FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

AJD21603 ROTRCRAFT SERVICING, MAINTENANCE AND ROLE EQUIPMENT

WEEK 13:INSPECTION REQUIREMENT FOR HELICOPTER AFTER MAJOR

MAINTENANCE ACTIVITY OR FOLLOWING COMPONENT REPLACEMENT (CONTINUE)

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

LEARNING OBJECTIVE & OUTCOME

OBJECTIVE:

1. GAIN KNOWLEDGE ON INSPECTION REQUIREMENT AFTER MAJOR INSPECTION ACTIVITY AND COMPONENT REPLACEMENT.

OUTCOME:

1. EXPLAIN THE SUBSEQUENT ACTIONS AFTER A PARTICULAR MAJOR MAINTENANCE OF COMPONENT REPACEMENT.

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

INTRODUCTION

THIS WEEK LESSON IS A CONTINUATION FROM LAST WEEK LESSON WITH THE FOCUS ON THE INSPECTION REQUIREMENT AFTER THE FOLLOWING MAINTENANCE ACTIVITIES;

1. PART OF STRUCTURE REPLACEMENT

2. PARTS OF FLYING CONTROL REPLACEMENT

3. PARTS OF TRANSMISSION EQUIPMENT REPLACEMENT

4. HYDRAULIC COMPONENTS REPLACEMENT

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

STRUCTURAL PARTS REPLACEMENT

OCCASIONALLY, SOME PARTS OF THE AIRCRAFT STRUCTURE MIGHT HAVE TO BE REPLACED DUE TO THE FOLLOWING CONDITIONS;

1. WEAR & TEAR OF THE AIRCRAFT

2. MODIFICATIONS

3. DAMAGE DUE TO INCIDENT SUCH AS HARD LANDING.

WHILE THE REPLACEMENT PART OF THE JOB IS FAIRLY STRAIGHT FORWARD, THE ENGINEERS STILL HAVE TO PERFORM CERTAIN INSPECTION TO ENSURE THE INTERGRITY OF THE AIRCRAFT.

SOME OF THE PARTS THAT ARE COMMONLY AFFECTED INCLUDES TAIL BOOM, HORIZONTAL & VERTICAL SABILIZER, PARTS OF THE PRIMARY STRUCTURE ETC.

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AS 355 STRUCTURAL PARTS

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

EXAMPLE OF STRUCTURAL PART REPLACEMENT – TAIL BOOM

WHILE THE INSTRUCTIONS ARE EASY TO FOLLOW, THE PERSONNEL INVOLVED IN THE JOB MUST ENSURE THAT THEY ARE FULLY COMPLYING THE INSTRUCTION & CAUTIONS STATED IN THE MANUAL.EXAMPLES, SOME MANUFACTURER CLEARLY SPECIFIED THAT THE BOLTS MUST BE REPLACED WHENEVER THE TAIL BOOM IS DETACHED FROM THE FUSELAGE.THE NEXT FEW SLIDES WILL SHOW THE PROCEDURES FOR TAIL BOOM REPLACEMENT OF AS355

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

POST INSTALLATION INSPECTIONSOME MANUFACTURER REQUIRE THAT YOU PERFORMED THE ALIGNMENT CHECK OR SYMMETRICAL CHECK AFTER ANY REPLACEMENT OF THE PRIMARY STRUCTURE COMPONENTS.

AFTER COMPLETION OF THE JOB, IT MAY BE NECESSARY TO DO FUNCTIONAL CHECK ON CERTAIN EQUIPMENT, FOR EXAMPLE THE AVIONICS SYSTEM IN WHICH MANY OF ITS SUB-COMPONENTS ARE LOCATED IN THE TAIL BOOM. EQUIPMENT LIKE RADIO TRANSCEIVERS AND NAVIGATION TRANCEIVERS ARE AMONG THE EQUIPMENT THAT FREQUENTLY AFFECTED.

IT IS VITAL THAT AVIONICS PERSONNEL ARE ALSO INVOLVED AFTER COMPLETION OF THE TAIL BOOM REPLACEMENT.

OTHER EQUIPMENT LIKE THE TAIL ROTOR SYSTEM (TR BLADES, TR GEARBOX & TR SHAFT) MAY REQUIRE VIBRATION CHECK AFTER RE-INSTALLATION.

IT MAY ALSO BE REQUIRED THAT YOU PERFORMED THE FLIGHT TEST TO CHECK THE BEHAVIOUR OF THE AIRCRAFT IN FLIGHT.

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FLYING CONTROL REPLACEMENTFLYING CONTROL SYSTEM FORM A VITAL PART ON HELICOPTER FLYING.WRONGLY FOLLOWED PROCEDURES DURING THE REPLACEMENT OF THE FLYING CONTROL PARTS MAY LEAD TO AIRCRAFT BEING UNABLE TO BE CONTROLLED IN FLIGHT.PAST INCIDENTS INVOLVING THE FLYING CONTROL SYSTEM INCLUDES;

1. RUDDER CABLES WRONGLY INSTALLED RESULTING THE HELICOPTER CRASHED.

2. LOSS OF TAIL ROTOR CONTROL DUE TO THE FAILURE OF THE TAIL ROTOR DRIVE.

3. FLYING CONTROL RODS NOT WIRE-LOCKED/SPLIT-PINNED RESULTING THE RODS BECOME DETACHED & CRASHED THE HELICOPTER.

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

EXAMPLE OF FLYING CONTROL REPLACEMENT – MAIN ROTOR SERVO

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MAIN ROTOR SERVO ON SA330J

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FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

POST INSTALLATION INSPECTION

AS CAN BE SEEN FROM THE PREVIOUS SLIDES THAT THE PROCEDURES FOR REPLACEMENT OF THE MAIN ROTOR SERVOS IS FAILY STRAIGHT FORWARD & YET IT CAN CAUSE THE AIRCRAFT TO CRASH IF IT IS WRONGLY INSTALLED.

AFTER COMPLETION OF THE JOB, IT IS VITAL THAT THE ENGINEERS WHO ARE DOING THE DUPLICATE INSPECTION ENSURED THAT THE FOLLOWINGS ARE SATISFIED;

1. CORRECT ASSEMBLY & LOCKING

2. MOVEMENT OF THE CONTROL IN A CORRECT SENSE

3. FULL & FREEDOM OF MOVEMENT OF THE CONTROLS IN ALL DIRECTION.

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

POST INSTALLATION INSPECTIONEVEN A REPLACEMENT FOR A SIMPLE COMPONENT, EXAMPLE THE CONTROL ROD DEMAND THE SAME KIND OF ATTENTION.THE SAME KIND OF ATTENTION IS ALSO APPLICABLE FOR ANY REPLACEMENT OF AUTO-PILOT COMPONENTS THAT INVOLVED DISTURBANCE TO THE FLIGHT CONTROL EQUIPMENT.SOME COMPONENTS REPLACEMENT MAY REQUIRE GROUND RUN TO CHECK FOR HYDRAULIC LEAKS & FLIGHT TEST TO CHECK THE AIRCRAFT BEHAVIOUR, EXAMPLE AFTER MAIN OR TAIL SERVOS REPLACEMENT.

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

HYDRAULIC SYSTEM COMPONENTS REPLACEMENT

NEALY ALL MODERN HELICOPTERS ARE FITTED WITH THE HYDRAULIC SYSTEM TO POWER-UP THE CONTROL SYSTEM & OTHER EQUIPMENT SUCH AS LANDING GEAR.

IMPROPERLY MAINTAINED HYDRAULIC SYSTEM CAN POSED A DANGER TO THE AIRCARFT, SUCH AS;

1. HYDRAULIC LEAKS – CAUSED LOSS OF FLIGHT CONTROL.

2. HYDRAULIC SYSTEM CONTAMINATION – CAUSED THE FILTER TO CLOG OR IT MIGHT DAMAGE THE PUMP & OTHER SENSITIVE EQUIPMENT SUCH AS AUTO-PILOT EQUIPMENT.

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

PARTS OF TRANSMISSION EQUIPMENT REPLACEMENT

TRANSMISSION EQUIPMENT CONSISTS OF ANY ITEM WITHIN THE MAIN ROTOR AND TAIL ROTOR ROTATING SYSTEM.

EXAMPLES; MAIN ROTOR BLADES, MAIN ROTOR HEAD, MAIN GEARBOX, TAIL ROTOR DRIVE SHAFT, TAIL ROTOR GEARBOX AND TAIL ROTOR BLADES.

AS THESE EQUIMENT PLAYS VITAL ROLE IN HELICOPTER FLYING, STRICT ADHERENCE TO THE MANUAL INSTRUCTIONS MUST BE FOLLOWED.

THE NEXT FEW SLIDES PROVIDE GENERAL GUIDELINES AS STATED IN AS 355 MANUAL;

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY Malaysian Institute of Aviation Technology