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Training manual - Module 7. Maintenance Practices

Content

7.1. Safety Precautions-Aircraft and Workshop

Aspects of safe working practices including precautions to take whenworking with electricity, gases especially oxygen, oils and chemicals.Also, instruction in the remedial action to be taken in the event of a fireor another accident with one or more of these hazards includingknowledge on extinguishing agents.

7.2. Workshop Practices

Care of tools, control of tools, use of workshop materials;

Dimensions, allowances and tolerances, standards of workmanship;

Calibration of tools and equipment, calibration standards.

7.3. Tools

Common hand tool types;

Common power tool types;

Operation and use of precision measuring tools;

Lubrication equipment and methods.

Operation, function and use of electrical general test equipment;

7.4. Avionic General Test Equipment

Operation, function and use of avionic general test equipment.

7.5. Engineering Drawings, Diagrams and Standards

Drawing types and diagrams, their symbols, dimensions, tolerances andprojections;

Identifying title block information;Microfilm, microfiche and computerised presentations;

Specification 100 of the Air Transport Association (ATA) of America;

Aeronautical and other applicable standards including ISO, AN, MS,NAS and MIL;

Wiring diagrams and schematic diagrams.

7.6. Fits and Clearances

Drill sizes for bolt holes, classes of fits;

Common system of fits and clearances;

Schedule of fits and clearances for aircraft and engines;

Limits for bow, twist and wear;

Standard methods for checking shafts, bearings and other parts.

7.7. Electrical Cables and Connectors

Continuity, insulation and bonding techniques andtesting;

Use of crimp tools: hand and hydraulic operated;

Testing of crimp joints;

Connector pin removal and insertion;

Co-axial cables: testing and installation precautions;

Wiring protection techniques: Cable looming andloom support, cable clamps, protective sleevingtechniques including heat shrink wrapping, shielding.

7.8. Riveting

Riveted joints, rivet spacing and pitch;

Tools used for riveting and dimpling;

Inspection of riveted joints.

7.9. Pipes and Hoses

Bending and belling/flaring aircraft pipes;

Inspection and testing of aircraft pipes and hoses;

nstallation and clamping of pipes.

7.10. Springs

Inspection and testing of springs.

7.11. Bearings

Testing, cleaning and inspection of bearings;

Lubrication requirements of bearings;

Defects in bearings and their causes.

7.12. Transmissions

Inspection of gears, backlash;

Inspection of belts and pulleys, chains and sprockets;

Inspection of screw jacks, lever devices, push-pull rod systems.

7.13. Control Cables

Swaging of end fittings;

Inspection and testing of control cables;

Bowden cables; aircraft flexible control systems.

7.14. Material handling

Sheet Metal

Marking out and calculation of bend allowance;Sheet metal working, including bending and forming;

Inspection of sheet metal work.

Composite and non-metallic

Bonding practices;

Environmental conditions

Inspection methods

7.15. Welding, Brazing, Soldering and Bonding

Soldering methods; inspection of soldered joints.

Welding and brazing methods;

Inspection of welded and brazed joints;

Bonding methods and inspection of bonded joints.

7.16. Aircraft Weight and Balance

Centre of Gravity/Balance limits calculation: use of relevant documents;

Preparation of aircraft for weighing;

Aircraft weighing;

7.17. Aircraft Handling and Storage

Aircraft taxiing/towing and associated safety precautions;

Aircraft jacking, chocking, securing and associated safety precautions;

Aircraft storage methods;

Refuelling/defuelling procedures;

De-icing/anti-icing procedures;

Electrical, hydraulic and pneumatic ground supplies.

Effects of environmental conditions on aircraft handling and operation.

7.18. Disassembly, Inspection, Repair and Assembly Techniques

Types of defects and visual inspection techniques;

Corrosion removal, assessment and reprotection.

General repair methods, Structural Repair Manual;

Ageing, fatigue and corrosion control programmes;

Non destructive inspection techniques including, penetrant,radiographic, eddy current, ultrasonic and boroscope methods.

Disassembly and re-assembly techniques.

Trouble shooting techniques

7.19. Abnormal Events

Inspections following lightning strikes and HIRF penetration.

Inspections following abnormal events such as heavy landings andflight through turbulence.

7.20. Maintenance Procedures

Maintenance planning;

Modification procedures;Stores procedures;

Certification/release procedures;

Interface with aircraft operation;

Maintenance Inspection/Quality Control/Quality Assurance;

Additional maintenance procedures;

Control of life limited components.