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Documente Profesional
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SYSTEMS LAB
MANUAL
S.No
1
2
3
4
5
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COMPONENTS
A STUDY OF PRESSURE TEST IN HYDRAULIC SYSTEMS
MAINTENANCE AND RECTIFICATION OF SNAGS IN FUEL
14
16
SYSTEM
MAINTENANCE AND RECTIFICATION OF SNAGS IN
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HYDRAULIC SYSTEM
STUDY OF FLOW TEST, ASSESS OF FILTER ELEMENT
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10
CLOGGING
A STUDY ON BRAKE TORQUE LOAD TEST ON WHEEL BRAKE
25
UNIT
Page No
2
5
7
9
11
Experiment : 1
Introduction
Lifting of the aircraft above the ground with the help of JACKS is called as
JACKING. It can be for servicing, weighting, changing of wheels, leveling
rigging and retraction tests of aircraft landing gear.
Precaution before jacking
1.
Small aircraft always jacked up inside the hangar. Big aircraft can be
jacked up outside hanger sometimes and the aircraft should be positioned
nose against wind position.
2.
Ensure that the ground floor where jacking has to be done should be level
and lead.
3.
Check the serviceability and aircraft jacks and tail supports (trustees).
4.
Check the aircraft weight, fuel state and centre of gravity are within
limits as specified in the aircraft maintenance manual.
5.
6.
7.
Check the main wheels front and real and release the brake.
8.
Take proper clearance for the jacking aircraft with other aircraft and
ground equipment.
9.
Jacking procedure
3
1.
2.
Slowly the position of jacks at each jacking points and raise them until
the adaptors are located centrally in the jacking pads.
3.
Attain the tail support to the tail skid place approximately 250 pounds of
ballast on the base of the tail support to hold down the tail.
4.
5.
Jack up steadily until the under carriage legs are fully extended and the
wheels are a feel inches off the ground.
6.
As the safety measure, the locking nuts on the jacks ram should also be
tightened simultaneously.
7.
Lowering of aircraft
1.
2.
3.
4.
5.
6.
After lowering the aircraft resting on its wheels, chocks should be placed.
1.
A bottle hack and on adapter are used to raise single under carriage for
the purpose of changing the wheel.
2.
The remaining side wheels are chocked in front and rear to present
aircraft movement. Sometimes tail supports also be utilized.
3.
The jack should be raised sufficient level for changing the wheel.
Result
Thus jacking up procedure of aircraft is fully understood.
Experiment : 2
Aim
To know various precautionary measures and procedures to be followed
while leveling an aircraft both laterally and longitudinally to ensure, Rigging and
weighing operations are carried out affectively and efficiently.
Apparatus required
Spirit level
Plumb bob
Note
Aircraft is to be Jacked up be carrying out the leveling procedures.
Procedure
i. Spirit level
Many aircrafts are leveled by use of a spirit level which is placed at jigged
positions on the airframe structure for light aircraft. The longitudinal level position
is generally obtained by placing the spirit level on the two legs on the heads of two
partially with drawn screws on the sides of fuselage and adjusting the jack until the
spirit level is centered. The lateral level position is obtained by placing the spirit
level on the centre section space boom and again adjusting jacks or tyre pressures
until the level is centered, with some large aircraft a spirit level may be used in
conjunction with special fittings which are secured to locations in the centre
fuselage (or) is one of the wheel bays. These fittings must be removed before flight
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and should have warning streamers attached. If adjustments have been necessary to
level an aircraft laterally, the longitudinal level should be rechecked.
Note
In case where tyre pressures are adjusted to level the aircraft, care must be
taken not be over inflate or to completely deflate a tyre.
ii. Plumb bob
On many aircraft, plumb bob is used in conjunction with leveling plate. The
plumb bob is suspended from a fixed position in the cabin loof (or) upper part of a
wheel bay and hangs over a leveling plate which may be permanent of mixture or
a separate fitting accurately located on the cabin floor or a lower part of the wheel
bay.
The leveling plate is marked with a zero position and scales indicating the
adjustment required about lateral and longitudinal axes to centre the plumb bob.
iii. Engineer transit method
The most accurate means of leveling and aircraft is by the use of an
engineers transit (theodolite) in conjunction with a lange pole or scale located on
the aircraft in lateral and longitudinal axis. The transit is setup below the aircraft
centre line and between the lateral leveling points leveled comfortably. Range
poles or scales are then located at force marked leveling points on the lower
surface of the fuselage and wings. Sightings are then taken on the longitudinal
large poles or scales and the nose jack is adjusted until identical readings are again
obtained. The aircraft is then considered level and the transit can be removed.
Note
The transit method is also employed when checking alignment of the aircraft
structure graduation on the range poles being used to check diagonal and
incidence.
Result
Thus the leveling procedure of aircraft is fully understood.
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Experiment : 3
Aim
To know the various methods and precautions to be allowed while rigging
on aircraft to ensure that the assembly checking and adjusting of an aircraft
components (includes control system) to their correct positions and angle as per the
aircrafts handbook and designers instructors.
Equipments required
Spirit level
Incidence board
Plumb bob
Steel rule
Fitter square
Straight edges
Tensiometer
Procedure
Aircraft rigging involves two principal types of operations.
1.
The aircraft structure must be rigged for correct alignment of all fixed
components. The fuselage is aligned at the time of manufacture in the
assembly jigs. All pacts are correctly positioned in the assembly jig.
Some types of fuselage require realignment at major overhaul periods or
after damage wings and other large structures are aligned and assembled
in jigs and fixtures to assure correct shape and positioning of attachment
fittings when the major components are assembled, they are aligned with
each other.
2.
The second type of rigging is the alignment of control surfaces and the
controls that move the surfaces. These operators require the adjustments
of cable length, cable tension, push pull parts. Angular deflection of
control surfaces must be measured with protractors or their measuring
devices to assure that the movements comply with the appropriate
specifications.
Note
The purpose of various rigging tools are given below
1.
2.
3.
Used with an ordinary spirit level to check the dihedral angle of the part
is at correct angle which can be shown when level is zero.
4.
5.
6.
Plumb bob consist of weights suspended on a thin cold and one used for
giving a true vertical line or for checking the vertical members.
7.
Trammels consists to two adjustable points on a long beam and one used
for comparing distances that should be equal such as the diagonal of
braced frame. For measuring purposes, steel rule and Fitter Square are
used.
Result
The rigging procedure of on aircraft is fully understood.
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Experiment : 4
Aim
To know the various methods and procedures to be followed during
symmetry check to ensure that a proper alignment of fully assembled new aircraft
or after repair/servicing/modification/heavy landing of an aircraft thereby the
airworthiness of an aircraft is ascertained.
Note
The precise figures tolerances and check points for a particulars aircraft will
be found in applicable service or maintenance manual.
Method - 1
On small aircraft, the measurements between points are usually taken using
a steel tape. When measuring long distance, it is suggested that a spring scale be
used with the tape to obtain equal tension. A five pound (lb) pull is usually
sufficient.
Method 2
Where large aircrafts concerned, their positions when dimensions are to be
taken are usually checked on the floor. This is done by suspending a plumb bob
from the checkpoints and making the floor immediately under the point of each
plumb bob. The measurements are then taken between the corner of each making.
Procedure
Check the track of the aircraft from trade centres of wheels. This
dimension should be as specified in the aircraft hand book.
Result
Symmetry check procedure of an aircraft is fully understood.
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Experiment : 5
Aim
To know the various tests to be called out on the fuel system of an aircraft to
ascertain the air worthiness of all fuel system components.
Equipments required
Fuel test rig.
Procedure
1. Vent system pressure test
For this test, the vent system on each side of the aircraft should be tested
separately. All vent openings should be blank and it will often be necessary to
blank float operated valves or to replace them with dunning components.
Alternative means of venting the tanks during the test should be applied to the
system either through drain or through an adopted filled to one of the blanks. The
pressure share is slowly raised to the pressure quoted in the relevant maintenance
manual.
When the air pressure supply lock is turned off, any depression in pressure
with indicate leakage and the drop in pressure over a prescribed time should be
noted the source of any leakage in excess that permitted should be cracked and
rectification action should be taken.
2. Feed system pressure test
The feed system from a tank to its associated engine should be tested
indirectly cross fed and values should be closed and the low pressure clock should
be opened on some aircraft. The feed system are pressured by switching ON both
pumps in the tank concerned which on other, the boost pumps are replaced by
dummy component. The fuel pressure is applied by means of an external testing.
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In some systems, the bleed hole on the external / internal fuel leak, all pipe
connections and valves should be checked visually for signs of leakage under
pressure. No leakage is normally permitted.
3. Transfer system pressure test
The pipes and couplings in the fuel transfer system may be pressurized in a
simitar manner to the fuel system. Pipes should be disconnected and blocked at
the positions specified in relevant maintenance manual and fuel pressure should be
applied by means of transfer pumps or by use of an external test rig supplied
through driving pump. No leaks should be identified and no fuel flow should be
recorded on test rig flow meter.
Note
Pressure tests are normally required at the regular intervals after repair.
Maintenances and replacement of components and whenever leakage is found in
those vent system which utilizes part of the wing structures top and bottom section
to form the vent ductivlent pressure test may also be required after structural
repairs. The test required will be specified in the relevant maintenance and should
be carefully carried out. Test rigs capable of supplying fuel or air pressure are
required and should include an accurate pressure gauge, a relief valve and in the
case of fuel pump rig.
Flow meters
All the rigs should be clearly indicated (or) identified with the citification
date. In addition, special blank plugs cover plates and dummy components may be
required. The vent feed and transfer systems are usually tested repeatedly. Since
different test pressure are generally prescribed.
Result
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Various pressure tests are carried out on an aircrafts fuel system and if is
understood completely.
15
Experiment : 6
Aim
To know the various check to be carried out to assume external / internal
leakage in hydraulic system of an aircraft.
Equipments required
External test rig or hydraulic serving trolley.
Procedure
1. Check for system deterioration
Sluggish (or) entire operation of hydraulics system may be caused by
external leakage from components of joints or by internal leakage resulting from
erosion or faulty loads. A small amount of external leakage may not seriously
affect system operation and some maintenance manuals specifically acceptable
limits, temperature indicator installed in some aircraft system will since flow
procedures heat, give some warning off incipient failures, but internal leakage tests
are generally conducted at specific intervals or when faulty system operation is
repeated. Depending on the type of system installed, either flow late or leak slate
check are carried out, an external hydraulic test rig usually being competed, the
aircraft and hydraulic system usually bring prepared for normal operation.
2. Flow rate check
This check is carried out with a flow indicator installed in the line with the
external test rig.
manner prescribed in the relevant maintenance manual and the flow rate being
recorded. Flow through a particular component may be checked by comparing the
flow reading at various actuator positions test some aircrafts are fitted with
maintenance hydraulic oil which uses separate pipeline and isolation posits of
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facilitate flow late checks components with internal leakage greater than the
maximum permitted should be removed for investigation.
3. Leak rate check
For this check, the system should be pressured to normal operation pressure,
when the test rig should be quickly turned off and the true taken for system
pressure to decay by prescribed amount should be recovered. If the leakage late is
excessively high part of system may be checked individually by blanking
appropriate connectors and recording the leakage late through particular
components (or) group components.
In some cases, leakage through components such as actuator may be
checked if disconnecting a pipeline. Applying system pressure to the opposite
connection and measuring the quantity of fluid discharge through open part over a
specified time. Components showing excessive leakage should be removed for
examinations and possible replacement of seals.
Result
Assessments of hydraulic leakage (internal or external) by pressure test is
being understood.
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Experiment : 7
Aim
To know about various troubles (snags) in an aircraft fuel system and their
respective remedy action.
Fuel system
Piper checker PA 28 140 fuel system consist of fuel tanks, selector
valves, filer screens and fuel pump.
This aircraft is equipped with aluminum fuel tanks are in each side inboard
leaching edge of wings. Each tank capacity is 25 gallons.
Fuel from the tank outlet through a strainer is routed to carburetor injector
inlet port by the selection of fuel selector valve.
While maintaining, servicing, repairing, the service manual instruction
should be followed.
Snags and their rectification of PA-28-140 aircraft fuel system are given
below
Sl.
No.
1
Trouble
Failure of
fuel of flow
Cause
Remedies
i.
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Fuel gauge
tail to
operate
value.
i. Broken wire and gauge
necessary.
iv. Replace fuel value.
i.
inoperative.
replace.
ii.
Replace float.
fuse blown.
replace.
v.
Fuel gauge
sticking.
Complete ground on
or repair.
Check ground connections at
indicate full
transmitter wire.
i. Check valve.
pressure
indication
when tanks
4
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Pressure
i. Defective gauge.
installation.
i. Replace gauge.
low or
ii.
pressure
to be in proper position
surges
Unidentified i. Obstruction in inlet side
leak
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Fuel valve
Check position of
selector and adjust if
i.
of pump.
required.
Trace lines and locate
obstruction.
ii.
i.
leaks
Replace
Replace or rebuild
pump.
ii.
Result
The various troubles in aircraft and respective remedial measures was
studied successfully.
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Experiment : 8
Introduction
Hydraulic system in aircraft provides a mean for the operation of large
aircraft components. The uses of hydraulic system in aerospace vehicle systems
are the operation of landing gear and gear doors, flight controls, breaks, flaps,
steering system and wore.
Basically hydraulic system requires a source of hydraulic power (pump) a
valve mechanism to control the flow and direction of hydraulic fluid, a device for
converting fluid power to movement (actuating cylinder).
Troubleshooting of hydraulic system
System fails to hold pressure cause is leaking relief valve and leak
in hydraulic pipe line.
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Sl.
No.
1
Trouble
Landing gear
Cause
Remedies
refraction
system fails
breaker open.
to operate.
i.
ii.
adjustment.
iii. Hydraulic pump
inoperative.
pump.
reservoir below
hydraulic fluid.
operating level.
v. Battery low or dead.
2
v.
Check condition of
i.
battery.
Isolate and check
lines.
hydraulic lines.
extremely
ii.
slow.
Pump stops
pump base.
i.
Landing gear actuator i.
during gear
retraction
breakers open.
(or)
ii.
extension
Mechanical
ii.
restriction in hydraulic
perform functional
systems to allow
pressure to build up
cause.
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Pump
i.
Internal leakage of
i.
Check auxiliary
running
system.
intermittently ii.
Leakage of high
internal leakage.
ii.
retracted.
All gears fail
to free fall
replace.
Result
Thus various troubles in aircraft hydraulic system along with remedies were
studied.
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Experiment : 9
Introduction
If fitter is an important part in any type of aircraft systems. Filters may be
located within reservoir, in pressure line, in return line or in any other location
where the designers of system decide that they are needed to safeguarded system
against impurities.
Different types of fitters and fitter elements are porous metal, magnetic type,
meteoric and wove. The purposes of the fitters are to prevent dirt and other debris,
foreign particles and contaminating substances from entering into the system.
Maintenance of filter
It involves cleaning of the filter and its elements periodically. Some filters
are put on ON condition maintenance and inspections are done routinely. Many
different defects / malfunctions of systems can be occurred due to filters. For the
entire defect with filters, the main cause is the filters clogging.
Clogging filters affect the fluid pressures and flow rates.
Filter clogging
IF the filters are deposited with debris and impurities, the slowly the outlet
flow form the filters are restricted. This is called as filters clogging. Signs and
symptoms of filter clogging are
i.
ii.
No supply of oil/fuel/air.
iii.
iv.
System collapse
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Visual inspection
2.
By mechanical indication
3.
Electrical indication
4.
Flow test
One type of the system has been equipped with an indicator pin that will
visually indicate a clogged element. When the spin protrudes from filter housing,
the filter elements should be removed or clean. In some systems like electronic
filters, electrical weaving indications will be ON with the help of filter clogging
sensors.
Flow test
Standard clogging indicators are replaced with differential pressure gauges
or transducers and provide continuous monitoring of filter element. In flow test,
build up upto the operating pressure of the system and measure the pressure at the
inlet and outlet of the filter.
Procedure
Start the external power source and build up the system pressure.
Result
Thus the study of flow test to assess the clogging of filter element is
understood.
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Experiment : 10
Introduction
Aircraft brake systems are very much important to bring aircraft speed under
control to permit taxiing.
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mechanical and electrical energy to provide maximum testing capabilities and can
simulate aircraft weight, clag, thrust, wind age and thee dynamic characteristics.
A static torque system to simulate parking brake forces and high response
servo controlled hydraulic subsystems.
The dynamometer covers an area approx 50 feet by 50 feet and has a total
mass of 6,00,000 lbs.
The province software package integrator dynamic meter operations, date
acquisition, data analysis and reporting.
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