedure on fuel !!te" co"ponent! 3&

9. rake +or4ue Load +e!t on ($eel rake unit! 30

1. 6aintenance and rectification of !nag! in $draulic and fuel !!te"! &

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INTROUCTION TO AIRCRAFT SYSTEM

An aeronautical engineer "u!t $ave a !olid foundation in a!ic! of AC S!te"7 t$e principle

of cooling and !ound kno(ledge of t$e (a t$e principle i! applied to variou! !!te"! u!ed in t$e

AC. +$e variou! !!te"! t$at e-i!t in aircraft! are a! follo(!

8draulic S!te" Aircraft -gen S!te" *neu"atic S!te" Air:conditioning and *re!!uri;ation S!te" ,lectrical S!te" ,ngine oil < 'uel S!te" Aircraft /n!tru"ent S!te" /ce and rain protection !!te" 'ire protection and !"oke detection !!te" Leak and =a!te !!te" Aircraft (eapon >#ocket7 ?un7 6i!!ile!7 o"< ,ection !!te"@

Co""unication and navigation !!te" *ropul!ion !!te"

+$oug$ t$e !!te"! are u!ed to operate t$e variou! counter and co"ponent!7 t$e re4uire da to da

c$eck7 repair < e-a"ination for !"oot$ and proper function. +$e purpo!e to conduct AC !!te" la i! to

fa"iliari;e da to da activitie! re4uired to "aintain air(ort$ condition of AC.

AIR1ORTHINESS

+$e continuing capailit of t$e AC to perfor" in !ati!factor "anner7 t$e flig$t

operation for ($ic$ it i! de!igned.

INSPECTION

/t i! t$e "o!t i"portant for" of function of aviation "aintenance. A! t$e AC give!

co"ple-it7 it eco"e! "ore i"portant to detect an po!!ile troule efore it eco"e! !eriou!.

+o a!!i!t t$i!7 aero engineer! are provided (it$ detail !pecial c$eck li!t and t$e "aintenance

"anual for eac$ tpe of AC. +$e engineer $a! to go t$roug$ "aintenance "anual t$oroug$l

efore atte"pting an kind of activit in aircraft and it! co"ponent!. +$e operation! "a e

carried out on AC on dail fling $our! andor ccle a!i!.

MAINTAINENCE

+$e !et of action including in!pection7 !ervicing7 and deter"ination of condition re4uired to

ac$ieve a derived outco"e ($ic$ re!tore an AC part and e4uip"ent in !erviceale condition.

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OVERHAUL

ver$aul "ean! !tripping a unit and re!toring it to it! de!ign perfor"ance level after

replacing7 re(orking of part! to a given !tandard.

SERVICING

/t "ean! preparing t$e AC for flig$t7 include! providing t$e AC (it$ fuel and ot$er fluid

and ga!e! ut do not include an (ork t$at i! "aintenance.

TROUBLE SHOOT

/t "ean! to anal!e! and identif t$e "alfunction.

REPAIR

/t "ean! to correct t$e defective condition.

MOIFICATION

/t i! a continuou! proce!! to i"prove it! reliailit and perfor"ance.

SERVICING SCHEULES

Servicing on 8our!CalendarCcle a!i!7 ($ic$ are to e carried out on aircraft at !et

8our!CalendarCcle a!i! are "entioned in t$e "anual or AC !ervicing !c$edule. +$e

!ervicing include! e-a"ination7 in!pection7 lurication and re"oval of "aor co"ponent! !uc$ a!

landing gear ack!7 door lock!7 air:conditioning e4uip"ent! aircraft rake unit! ($eel! etc.

landing gear functional te!t7 fling control range and "o"ent c$eck.7 AC rigging procedure7

$draulic fluid conta"ination te!t7 fuel conta"ination te!t < !o"e activitie! re4uire! replace"ent

of co"ponent!.

Aircraft "aintenance c$eck! are periodical c$eck! t$at $ave to e done on all aircraft after a

certain a"ount of ti"e u!age. Aircraft! u!uall refer to a! one of t$e follo(ing c$eck!.

A CHEC

+$i! i! perfor"ed appro-i"atel ever "ont$. +$i! i! u!uall done over nig$t. +$e actualoccurrence of t$i! c$eck varie! t$e tpe7 ccle or nu"er of $our! flo(n !ince t$e la!t c$eck. +$e

occurrence can e delaed t$e aircraft if certain predeter"ine condition! are "et.

B CHEC

+$i! i! perfor"ed in appro-i"atel 3 "ont$!.

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C CHEC

+$i! i! perfor"ed ever 12 to 1% "ont$!. +$i! c$eck put! aircraft out of !ervice and re4uire!

plent of !pace u!uall at t$e $anger and "aintenance a!e. Sc$edule and occurrence $a! "an factor!.

+$e co"ponent i! de!cried and t$u! varie! (it$ t$e AC categor and tpe.

CHEC

+$i! i! t$e $eavie!t c$eck of an AC. +$i! c$eck i! done appro-i"atel ever & to 5 ear.

+$i! i! t$e c$eck t$at take! t$e entire AC apart for in!pection. A co"pre$en!ive c$eck7 anal!i!

Bon e!tructive +e!ting >B+@ c$eck and co"plete $ealt$ "onitoring of t$e engine $a! to e

recorded. Co"plete over$auling of t$e AC and it! co"ponent! even AC painting i! al!o

re4uired in t$i! proce!!.

CONCLUSION

/n order to en!ure air (ort$ine!! condition of an AC and it! a!!ociated !!te"!. Dariou!c$eck!in!pection! (it$in !tipulated ti"e7 follo(ing t$e !c$edule !$o( t$e AC and it! !!te" are

kept in full !erviceale condition at all ti"e and in turn en$ance t$e AC !afet. +$e ti"e fra"e

of !c$edule! varie! fro" AC to AC.

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SAFETY PRECAUTIONS 1HILE HANLING AIRCRAFT

SYSTEMS AN ITS COMPONENTS

AIM

+o prevent accident and da"age to "an and "aterial.

OCCASIONS

=$enever re4uired to $andle t$e AC and it! !!te" co"ponent! and ground e4uip"ent!.

AIRCRAFT

efore caring out an (ork on t$e AC7 t$e re!pective "aintenance "anual i! to ereferred for furt$er in!truction!. +$e nece!!ar !afet precaution! are to e !trictl

follo(ed.

efore entering t$e cock pit of a fig$ter AC7 en!ure t$at t$e eection !eat i! in !afe and all ar"a"entoperating !(itc$e! are in !afe po!ition and all t$e !afel pin! are in po!ition.

efore !(itc$ing on t$e "a!ter atter !(itc$ en!ure t$at t$e under carriage !electorlever i! in do(n po!ition and latc$ed and all t$e ar"a"ent !tore door !(itc$e! are in

!afe condition.

,n!ure t$at t$e ($eel c$ock! are engaged. efore operating t$e control !urface7 en!ure t$at t$e control lock! are re"oved. efore !tarting t$e engine. C$ock! are to e kept in front of t$e ($eel. AC rake !!te" in !erviceale. A !erviceale fire e-tingui!$er i! availale.

Bever to( an aircraft (it$out a per!on in!ide t$e cockpit efore to(ing t$e AC7 c$eckt$e rake pre!!ure.

=$ile to(ing t$e AC never e-ceed t$e (alking !peed. Bever drop an tool ($ile (orking. =$ile (orking in!ide t$e AC7 collect all t$e tool! and !pace on co"pletion of t$e o

and en!ure no ite"! are left e$ind.

HYRAULIC SYSTEM

Al(a! relea!e t$e !!te" pre!!ure efore re"oving a co"ponent fro" t$e AC Bever doe! an "aintenance (ork on airplane (it$ an ot$er !pecified oil ot$er t$an t$e

reco""ended one. Carr out t$e patc$ te!t on t$e !!te" to prevent t$e conta"ination of oil. +$i! can

e carried out u!ing 6illipore patc$ te!t kit.

Bever "i- different grade of $draulic oil to !ervice t$e AC.

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lank all t$e port! of t$e re"oved co"ponent! and t$e AC pipe end! to avoid t$e entrof du!t7 dirt and foreign particle!.

'ollo( t$e nece!!ar precaution! to di!"antle t$e $draulic co"ponent!. Avoid !pilling of $draulic fluid on t$e AC and in and around fro" t$e AC. /f !pilled it

!$ould e cleaned i""ediatel to avoid !lipping.

efore fitting a ne( $draulic co"ponent7 it !$ould e unlanked7 degrea!ed7 (a!$edand flu!$ed. =$ile fitting t$e non return valve and re!trictor!7 en!ure t$at t$e "arked arro(! are in

t$e de!ired direction.

PNEUMATIC SYSTEM

#elea!e t$e !!te" pre!!ure efore atte"pting a o. Clean all t$e vent! of t$e aircraft n re"oval of co"ponent!7 lank all t$e part! of t$e co"ponent and t$e re!pective pipe!.

=$ile carring out t$e pre!!ure te!t never e-ceed t$e given li"itation

=$ile c$arging t$e pneu"atic pre!!ure al(a! u!e t$e pre!!ure regulator and !afet valve.rain t$e oil and (ater !eparator.

Bever $andle an ottle or clinder fro" it! c$arging no;;le. Al(a! u!e protective

cover

O,YGEN SYSTEM

S"oking7 open fla"e! or !"oke! !$ould not e per"itted ($ile (orking on t$e o-gen!!te".

o not carr "atc$e! ($ile $andling t$e 2 !!te" AC "u!t e grounded and all electrical po(er "u!t e !(itc$ed off. Eeep (orking area and e4uip"ent free of oil7 grea!e or an ot$er fla""ale "aterial.

Eeep t$e tool! and clot$ing free of oil and grea!e. ect !$ould not co"e in contact (it$ grea!e or !olvent! a! t$i! (ill cau!e !pontaneou!

e-plo!ion!.

Bever luricate t$e 2 !!te" co"ponent! e-cept on approved co"patile luricant. 8and !$ould e clean and free fro" oil. o not u!e grea!ing glove!. A !park i! not nece!!ar to cau!e a fire or e-plo!ion ut t$e c$e"ical reaction of fuel7 ga!

and oil co"ined (it$ 2 i! !ufficient to develop in!tant co"u!tion and cau!e fire and

e-plo!ion.

Bever per"it 2 clinder to co"e in contact (it$ electrical (elding circuit!and apparatu!.

Bever u!e o-gen fro" clinder (it$out reducing t$e pre!!ure t$roug$ areducing regulator and !afet valve!. Bever "i- ot$er ga! or co"pre!!ed air i! an 2 clinder.

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Bever te!t for pipe line leak! or flo( pipe line (it$ o-gen unle!! t$e line! are

!pecificall "ade for t$at.

SAFETY PRECAUTIONS TO BE FOLLO1E URING FUELLING AN

EFUELLING

o not operate radio7 radar or an ot$er electrical and electronic e4uip"ent e-ceptt$o!e !pecified.

?round t$e fuel !uppl unit and aircraft. 6ake !ure t$e fuelling !ource contain t$e proper fuel grade a! !pecified

t$e "anufacture.

Bo !"oking7 open fla"e i! per"itted in and around t$e AC. /t i! not per"itted to drop an tool ($ile t$e operation i! on. +$e operation !$ould e carried out in an open or full ventilated !pace. o not carr out o-gen related (ork.

CONCLUSION

+$u! t$e variou! !afet precaution! ($ile $andling aircraft !!te" are !tudied.

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Tr(p* :a7

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PRECAUTIONS

#efer aircraft "aintenance "anual 7 en!ure t$e capacit and !e"i circularit of ack +$e acking area !$ould e oil free +$e acking point !$ould of ($ic$ 2 at (ing! and one at "a-i"u" c.g location +$ere !$ould e no per!on in!ide t$e aircraft ($ile acking Central !urface! !$ould e locked +$e alla!ted (eig$t !$ould e re"oved efore acking Jack $andle !$ould not da"age !tructure of (eig$t Clearance of propeller !$ould e en!ured efore acking

PROCEURE

Jacking *rocedure:#ai!ing

+$e general procedure for rai!ing t$e co"plete aircraft on ack! i! a! follo(!I

/t differ! fro" variou! aircraft and refer re!pective aircraft "aintenance "anual #e"ove t$e "ooring

/dentif t$e acking point! of t$e aircraft placing it in level After finding t$e acking point! place t$e ack! at t$e point!. *lace a per!on at t$e acking point to look after t$e rai!ed ack! All t$e ack! !$ould e !i"ultaneou!l rai!ed. After acking7 ack lock! !$ould e c$ecked for !tailit and tig$tened. +$e nece!!ar in!pection $a! to e carried out. /f t$e aircraft i! likel to e c$ecked for "ore t$an 2& $r!7 place t$e adu!tale tru!! at

!pecified !tation

*lace t$e di!place oard aircraft ack! near t$e aircraft

Jacking *rocedure:Lo(ering

+$e general procedure for lo(ering t$e co"plete aircraft on ack! i! a! follo(!I

,n!ure t$at t$e landing gear control lever in t$e cockpit i! !elected tot$eDownpo!ition.

,n!ure t$at ?round Safet Lock! are fitted on all Landing ?ear!. ,n!ure t$at t$e rake! are relea!ed. ,n!ure t$at all t$e pa!!engercre( door!7 t$e e"ergenc e-it! and t$e cargo door!

are clo!ed and locked or full open and locked.

Clear t$e area around t$e aircraft of all ground !upport and "aintenance e4uip"ent

and en!ure t$at no ot$er (ork i! eing carried out. Loo!en t$e ack Safet Locking Collar!.

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http://aviamech.blogspot.in/2011/05/jacking-procedure-lowering.htmlhttp://aviamech.blogspot.in/2011/05/jacking-procedure-lowering.html


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9UESTIONS E,PECTE FROM UNIVERSITY3

1. ,-plain riefl aout t$e acking up and acking do(n procedure for Ce!ena "odel

aircraft

2. ,-plain aout variou! tpe! of ack! are currentl u!ed to rai!ing and lo(ering t$e

aircraft

3. e!crie aout t$e variou! tpe! of e4uip"entK! are u!ed to acking up and do(n t$e

aircraft

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E, NO3 2 LEVELLING OF PUSHPA AIRCRAFT

AIM

+o level t$e aircraft for in!pection purpo!e

LEVELING

Leveling i! t$e proce!! of placing an aircraft in it! rigging po!ition "ean!of $draulic or !cre( ack!

+$e rigging po!ition i! t$e po!ition of t$e aircraft at ($ic$ longitudinal and laterala-i! are parallel to ground.

Leveling "ean! leveling t$e aircraft in t$e $ori;ontal po!ition for rigging. +$ereare t$ree tpe! of leveling. +$e are a! follo(!

Straig$t edge "et$od

?rid plate "et$od

,ngineer! tran!"it "et$od

OCCASION

uring replace"ent or rene(al of "aor co"ponent!7 rigging c$eck!7 !""etr

c$eck! and a! ($en ?CA re4uire leveling proce!! i! carried out.

RE9UIREMENTS

6an $our! F 3 $r! 6an po(erF 3G1 ocu"ent!F Aircraft "aintenance "anual

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4. =$at are t$e tpe! of e4uip"entK! are u!ed for leveling

5. =$at i! t$e function of !prit level

6. =$at i! "eant datu" plate leveling


1. ,-plain riefl aout tpe of t$e leveling "et$od! (it$ !uitale diagra"!

2. ,-plain aout align"ent and (ing t(i!t c$eck of Ce!ena 152 "odel aircraft

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E, NO3 ; RIGGING CHECING UP OF AILERON EFLECTION AN

ELEVATOR EFLECTION

AIM

+o en!ure t$e deflection angle of aileron and elevator

THEORY

N#iggingN i! t$e ter" u!ed to de!crie t$e geo"etric !et:up of t$e fling !urface! of

an aircraft. +$i! include!I

1) Setting t$e angle of incidence of eac$ (ing and fi-ed !taili;ing !urface in relation

to !o"e defined reference line in t$e fu!elage

2) Adu!ting t$e !urface! for an di$edral

3) Adu!ting t$e (ing! for an geo"etrical t(i!t or N(a!$outN >relative incidence of eac$

!eg"ent of t$e (ing@

4) Adu!t"ent of control !urface! for t$e correct angular travel

5) C$ecking t$e !""etr of t$e aircraft7 t$at i!7 for e4ualit leftrig$t and

overall !4uarene!! or regularit

AileronI t$e "ove"ent of aircraft aout lateral a-i! i! called rolling or ank. +$i!

"o"ent aileron! are linked toget$er control cale. So t$i! one aileron i! do(n ($en ot$er i!

up t$at i! t$e function in different direction!.

,levatorI +$e "ove"ent of aircraft aout longitudinal a-i! i! called pitc$ing. ,levator

are u!ed to control t$i! pitc$ing "ove"ent. ,levator! are linked toget$er actual cale !o

t$at ot$ elevator are do(n t$at i! "ove in !a"e direction

OCCASION

6aor !ervicing of aircraft Aircraft flie! ($en one (ing lo( A! and ($en re4uired ?CA

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RE9UIREMENTS

6an $our!F3 6an po(erF3G1 ocu"ent!F Aircraft "aintenance "anual

TOOLS AN E9UIPMENTS

+ripod Aircraft ladder Longitudinal and lateral leveling oard Spirit level *lu" o 6ea!uring tape

PRECAUTIONS

FOR AILERONS

!erve all t$e !afet precaution! for levelingM Accurac of !pirit level $a! to e c$ecked

PROCEURE

*lace t$e aircraft over t$e level oard 2


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Locate t$e C.? point and place t$e leveling oard and !pirit level on it Locate t$e C.? point and place t$e leveling oard and !pirit level over it Level t$e aircraft a! per t$e concerned "aintenance "anual 6ea!ure t$e c$ord lengt$ of aileron 6ea!ure t$e di!tance travelled aileron in up(ard direction fro"

neutral po!ition to port !ide +ake t$e di!tance fro" upper (ing 6ea!ure t$e do(n(ard di!tance travelled aileron for" neutral po!ition 'ind deflection angle fro" "ea!ured di!tance C$eck angle of deflection (it$in !pecified li"it

FOR ELEVATORS

6ea!ure t$e di!tance travelled in up(ard direction fro" neutral po!ition todeflected po!ition

+ake di!tance fro" upper $inge 6ea!ure di!tance travelled elevator fro" neutral po!ition

'ind t$e deflection angle fro" neutral po!ition C$eck t$e angle of deflection i! (it$in t$e !pecified li"it

RESULT

+$u! t$e aileron and elevator deflection i! verified and c$ecked.

VIVA-VOCE 9UESTIONSI

1. =$at i! "eant rigging

2. =$at i! t$e purpo!e of #ig pin

3. =$at i! t$e purpo!e of rigging

4. =$at are t$e tpe! of a-ial ack!

5. =$at i! t$e purpo!e of ten!io"eter

6. =$at i! t$e purpo!e of t$ro(oard

7. =$at i! "eant ter"inal !(aging

8. =$at i! t$e procedure for cale "aintenance

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9. =$at i! t$e procedure for 4uick di!connecting

10. =$at i! "eant 4uick di!connect


11. ,-plain riefl aout t$e rigging procedure for control !urface! of t$e aircraft

12. ,-plain aout variou! tpe! of co"ponent! are currentl u!ed for rigging of flig$t

control !!te"!

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E, NO3 4 AIRCRAFT SYMMETRY CHECS

AIM

+o c$eck t$e !""etr of aircraft

SYMMETRY CHEC

A !""etr c$eck i! an in!pection to !ee $o( t$e aircraftK! individual co"ponent! are

po!itioned in relation!$ip to eac$ ot$er.

METHO3

"ean! of direct "ea!uring (it$ tape

MEHTO32

dropping plu" o and "arking and "ea!uring "et$od

OCCASION

n a!!e"leerection of ne( aircraft #eplace"entre"oval of "aor co"ponent 8eav landing report! 'ollo(ed flig$t t$roug$ turulence #epeated !"og on flig$t c.! An "odification! on aircraft ($ic$ affect it! perfor"ance

A! and ($en re4uired ?CA

PRECAUTIONS

#efer aircraft "aintenance "anual en!ure t$e caution !urrounding! of aircraft +$e acking area !$ould e free !erve all !afet precaution for leveling C$eck t$e accurac of !pirit level Al(a! fini!$ leveling procedure onl c$ecking t$e longitudinal level

RE9UIREMENT

=orking $r!F3 6an po(erF3 ocu"entF aircraft "aintenance "anual and rigging c$eck up

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TOOLS USE

6ea!uring tape Spirit level

*lu" o Leveling oard +ripod ack Support ack

PROCEURE

*lace t$e aircraft in rigging po!ition C$eck t$e incident angle of (ing

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C$eck t$e di$edral angle of "ain plane C$eck t$e !(eep ack angle C$eck t$e di$edral angle of tail plane rop t$e plu" o fro" !pin centre and tail ($eel centre and "ea!ure t$e

lengt$ of aircraft

rop t$e plu" o fro" eit$er (ing tip! and "ark it on t$e ground 'ro" fin top $inge or tail ($ere centre drop! t$e plu" o and "ark it

6ea!ure t$e diagonal di!tance C$eck t$e fin verticalit 6ea!ure t$e !pin centre to eac$ (ing tip +aulate in t$e for"at given

RESULT

Aove !tated difference are "ea!ured and co"pared (it$ t$e rigging c$art and found

(it$ per"i!!ile li"it!


1. =$at i! "eant !""etr c$eck

2. =$at are t$e e4uip"entK! are involved in !""etr c$eck

3. =$at i! t$e purpo!e of !""etr c$eck


$ ,-plain riefl aout t$e !""etr c$eck procedure for naval aircraft

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E, NO3 5 FLO1 TEST TO ASSESS OF FILTER ELEMENT CLOGGING

AIM

+o en!ure t$e cleanline!! of t$e follo(ing ele"ent and for t$e oil a flo( te!t i! carried out

in order to deter"ine t$e filtering capacit of t$e filtering ele"ent.

OCCASION

1. Specified period interval!

2. 'ollo(ed a filter! failure or !nag

3. After in!tall of ne( filter

PRECAUTION

1. ,n!ure t$at t$e filter ele"ent! are !uected to a ultra!onic cleaning efore carring outt$i! te!t

2. Carrout t$i! te!t onl in a du!t proof roo" condition.

3. U!e $and glove! during t$i! te!t for $andling filter ele"ent and te!t e4uip"ent

PROCEURE

1. *our !pecified $draulic oil >!kdroll @ up to "ove in t$e container

2. ,ngage t$e otto" plug to t$e filter ele"ent! otto" pu!$ing top

3. ,ngage t$e upper adapter on t$e top of t$e fitter ele"ent pu!$ing do(n.

4. ,ngage t$e plunger a!!e"l to t$e top of adapter !creening do(n

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5. lank t$e upper part of t$e plunger !te" t$u" clip t$e plunger (it$ t$e fitter

fuel t$e upper adapter flange i""er!e in t$e oil of t$e container.

6. Un lank t$e upper part of t$e plunger

7. re"oving t$e t$u":clip and !i"ultaneou!l !tart t$e !top (atc$ to note do(n

t$e ti"ing.

8. Bote do(n t$e ti"e taken for t$e !te" to co"e up unlike (it$ plunger and t$e ti"ing u!e

(it$in 5 to ) !econd!

9. /ncrea!e of e-ce!! ti"ing !uected t$e filtering ele"ent again to ultra!onic cleaning.

10. #eect t$e filtering ele"ent! for aircraft and it doe! not filter (it$in 5:) !econd!

follo(ed t(o !ucce!!ive ultra!onic cleaning operation!.

RESULT

+$e !uected te!t i! carried out and found !ati!factor.


1. =$at i! "ean $draulic fluid

2. +pe! of $draulic fluid.

3. =$at i! t$e !i;e of filter ele"ent!

4. =$at i! "ean !trainer


1. o a flo( te!t to a!!e!! of filter ele"ent clogging

2. +e!t a filter ele"ent for clogging.

20


28/44

E, NO3 < =PRESSURE TEST> TO ASSESS HYRAULIC E,TERNAL?INTERNAL

LEAAGE

AIM

+o perfor" t$e pre!!ure te!t on $draulic !!te" co"ponent! to locate t$e internal and

e-ternal leakage

HYRAULIC LEAAGE

An $draulic !!te" (ill $ave a certain a"ount of leakage. An leakage (ill reduce efficienc

and cau!e po(er lo!!. So"e leakage i! uilt in >planned@7 !o"e i! not. Leakage "a e internal7

e-ternal7 or ot$.

I)er)a6 6ea7a/e

+oo "uc$ internal leakage (ill !lo( do(n actuator!. +$e po(er lo!! i! acco"panied

t$e $eat generated at a leakage pat$. /n !o"e in!tance!7 e-ce!! leakage in a valve could cau!e a

clinder to drift or even creep ($en a valve i! !uppo!edl in neutral. /n t$e ca!e of flo( or

pre!!ure:control valve!7 leakage can often reduce effective control or even cau!e control to e

lo!t.

Bor"al (ear increa!e! internal leakage7 ($ic$ provide! larger flo( pat$! for t$e leaking oil.

An oil t$at i! lo( in vi!co!it leak! "ore readil t$an a $eav oil. +$erefore oilK! vi!co!it and

vi!co!it inde- are i"portant con!ideration! in providing or preventing internal leakage. /nternal

leakage al!o increa!e! (it$ pre!!ure7 u!t a! $ig$er pre!!ure cau!e! a greater flo( t$roug$ an orifice.

perating aove t$e reco""ended pre!!ure! add! t$e danger of e-ce!!ive internal leakage and $eat

generation to ot$er po!!ile $ar"ful effect!.

A lo(n or ruptured internal !eal can open a large enoug$ leakage pat$ to divert all of a

pu"pO! deliver. =$en t$i! $appen!7 evert$ing e-cept t$e oil flo( and $eat generation at a

leakage point can !top.

E.er)a6 6ea7a/e

,-ternal leakage can e $a;ardou!7 e-pen!ive7 and un!ig$tl. 'ault in!tallation and poor

"aintenance are t$e pri"e cau!e! of e-ternal leakage. Joint! "a leak ecau!e t$e (ere not put

toget$er properl or ecau!e !$ock and viration in t$e line! !$ook t$e" loo!e. Adding !upport! to t$e

line! prevent! t$i!. /f a!!e"led and in!talled correctl7 co"ponent! !eldo" leak. 8o(ever7 failure to

connect drain line!7 e-ce!!ive pre!!ure!7 or conta"ination can cau!e !eal! to lo( or e da"aged7

re!ulting in e-ternal leakage fro" t$e co"ponent!.

2%


29/44

PREVENTION

*roper in!tallation7 control of operating condition!7 and proper "aintenance $elp prevent

leakage.

OCCASION


2. 'ollo(ed a $draulic !!te" failure or !nag

PROCEURE

I)er)a6 6ea7a/e

1. #e"ove t$e !(ivel nut fro" t$e !trainer o(l and drain t$e fluid co"pletel.

2. +urn off t$e $draulic pu"p.

3. +urn off t$e fluid !elector valve.

4. /f t$e valve i! looking interval!7 fluid (it$ flo( into t$e !trainer o(l.

E.er)a6 6ea7a/e

1. Locating leak! or dete!t in t$e $draulic !!te" e-ternal portion! involved ver little

ti"e in co"pari!on!

2. C$eck for !train! on ne(l developed (et !pot! in t$e fluid line! and $o!e!.

3. /f t$ere i! onl fuel o dour t$at (ill indicating fluid leak!.

4. Carefull e-a"ine t$e plu"ing7 cla"p!7 ga!ket! !upport! etc for fluid leak! or

aircraft !tructure for evidence of fluid leak!.

5. C$eck t$e repaired tank! "anufacturing an defect! on leak! in t$e internal or

e-ternal fluid !!te" i! potential $a;ard.

29


30/44


31/44

E, NO3 @ FUNCTIONAL TEST TO AGJUST OPERATING PRESSURE

AIM

+o deflecting a !$ock !trut !ervicing and reinflate

THEORY

+$e a!ic (eig$t !upport function of t$e oleo:pneu"atic !$ock !trut!7 ($ic$ $ave a $ig$

efficienc under dna"ic condition! ot$ in ter"! of energ a!orption and di!!ipation7 i! provided

a co"pre!!ed clinder of air and oil. A !ingle:acting !$ock a!orer7 ($ic$ i! t$e "o!t co""onl

u!ed de!ign for co""ercial tran!port!. +$i! tpe of !$ock !trut a!or! energ fir!t forcing a

c$a"er of oil again!t a c$a"er of dr air or nitrogen and t$en co"pre!!ing t$e ga! and oil. uring

t$e co"pre!!ion proce!!7 t$e oil and ga! eit$er re"ain !eparated or are "i-ed depending on t$e tpe

of de!ign. After t$e initial i"pact7 energ i! di!!ipated a! t$e air pre!!ure force! t$e oil ack into it!

c$a"er t$roug$ recoil orifice!.

Alt$oug$ t$e co"pre!!ion orifice could e "erel a $ole in t$e orifice plate7 "o!t de!ign!

$ave a "etering pin e-tending t$roug$ it7 and varing t$e pin dia"eter t$e orifice area i!

varied. +$i! variation i! adu!ted !o t$at t$e !trut load i! fairl con!tant under dna"ic loading. /f

t$i! can e "ade con!tant7 t$e gear efficienc (ould e 1 percent. /n practice7 t$i! i! never

otained and efficiencie! of % to 9 percent are "ore u!ual. Since onl t$e efficienc factor i! of

intere!t in t$e conceptual de!ign p$a!e7 no additional di!cu!!ion on t$e de!ign of t$e "etering pin

(ill e provided.

31


32/44

OCCASION


2. Lack! in pre!!ure

3. 'ailure of !$ock !trut

32


33/44


34/44


1. ifferent tpe! of !$ock a!orer

2. =$at i! orifice valve

3.=$at i! t$e function of "etering pin


1. *refor" t$e functional te!t on oleo pneu"atic !$ock a!orer.

2. =rite t$e for !ervicing t$e oleo pneu"atic !$ock a!orer.

3&


35/44

E, NO3 PRESSURE TEST ON FUEL SYSTEM COMPONENTS

AIM

+o perfor" t$e pre!!ure te!t on fuel !!te" co"ponent! to locate t$e internal and e-ternal

leakage

THEORY3

Fuel System Components: efore doing an fuel pre!!ure te!ting7 it i! a good idea to under!tand$o( fuel

!!te" co"ponent! (ork and $o( t$e relate to one anot$er. +$e fuel pu"p pu"p! fuel fro" t$e fuel

tank to t$e fuel pre!!ure regulator and fuel inector!. +$e fuel pre!!ure regulator divide! fuel et(een t$e

pre!!ure line and t$e return line. +$e fuel in t$e pre!!ure line goe! to t$e fuel inector! ($ile t$e fuel in

t$eir turn line i! returned to t$e fuel tank

Fuel Tank: A large container t$at $old! our ve$icle! !uppl of fuel.

Fuel Pump Filter: A filter t$at i! u!uall located in t$e fuel tank. /t! function i! to prevent

foreign particle! fro" reac$ing t$e fuel pu"p. A clogged or re!tricted fuel pu"p filter can cau!e

lo( fuel pre!!ure reading!. =$en replacing a fuel pu"p it i! a good idea to clean or replace t$e

fuel pu"p filter.

Fuel Pump: An electric "otor t$at pu"p! fuel into t$e fuel !!te" at a con!tant pre!!ure. /t i!

"ounted in t$e fuel tank or on t$e fra"e. So"e ve$icle! $ave "ore t$an one fuel pu"p.

Return Line: *at$ (a for e-ce!! fuel to return to t$e fuel tank.

Pressure Line: A pre!!uri;ed fuel line t$at carrie! fuel fro" t$e fuel tank to t$e fuel inector!.

Fuel Filter: A filter t$at i! located in:line (it$ t$e pre!!ure line. /t! function i! to prevent foreign

particle! fro" reac$ing t$e fuel inector!. A clogged or re!tricted fuel filter can al!o cau!e lo( fuel

pre!!ure reading!. +$i! i! t$e onl fuel !!te" co"ponent t$at re4uire! periodic replace"ent.

#efer to ve$icle o(nerK! "anual for replace"ent interval.

Fuel Pressure Regulator: +$e fuel pre!!ure regulator i! connected acro!! t$e pre!!ure line and return line. /t

contain! a !pring loaded valve a!!e"l t$at open! to allo( fuel to "ove into t$e return line7 ($en t$e pre!!ure

line fuel pre!!ure i! e-ceeded. /t i! u!ed to keep a con!tant fuel pre!!ure drop acro!! t$e fuel inector!. So"e

fuel pre!!ure regulator! $ave a vacuu" port !o fuel pre!!ure can e adu!ted a!ed on engine load. +$e!e are

co""onl called vacuu" actuated

35


36/44

>co"pen!ated@ fuel pre!!ure regulator!. A leaking fuel pre!!ure regulator can cau!e lo( fuel

pre!!ure reading! and $ard !tarting prole"!.

Fuel Injectors: A preci!ion valve t$at i! controlled a !olenoid. 'uel inection i! controlled t$e a"ount of

fuel pre!!ure and t$e !i;e and duration of t$e valve opening. 'uel inector! contain a filter u!ed to prevent ver

!"all particle! fro" 6*//()/t$e valve. Leaking fuel inector! (ill cau!e fuel pre!!ure to !lo(l decrea!e

($en t$e ignition ke i! on and engine i! off.

PREVENTION

*roper in!tallation7 control of operating condition!7 and proper "aintenance $elp prevent

leakage.

OCCASION


2. 'ollo(ed a fuel !!te" failure or !nag

PROCEURE

I)er)a6 6ea7a/e

#e"ove t$e !(ivel nut fro" t$e !trainer o(l and drain t$e fuel co"pletel.

3)


37/44

+urn off t$e fuel engine oo!ter pu"p. +urn off t$e fuel !elector valve. /f t$e valve i! looking interval!7 fuel (it$ flo( into t$e !trainer o(l.

E.er)a6 6ea7a/e

Locating leak! or dete!t in t$e fuel !!te" e-ternal portion! involved ver little ti"ein co"pari!on!

C$eck for !train! on ne(l developed (et !pot! in t$e fuel line! and $o!e!. /f t$ere i! onl fuel odour t$at (ill indicating fuel leak!. Carefull e-a"ine t$e plu"ing7 cla"p!7 ga!ket! !upport! etc for fuel leak! or aircraft

!tructure for evidence of fuel leak!.

C$eck t$e repaired tank! "anufacturing an defect! on leak! in t$e internal or

e-ternal fuel !!te" i! potential $a;ard.

RESULT

+$u! pre!!ure te!t on fuel !!te" co"ponent! carried out to detect (it$ t$e internal ande-ternal leakage.


1. ifferent fuel !!te".

2. =$at i! clogging

3. =$at i! function of pre!!ure regulator


1. ,-plain riefl aout t$e fuel !!te" pre!!ure te!t.2. =rite a procedure for pre!!ure te!t on fuel !!te".

30


38/44

E, NO3 BRAE TOR9UE LOA TEST

AIM

+o prevent t$e rake failure during rake application and to keep t$e rake !!te" al(a!

in !erviceale condition

THEORY

+$e aircraft ($eel rake! are de!igned to provide !lo(ing do(n of aircraft ontouc$do(n and totall to !top t$e aircraft

/t $old! t$e aircraft ($ile parking and during ground running of engine +$e rake unit "a e !$oe tpe7 di!c tpe or "ulti di!c tpe proper "aintenance of rake unit t$e "a-i"u" flig$t accident! "a e

prevented

/f t$e air i! found in t$e $draulic rake !!te" rake (ill not e effective So t$e pre!ence of air i! found in t$e $draulic rake !!te" i! to e e-pelled

fro" !!te" i! called L,,/B? ' SPS+,6

/f air i! not re"oved t$e rake! !!te" (ill e !pong +o avoid t$at rake leeding $a! to e carried out of regular interval!

OCCASION

n an periodic !ervicing a! per la do(n in !ervicing !c$edule /f an $draulic rake detected fro" pi!ton a!!e"l of rake unit =$enever pilot report! t$at t$e rake unit i! !lugging!pong action of rake

pedal! At t$e ti"e of rake pipe rene(al and topping up of rake re!ervoir

RE9UIREMENTS

6an $ourF3 $r! 6an po(erF3G1 ocu"ent! F aircraft !ervicing for"7 aircraft "aintenance "anual

E9UIPMENTS?TOOLS

+ripod !cre($draulic or ottle ack

leeding $o!e Clean container (it$ !pecified $draulic oil 8and glove!

3%


39/44


40/44

Lo(er t$e aircraft taking proper precaution 6ake nece!!ar entr in t$e aircraft !ervicing for"log ook

RESULT

+$e aircraft rake !!te" leeding i! carried out and found !ati!factor.


1. ,nu"erate different tpe! of rake !!te" u!ed in aircraft.

2. =$at i! leeding

3. =$at i! "ean di!k rake

4. ifferentiate et(een di!k rake and dru" rake.


1. =rite a procedure for find a leeding in rake !!te".

2. e!crie t$e rake load tor4ue te!t.

&


41/44

E, NO3 0 MAINTENANCE AN RECTIFICATION OF SNAG IN HYRAULIC AN

FUEL SYSTEMS

AIM

+o !tud t$e troule !$ooting procedure on aircraft $draulic !!te"

HYRAULIC SYSTEM MAINTENANCE PRACTICES

+$e "aintenance of $draulic and pneu"atic !!te"! !$ould e perfor"ed in accordance

(it$ t$e aircraft "anufacturerK! in!truction!. +$e follo(ing i! a !u""ar of general practice!

follo(ed ($en dealing (it$ $draulic and pneu"atic !!te"!.

Ser(e

+$e !ervicing of $draulic and pneu"atic !!te"! !$ould e perfor"ed at t$e interval i!!pecified t$e "anufacturer. So"e co"ponent!7 !uc$ a! $draulic re!ervoir!7 $ave !ervicing

infor"ation adacent to t$e co"ponent. =$en !ervicing a $draulic re!ervoir7 "ake certain to u!e

t$e correct tpe of fluid. 8draulic fluid tpe can e identified color and !"ell $o(ever7 it i!

good practice to take fluid fro" t$e original "arked container and t$en to c$eck t$e fluid

color and !"ell for verification. 'luid container! !$ould al(a! e clo!ed7 e-cept ($en fluid i!

eing re"oved.

I)%pe(*)%

8draulic and pneu"atic !!te"! are in!pected for leakage7 (orn or da"aged tuing7 (orn or

da"aged $o!e!7 (ear of "oving part!7 and !ecurit of "ounting for all unit!7 !afe ting7 and an ot$er

condition !pecified t$e "aintenance "anual. A co"plete in!pection include! con!idering t$e age7 cure date7

!tiffne!! of t$e $o!e7 and an operational c$eck of all !u!!te"!.

1. Leakage fro" an !tationar connection in a !!te" i! not per"itted7 and if found7 it !$ould

e repaired. A !"all a"ount of fluid !eepage "a e per"itted on actuator pi!ton rod! and

rotating !$aft!. /n a $draulic !!te"7 a t$in fil" of fluid in t$e!e area! indicate! t$at t$e !eal!

are eing properl luricated. =$en a li"ited a"ount of leakage i! allo(ed at an point7 it i!

u!uall !pecified in t$e appropriate "anual.

2. +uing !$ould not e nicked7 cut7 dented7 collap!ed7 or t(i!ted eond approved li"it!.+$e identification "arking! or line! on a fle-ile $o!e (ill !$o( ($et$er t$e $o!e $a!

een t(i!ted.

3. All connection! and fitting! a!!ociated (it$ "oving unit! "u!t e e-a"ined for pla

evidencing (ear. Suc$ unit! !$ould e in an unpre!!uri;ed condition ($en t$e are

c$ecked for (ear.

&1


42/44

4. Accu"ulator! "u!t e c$ecked for leakage7 air or ga! preload7 and po!ition. /f t$e

accu"ulator i! e4uipped (it$ a pre!!ure gauge7 t$e preload can e read directl.

5. An operational c$eck of t$e !!te" can e perfor"ed u!ing t$e engine:driven pu"p7 an

electricall:operated au-iliar pu"p >if !uc$ a pu"p i! included in t$e !!te"@7 or a ground

te!t unit. +$e entire !!te" and eac$ !u!!te" !$ould e c$ecked for !"oot$ operation7

unu!ual noi!e!7 and !peed of operation for eac$ unit. +$e pre!!ure !ection of t$e !!te"

!$ould e c$ecked (it$ no !u!!te"! to !ee t$at pre!!ure $old! for t$e re4uired ti"e (it$out

t$e pu"p !uppling t$e !!te". S!te" pre!!ure !$ould e o!erved during operation of eac$

!u!!te" to en!ure t$at t$e engine:driven pu"p "aintain! t$e re4uired pre!!ure.

S$)* PROBLEM CAUSE REMEY

1. Lack of $draulic pre!!ure efective pu"p #eplace t$e pu"p

in a !!te"eflective relief valve

*re!!ure regulator defective

Lack of $draulic fluid 'ill (it$ fluid

2. S!te" failed to $old Cefective pre!!ure regulator #eplace t$e valve

pre!!ure >or@ Unloading valve

Leaking relief valve >or@ c$eck

valve

3. 8ig$ pre!!ure in a !!te" Cefective >or@ i"properl Set t$e re4uired pre!!ure

adu!ted o!truction in a line in regulator and re"ove

or control unit t$e o!truction.

&. U!uall noi!e in a Air >or@ conta"ination in t$e #e"ove conta"ination

$draulic !!te"! !uc$ a! !!te"#eplace (it$ ne( one

c$attering and 5earing'ault pre!!ure regulator

C$eck fluid level in

Lack of proper accu"ulator accu"ulator

5. ?ra55ing 5rake il or !o"e ot$er foreign Clean t$e di!k

"atter on di!k and lining#eplace t$e di!k or dru"

#eplace t$e lining

&2

). 'ailing rake 3rake $ave 5een over $eated #e"ove t$e airand t$ing! urned #eplace t$e !pring


43/44

C$ange t$e ne( valve

0. ragging rake Air in $draulic #e"ove t$e air

roken do(n or (eak return #eplace t$e !pring!pring

C$ange t$e ne( valve

efective valve!

RESULT

+$u! a different !nag on aircraft $draulic !!te" and t$eir cau!e and re"ed i!

fa"iliari;ed.


1. =$at i! ,ngine Align"ent

2. =$at i! in!pection

3. 8o( often t$e $draulic !!te" !ervice!4. =$at i! A66


1. e!crie t$e different !nag! and prole" occur! in $draulic !!te" and it! rectification!.

&3


44/44

Aircraft Systems Lab Manual by Gp

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