EXCEL ENGINEERING COLLEGE, KOMARAPALAYAM

DEPARTMENT OF AERONAUTICAL ENGINEERING

AERO ENGINE MAITENANCE AND REPAIRS LAB

LAB MANUAL

LAB INCHARGE
N. SENTHIL KUMAR
Lecturer
Dept. of. Aeronautical
Excel Engineering College

EXCEL ENGINEERING COLLEGE, KOMARAPALAYAM

DEPARTMENT OF AERONAUTICAL ENGINEERING

AERO ENGINE MAITENANCE AND REPAIRS LAB

LAB MANUAL

LAB INCHARGE
N. SENTHIL KUMAR
Lecturer
Dept. of. Aeronautical
Excel Engineering College

INTRODUCTION TO AERO ENGINE:

An aeronautical engineer must have a solid foundation in basics of A/C Engine System,
the knowledge of the maintenance and repair of both piston and jet aero engines and the
procedures followed for overhaul of aero engines.
Though the systems are used to operate the various counter and components, they require
day to day check, repair & examination for smooth and proper function. The purpose to conduct
A/C engine repair lab is to familiarize day to day activities required to maintain airworthy
condition of A/C.

AIRWORTHINESS:
The Continuing capability of the A/C to perform in satisfactory manner, the flight
operation for which it is designed.

INSPECTION
It is the most important form of function of aviation maintenance. As the A/C gives
complexity, it becomes more important to detect any possible trouble before it becomes serious.
To assist this, aero engineers are provided with detail special check list and the maintenance
manual for each type of A/C. The engineer has to go through maintenance manual thoroughly
before attempting any kind of activity in aircraft and its components. The operations may be
carried out on A/C on daily flying hours and/or cycle basis.

MAINTAINENCE
The set of action including inspection, servicing, and determination of condition required
to achieve a derived outcome which restore an A/C part and equipment in serviceable condition.

OVERHAUL
Overhaul means stripping a unit and restoring it to its design performance level after
replacing, reworking of parts to a given standard.

SERVICING
It means preparing the A/C for flight, includes providing the A/C with fuel and other fluid
and gases but do not include any work that is maintenance.

TROUBLE SHOOT
It means to analyses and identify the malfunction.

REPAIR
It means to correct the defective condition.

SERVICING SCHEDULES
Servicing on Hours/Calendar/Cycle basis, which are to be carried out on aircraft at set
Hours/Calendar/Cycle basis are mentioned in the manual or A/C servicing schedule. The
servicing includes examination, inspection, lubrication and removal of major components such
as landing gear jacks, door locks, air conditioning equipments; aircraft brake units wheels etc.
landing gear functional test, fuel contamination test & some activities requires replacement of
components.
Aircraft maintenance checks are periodical checks that have to be done on all aircraft
after a certain amount of time usage. Aircrafts usually refer to as one of the following checks.

A CHECK
This is performed approximately every month. This is usually done over night. The actual
occurrence of this check varies by the type, cycle or number of hours flown since the last check.
The occurrence can be delayed by the aircraft if certain predetermine conditions are met.

B CHECK
This is performed in approximately 3 months.

C CHECK
This is performed every 12 to 18 months. This check puts aircraft out of service and
requires plenty of space usually at the hanger at the hanger and maintenance base. Schedule and
occurrence has many factors. The component is described and thus varies with the A/C category
and type.

D CHECK
This is the heaviest check of an A/C. This check is done approximately every 4 to 5 year.
This is the check that take the entire A/C apart for inspection. A comprehensive check, analysis
Non Destructive Testing (NDT) check and complete health monitoring of the engine has to be
recorded. Complete overhauling of the A/C and its components even A/C painting is also
required in this process.

CONCLUSION
In order to ensure air worthiness condition of an A/C and its associated systems. Various
checks/inspections within stipulated time, following the schedule show the A/C and its system
are kept in fully serviceable condition at all time and in turn enhance the A/C safety. The time
frame of schedules varied from A/C to A/C.

SAFETY PRECAUTIONS WHILE HANDLING AIRCRAFT SYSTEMS AND

ITS COMPONENTS
Exp.No;
Date
Aim
To prevent incident, accident and damage to man and material.

Occasions
Whenever required to handle the A/C and its system components and ground equipments.

Aircraft
Before carrying out any work on the A/C, the respective maintenance manual is to be
referred for further instructions. The necessary safety precautions are to be strictly followed.
1. Before entering the cock pit of a fighter A/C, ensure that the ejection seat is in safe
and all armament operating switches are in safe position and all the safely pins are in
position.
2. Before switching on the master battery switch ensure that the under carriage selector
lever is in down position and latched and all the armament store door switches are in
safe condition.
3. Ensure that the wheel chocks are engaged.
4. Before operating the control surface, ensure that the control locks are removed.
5. Before starting the engine.
a.
b.
c.
d.

Chocks are to be kept in front of the wheel

A/C brake system in serviceable.
A serviceable fire extinguisher is available
Never tow an aircraft without a person inside the cockpit before towing the
A/C, Check the brake pressure.
e. While towing the A/C never exceed the walking speed.
f. Never drop any tool while working.
g. While working inside the A/C, collect all the tools and space on completion of
the job and ensure no items are left behind.

Hydraulic System
1. Always release the system pressure before removing a component from the A/C.
2. Never does any maintenance work on airplane with any other specified oil other than
the recommended one.
3. Carry out the patch test on the system to prevent the contamination of oil. This can be
carried out using Millipore patch test kit.
4. Never mix different grade of hydraulic oil to service the A/C.
5. Blank all the ports of the removed components and the A/C pipe ends to avoid the
entry of dust, dirt and foreign particles.
6. Follow the necessary precautions to dismantle the hydraulic components.
7. Avoid spilling of hydraulic fluid on the A/C and in and around from the A/C. If
spilled it should be cleaned immediately to avoid slipping.
8. Before fitting the non return value and restrictors, ensure that the marked arrows are
in the desired direction.

Pneumatic system:
1. Release the system pressure before attempting a job.
2. Clean all the vents of the aircraft
3. On removal of components, blank all the parts of the component and the respective
pipes.
4. While carrying out the pressure test never exceed the given limitation
5. While charging the pneumatic pressure always use the pressure regulator and safety
value. Drain the oil and water separator.
6. Never handle any bottle or cylinder from its charging nozzle. Always use protective
cover.

Oxygen System
1. Smoking, open flames or smokes should not be permitted while working
on the oxygen system.
2. Do not carry matches while handling the o2 system
3. A/c must be grounded and all electrical power must be switched off.
4. Keep working area and equipment free of oil, grease or any other flammable material.
5. Keep the tools and clothing free of oil and grease.
6. Object should not come in contact with grease or solvents as this will cause
spontaneous explosions.
7. Never lubricate the o2 system components except on approved compatible lubricant.
8. Hand should be clean and free from oil. Do not use greasing gloves.
9. A spark is not necessary to cause a fire or explosion but the chemical reaction of fuel,
gas and oil combined with O2 is sufficient to develop instant combustion and cause
fire and explosion.

10. Never permit O2 cylinder to come in contact with electrical welding circuits and
apparatus.
11. Never use oxygen from cylinder without reducing the pressure through a reducing
regulator and safety valves.
12. Never mix other gas or compressed air is an O2 cylinder.
13. Never test for pipe line leaks or flow pipe line with oxygen unless the lines are
specifically made for that.

Safety Precautions to Be Followed During Fuelling and Defuelling

1. Do not operate radio, radar or any other electrical and electronic
equipment except those specified.
2. Ground the fuel supply unit and aircraft.
3. Make sure the fuelling source contain the proper fuel grade as specified by the
manufacture.
4. No smoking, open flame is permitted in and around the A/C.
5. It is not permitted to drop any tool while the operation is on.
6. The operation should be carried out in an open or fully ventilated space.
7. Do not carry out oxygen related work.

AIRCRAFT JACKING PROCEDURE

Exp.No;
AIM
To lift the A/C by using jacks.

Theory
For maintenance activities such as rigging, leveling, retraction test, wheel brake assembly
change and major component change the A/C must be jacked up properly. The jacking up can be
done by 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 A/C maintenance manual before
attempting to perform jacking up operation.

REQUIREMENT
1. Man hours
2. Man power
3. Document
4. Equipment

3
3+1
A/C maintenance manual
bottle jack, wheel chocks, A/C ladder

PRECAUTIONS
1. Refer A/C manual before jacking up the A/C to know the correct method/procedure,
sequence of operation and requirement of equipments.
2. Ensure the lifting capacity of the jack and the jacks are fully serviceable.
3. If necessary fit the jack pads on the A/C structure.
4. Avoid A/C jacking up operation in open area.
5. Find out the weather status from the ATC/MET department.
6. Select the hard & level ground.
7. If required keep trestles ready for use. Do not jack up the A/C before ensuring that the
C.G and Gross weight are within safety limits.
8. Do not attempt to jack up the A/c by the main gear shock strut.
9. Ensure that the nose landing gear upper & lower torque links are connected prior to
jacking.
10. Maintain the communication between the crews.
11. Ensure all ground support units are clear of the A/C.

12. Place caution boards/sign boards on the ground near the nose, wing tip and tail of the
A/C.
13. Keep safety lines around the A/C.

PROCEDURE
The procedure offers as per the type of A/C and as per the manufacture instruction.
1.
2.
3.
4.
5.
6.

Ensure that the ground is hard & level without slipping

Remove the Chocks from the wheels
Place the trestles wherever it is applicable
Place all jacks at specified jacking points.
Deploy one person at each jacking point, ensure that the jacks are properly placed
Raise the jack slowly till the contact of the A/C jacking pod is at the correct place
slightly way out the jack and align it.
7. First raise the nose slightly then simultaneously all the jacks till the wheels are clear
by one inch from the ground
8. Engage the lock mechanism and lock the jack to prevent the sudden collapse due to
hydraulic leakage of jacks.
9. If the A/C is likely to be jacked more than 24 hours or over night, it is recommended
to adjust the trestles at all specified stations to support the A/C weight.
10. Place a display board (A/C ON JACKS) in front of A/C
11. While lowering the A/C from the jack, ensure the parking brakes are in off position.
12. No loose items are available in and around the A/C while lowering the A/C and
abstraction if any to be cleared before lowering.

RESULT:
A/C jacked up safely without any damage to men, material and equipments.

AIRCRAFT LEVELING PROCEDURE

Exp.No;
Aim
To place the A/C level with the ground by using strain gauge and spirit level method.
(A/C type light wt)

Theory
Leveling of an a/c is the procedure of placing an a/c in its rigging position by means of
lifting the a/c by hydraulic jacks so as to enable the rigging check on newly assembled a/c or
replacement/renewal of any major component of the a/c in order to ensure the correct fitting and
alignment of a/c.
The rigging position is the position of the a/c at which longitudinal and lateral axis are
parallel to the ground (straight level position). It can be done by three different methods on the
a/c type as follows.
1. Strain gauge and spirit level method (Light A/C)
2. Plumb ball method (Large wide body)
3. Engineers steeper method for super sonic A/C

Note
As the procedure differs always, therefore always refer the instruction specified by
manufacturer for the correct procedure for rigging and instructions required.

Occassions
1.
2.
3.
4.

On replacement/renewal of major components.

During rigging check
During symmetry check
As required by manufactures and competent authority

Requirement
1. Man hours 2. Manpower 3. Document 4. Equipment -

3
3+1
A/C Maintenance manual, A/C forms, A/C rigging charts
Tripod jack (hydraulic/screw), A/C ladder, leveling

board, spirit level, tail trestles

Precautions
1. Observe all the precautions while jacking up the a/c
2. Check accuracy of spirit level

Procedure
1.
2.
3.
4.
5.
6.
7.
8.

Ensure that the A/C 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 double of spirit level in 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 center
Recheck the lateral level as well as longitudinal level

Caution
Always finish the leveling procedure by checking the longitudinal level without any
adjustment

Result
The A/C is level and ready for further checks
1. If the bubble is away from the center the incident angle in member less than the
specified dispending upon the position of the bubble.
2. If the incidence angle is not correct the mounting point of the wing fuselage is to be
checked for its correct fitment crackers, losers, distortion.
3. The necessary repair/ repair replacement work may be initiated as per the
maintenance manual

DISINTEGERATION OF AIRCRAFT PISTION ENGINE

Exp.No;
Aim
To Dismantle Aircraft Piston Engine.

Occasions
1. During flying hour basis
2. During calendar hour basis

Requirement
1. Man hours 2. Manpower 3. Document 4. Equipment -

3
3+1
A/C engine manual, Maintenance chart
Engine stand, tool box

Procedure
As per instructions on engine maintenance manual of manufacturers

Result
The aircraft piston engine disintegrated successfully as per letdown procedures

ENGINE (PISTION ENGINE) - CLEANING, VISUAL INSPECTION, NDT

CHECKS
Exp.No;
Aim
To clean and carry out visual inspection and NDT checks on aero engine piston

Occasions
1. During flying hour basis
2. During calendar hour basis

Requirement
1. Man hours
2. Manpower
3. Document
4. Equipment

3
3+1
A/C engine manual, Maintenance chart
Engine stand, tool box

Procedure
As per instructions on engine maintenance manual of manufacturers

Result
The aircraft piston engine inspections carried out successfully as per letdown procedures.

STUDY OF PISTON ENGINE COMPONENTS DIMENSIONAL CHECKS

Exp.No;
Aim
To clean study of piston engine components and check their dimensions as per
maintenance manual

Occasions
1. During flying hour basis
2. During calendar hour basis

Requirement
1. Man hours
2. Manpower
3. Document
4. Equipment

3
3+!
A/C engine manual, Maintenance chart
Engine stand, tool box

Procedure
As per instructions on engine maintenance manual of manufacturers

Result
The study of aircraft piston engine components and dimensional checks carried
successfully as per letdown procedures

ENGINE (PISTON ENGINE) REASSEMBLY

Exp.No;
Aim
To reassemble the engine after cleaning and visual inspection and NDT checks

Occasions
1. During flying hour basis
2. During calendar hour basis

Requirement
1. Man hours
2. Manpower
3. Document
4. Equipment

3
3+1
A/C engine manual, Maintenance chart
Engine stand, tool box, NDT equipments, magnifying
Glass

Procedure
As per instructions on engine maintenance manual of manufacturers

Result
The aircraft piston engine reassembled successfully as per letdown procedures

DISINTEGERATION AND STUDY OF FUEL SYSTEM OF A JET ENGINE

Exp.No
Aim
To dismantle and study of aircraft fuel system (jet engine)

Occasions
1. During flying hour basis
2. During calendar hour basis

Requirement
1. Man hours
2. Manpower
3. Document
4. Equipment

3
3+1
A/C fuel system manual, Maintenance chart
Tool box, fuel system draining kit, dip tray

Procedure
As per instructions on engine maintenance manual of manufacturers

Result
The aircraft fuel system disintegrated and study carried out successfully as per letdown
procedures

IDENTIFICATION OF COMPONENTS & TROUBLE SHOOTING OF JET

ENGINE
Exp.No
Aim
To identify the components and troubleshooting of jet engine

Occasions
1. During flying hour basis
2. During calendar hour basis

Requirement
1. Man hours
2. Manpower
3. Document
4. Equipment

3
3+1
A/C engine manual, Maintenance chart
Engine stand, tool box,

Procedure
As per instructions on engine maintenance manual of manufacturers

Result
The aircraft jet engine disintegrated parts are successfully identified and troubleshooting
carried out as per letdown procedures.

NDT CHEKS AND DIMENSIONAL CHECKS OF JET ENGINE

Exp.No
Aim
To carry out NDT checks and dimensional checks of jet engine

Occasions
1. During flying hour basis
2. During calendar hour basis

Requirement
1. Man hours
2. Manpower
3. Document
4. Equipment

3
3+1
A/C engine manual, Maintenance chart
Engine stand, tool box, NDT kid, engine testing kid

Procedure
As per instructions on engine maintenance manual of manufacturers

Result
The NDT checks and dimensional checks carried out as per letdown procedure.