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MODULE 7 MAINTENANCE PRACTICE

7.1 SAFETY PRECAUTION

CAT B1.1
ANSWER ALL QUESTIONS
7.1.1 High-Pressure Gases
1. Compressed gases are frequently used in the maintenance and servicing of aircraft.
The use of compressed gases requires a special set of safety measures.
Q1: State safety rules apply for the use of compressed gases:

7.2.1.1 General Notes on Calibration


2. The scope of the records maintained, are dependent upon the standards required and
the nature of the equipment. The record system can also provide a valuable reference
in case of dispute or warranty claims. These records can also indicate drift and can
help in reassessing calibration intervals.
Q2: List a minimum information content of any appliance Calibration Record or
Certificate

7.3.1.1 Combination Set


3. The Combination Set (refer to Fig. 4), consists of a graduated steel rule, which has a
machined groove running along the centre of its entire length. The rule can be slid into three
different heads and secured, by a locking screw device, so that the combination of rule and
head will enable certain tasks to be accomplished.

Q3 : Based on the picture describe the name of parts A, B, C, D, E and F


D
C
A

Combination Set

7.5.1

DRAWING IDENTIFICATION SYSTEM

4. An aircraft engineering drawing (refer to Fig. 7), must certain data, which is used to
prove its validity (and legality). All alterations to drawings must be made in
accordance with a drawing amendment system, which will ensure amendment to
design records. If an alteration is made, a new issue number and date must be
allocated to the drawing.
To comply with legislation, procedures must be introduced to progressively amend
the total definition of the product in terms of its associated list of drawings at specific

issues. Each particular variant of a product and its state of modification must be
identifiable in relation to the appropriate list of drawings.
Q4 : State the information that can be found on the conventional drawing as per
Fig. 7

A. Summary of Recommended Drawing Information

DRAWING No.

TC002

DRAWING ISSUE No.

N/
A

APPROVAL

New Drawing

ALTERATION

DATE OF ISSUE

WORKBENCH EXERCISE No
1

15.0

65.0

R5

25.0

45

R5

10.0
60.0
115.0

Note: Stamp initials on workpiece


before case hardening

TC002-1

ITEM

AIRCRAFT

CHECKED BY.

SCALE

ANY ERRORS SHOULD BE


REPORTED TO THE INSTRUCTORS

IF IN DOUBT ASK

THIS DOCUMENT IS THE PROPERTY OF KLM uk ENGINEERING LIMITED AND MAY NOT
BE COPIED OR COMMUNICATED TO A THIRD PARTY OR USED FOR ANY PURPOSE
OTHER THAN THAT FOR WHICH IT IS SUPPLIED WITHOUT THE EXPRESS WRITTEN
AUTHORITY OF KLM uk ENGINEERING LIMITED.

DATE
TITLE

19-0901

N/A

1:1
DIMENSIONS IN
mm

N/A

APPROVED BY.

DO NOT SCALE

MATERIAL / SPECIFICATION

DRAWN BY.

STRESS

CAD GENERATED DRAWING - NO MANUAL ALTERATIONS

Mild Steel

PART No.

N/
A

THIRD ANGLE
PROJECTION

RIVETING BLOCK

Case Harden
TREATMENT
TOLERANCE
0.05
mm

USED ON:
N/
A

Riveting Block

DESCRIPTION

uk

QTY

HURRICANE WAY
NORWICH AIRPORT
NORWICH
NORFOLK

engineering ENGLAND
NR6 6HB
TECHNICAL COLLEGE
DRAWING No.

TC002

SHEET 1 OF 1

7.6.1.1 Tolerances
5. The tolerance on a dimension is the variation tolerated and may be considered as a
numerical expression of the desired quality of workmanship. It is the difference
between the high and low limits of size for that dimension (refer to Fig. 1). Thus, a
part that should be exactly 25 mm nominal diameter, will be accepted for a certain
purpose if it is within the limits 25.1 mm, (the high limit); and 24.9 mm, (the low limit).
The difference between the two (0.2 mm) is the tolerance.

Q5: Refer Fig. 1 and describe A, B, C and D

7.8.1 TYPES OF RIVETED JOINTS


6.
The location of the riveting dictates the type of joint (refer to Fig. 3) that is
made. An ordinary lap joint is used on lightly loaded members and, to provide a flush
surface on one side, the joint may be joggled. Where one flush surface and greater
strength is required, the single butt joint is used. The strongest joint is the double
strap butt joint.

D
Types of Riveted Joints
Fig. 3

Q6 : Describe the types of riveted joints as illustrated in Fig. 3

7.9.1.1

MAINTENANCE OF PIPES AND HOSES

7. The correct methods of installing pipes and hoses (refer to Fig. 6) must be followed if
damage (and possibly disaster) is not to result. Pipes attached to the airframe
structure, are often shielded and will not usually be liable to accidental damage. Other
pipes may be located in exposed positions, where they may be susceptible to
damage or corrosion.
Structure

C
Fig. 6

Q7 : Refer to Fig. 6 describe state of hose installation

7.10.1 INSPECTION AND TESTING OF SPRINGS


8. Springs will generally require little in the way of maintenance. Those that are in
exposed areas can become corroded over time and those in areas of high
temperature can, if they become overheated, lose their temper and cease to have the
necessary mechanical compliance to satisfy the task for which they were designed.
Q8 : State the types of check carried out in order to established the condition or
serviceability of spring?

7.11.1.1 Installation and Misalignment


9. Installation damage is usually the result of an impact that occurs when a bearing is
fitted incorrectly. This may be due to a sharp strike from a drift or pressing the wrong
raceway when mounting the bearing.

Q9 : Describe how to detect misalignment of bearing installation and what kind of


effect on the bearing.

7.12

TRANSMISSIONS

10. There are various types of transmission mechanisms which served variable purposes
used in aircraft systems. Some of which are as listed below.

Gears
Belts and Pulleys
Chains and Sprockets
Screw Jacks
Levers
Push-Pull Rod Systems.

Q10. : State the purpose or function of gear transmission system


7.13.1 INSPECTION OF CONTROL CABLE PULLEYS
11. When inspecting cables for the previously mentioned wear and breakages, the
complete cable runs must be examined for incorrect routing, fraying, twisting or wear
at fairleads, pulleys and guards.
Pulleys must be inspected for wear (refer to Fig. 2), to detect indications of seizure, flat
spots, embedded foreign material and excessive tension. Any signs of contact with
adjacent structure, pipe-work, wiring and other controls must also be thoroughly
investigated.
Q11: Refer to Fig. 2 below and state the reason for defect on the pulleys

Types of Pulley Wear


Fig. 2

7.14.1 SHEET METAL


12. While the majority of metals can be rolled into sheet form, consideration is confined
here solely to the working with sheets of the light alloys, which are encountered on
aircraft and, in particular, those formed from aluminium alloy ingots.
By definition, sheets of aluminium alloy are comparatively thin in cross-section and,
as such, they not only pose a health hazard, through cuts, when being handled but
they are, also, prone to buckling and creasing if handled carelessly.
Q12 : Describe the method of storing and handling of sheet metal

7.16

AIRCRAFT WEIGHT AND BALANCE

13. The main purposes, of monitoring the mass and balance of aircraft, are to maintain
safety and to achieve efficiency in flight. The position of loads such as passengers,
fuel, cargo and equipment will alter the position of the Centre of Gravity (CG) of the
aircraft.
Q13. : Describe the effect or direct result of incorrect loading on aircraft
performance

7.17.1 AIRCRAFT FUELLING PROCEDURES


14. The use of the term fuelling can include both refuelling and defueling procedures and
these notes contain examples of the essential points to be considered when refuelling
and defueling aircraft.
There may, however, be some further, local instructions, regarding the responsibilities
of the various personnel involved in fuelling procedures and these will always take
precedence in conjunction with the relevant Maintenance Manual.
Q14 : State types of aircraft refuelling

7.18.1 TYPES OF DEFECTS


15. An operational aircraft can suffer from many defects and these can be defined as any
event or occurrence, which reduces the serviceability of the aircraft below 100%.
The manufacturer should specify the inspection areas and the faults, which are
expected to be found. In most instances the inspector is looking for indications of
abnormality in the item being inspected.
Q15 :
List out inspection and defect as applicable to all metal parts, bodies or casings
of units in systems and in electrical, instrument and radio installations, metal
pipes, ducting, tubes, rods and levers.

7.19 ABNORMAL EVENTS


16. All aircraft are designed to withstand the normal flight and landing loads expected
during a typical flight cycle. These loads will include the normal manoeuvres the
aircraft is expected to make. The designer will build in a safety factor to compensate
for loads slightly larger than normal. Sometimes extreme circumstances occur which
causes stresses outside the normal design limits.
If the design limits are exceeded, then damage may occur to the aircraft. If it is known
or suspected that the aircraft has been subjected to excessive loads, then an
inspection should be made, to ascertain the nature of any damage that may have
occurred. The manufacturer will normally have anticipated the nature of some of
these occurrences and detailed special checks for these Abnormal Occurrences.

Q16:
The aircraft maintenance manual will normally list the types of abnormal
occurrences needing special inspection. The list may vary, depending on the
aircraft. List the abnormal events most commonly encountered.

7.20.1 CONTROL OF LIFE-LIMITED COMPONENTS


17. On almost any aircraft, there will be a number of components that have a stated life,
usually quoted in flying hours, cycles, calendar time or operating hours.
The correct terminology for life is Mandatory Life Limitation. The components will
have been given a life for various reasons. For example, a fatigue life on a structural
component in flying hours; the landing gear legs due for retirement after 10,000
landings, the batteries due for replacement after 3 or 4 months and a retirement life
on an APU measured in hours running time.
Q17:
Who are responsible for monitoring and control of life components and how the
procedures are being carried out?

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