MAINTENANCE PRACTICES - KSU

Category B1/B2 according Part-66 Appendix 1

Module 7 Maintenance Practices

Part 66 Cat. B1 Module 7

MAINTENANCE PRACTICES

Volume 1

Issue 1. Effective date 2017-02-28

Vilnius-2017

FOR TRAINING PURPOSES ONLY

Page 1 of 280

Category B1/B2 according Part-66 Appendix 1

Module 7 Maintenance Practices

Table of Contents

Part-66 Module 7. Maintenance Practices (Cat. B1) Syllabus......................................................................13 Part-66: Appendix I - Basic Knowledge Requirements.................................................................................17 7.1. Safety Precautions ? Aircraft and Workshop ............................................................................................19 Basic Rules ....................................................................................................................................................19 Electrical Safety ............................................................................................................................................19 Safety around Compressed Gases................................................................................................................21

Safe Use of Compressed Air .....................................................................................................................21 Inflating Aircraft Tires...............................................................................................................................22 High Pressure Compressed Gases Including Oxygen ...................................................................................22 Servicing Aircraft Oxygen Systems ...........................................................................................................24 Safe Welding ................................................................................................................................................24 Oils, Chemicals and Chemical Compounds ..................................................................................................25 Fire Safety.....................................................................................................................................................26 Fire Protection..............................................................................................................................................26 Types of Fire .............................................................................................................................................27 Fire Pre-requisites ....................................................................................................................................27 Types of Fire vs. Extinguishing Agent .......................................................................................................28 Fire Extinguishing Agents .........................................................................................................................29 Standard Aviation Extinguishants in General Use ....................................................................................30 Recommended Markings to Indicate Extinguisher Suitability .................................................................31 Extinguishers not suited for Airborne Application ...................................................................................32 Ground Type Hand Type Extinguishers ........................................................................................................33 Carbon Dioxide Extinguisher ........................................................................................................................33 Operating Carbon Dioxide Extinguisher ...................................................................................................34 Dry Chemical Extinguisher............................................................................................................................35 Action in the Event of Fire............................................................................................................................35 Using Fire Extinguishers ...........................................................................................................................37 Care and Maintenance of Fire Extinguisher .................................................................................................38 Oxygen Systems ...........................................................................................................................................38 Aviation Oils and Fuels .................................................................................................................................39 Chemical and Physiological Hazards ............................................................................................................40 7.2 Workshop Practices....................................................................................................................................41 Tool and Equipment Usage ..........................................................................................................................41 Tool and Equipment Classification ...........................................................................................................41 Tool Acceptance .......................................................................................................................................41

Issue 1. Effective date 2017-02-28

FOR TRAINING PURPOSES ONLY

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Category B1/B2 according Part-66 Appendix 1

Module 7 Maintenance Practices

Rejection of Tool / Equipment ................................................................................................................. 42 Tool and Equipment from Store .............................................................................................................. 42 Use of Tool / GSE by Staff ........................................................................................................................ 42 Measurements and their Principles............................................................................................................. 45 Estimation ................................................................................................................................................ 45 Precision................................................................................................................................................... 45 Accuracy ................................................................................................................................................... 46 Allowance..................................................................................................................................................... 47 Examples of Engineering and Machining Allowances.............................................................................. 47 Tolerance ..................................................................................................................................................... 48 Mechanical Component Tolerance .......................................................................................................... 48 International Tolerance Grades ............................................................................................................... 50 Measurement Instruments and Equipment ................................................................................................ 51 Calibration of Measurement Instruments ............................................................................................... 52 7.3 Tools........................................................................................................................................................... 53 Pounding Tools............................................................................................................................................. 53 Peen Hammers......................................................................................................................................... 53 Claw Hammers ......................................................................................................................................... 54 Sledge Hammers ...................................................................................................................................... 55 Body Hammers......................................................................................................................................... 55 Mallet ....................................................................................................................................................... 56 Using Hammers ........................................................................................................................................ 56 Screwdrivers ................................................................................................................................................ 57 Using Screwdrivers................................................................................................................................... 59 Holding Tools ............................................................................................................................................... 60 Slip-joint Pliers ......................................................................................................................................... 60 Interlocking-joint or Tongue-and-Groove Water Pump Pliers................................................................. 61 Vise-GripTM Pliers ..................................................................................................................................... 61 Duckbill Pliers........................................................................................................................................... 62 Needle Nose Pliers ................................................................................................................................... 62 Flat- and Round-nose Pliers ..................................................................................................................... 63 Diagonal Pliers ......................................................................................................................................... 64 Safety Wire Pliers ..................................................................................................................................... 64 Using Pliers............................................................................................................................................... 65 Punches ........................................................................................................................................................ 65 Prick Punches ........................................................................................................................................... 66 Centre Punches ........................................................................................................................................ 66

Issue 1. Effective date 2017-02-28

FOR TRAINING PURPOSES ONLY

Page 4 of 280

Category B1/B2 according Part-66 Appendix 1

Module 7 Maintenance Practices

Repair of Wiring System.............................................................................................................................248 Repair of Unshielded Wire .....................................................................................................................250 Shielded Wire .........................................................................................................................................251

Wire and Wire Harnesses Cleaning ............................................................................................................252 7.8. Riveting....................................................................................................................................................254

Strength of Joints .......................................................................................................................................254 Types of Rivet Spacing................................................................................................................................254 Types of Joints ............................................................................................................................................255 Faying Surfaces...........................................................................................................................................256 Guide to Rivet Pitch and Position...............................................................................................................257

Rivet Clearance.......................................................................................................................................257 Rivet Grip Length....................................................................................................................................258 Allowances for Riveting..........................................................................................................................258 Rivet Installation.........................................................................................................................................259 Hole Duplicators .....................................................................................................................................259 Rivet Cutters...........................................................................................................................................259 Bucking Bars ...........................................................................................................................................260 Hand Rivet and Draw Sets ......................................................................................................................260 Dimpling Dies .........................................................................................................................................262 Pneumatic Rivet Guns ................................................................................................................................264 Slow-hitting (Long Stroke) Riveting Hammers .......................................................................................264 Squeeze Riveters ........................................................................................................................................265 Preparation of Rivet Holes .........................................................................................................................266 Drilling ....................................................................................................................................................266 Countersinking and Dimpling .................................................................................................................267 Thermo-Dimpling ...................................................................................................................................269 Driving Rivets..............................................................................................................................................271 Bucking ...................................................................................................................................................271 Hand Driving...............................................................................................................................................272 Solid Riveting Procedure (Snap Head)....................................................................................................273 Solid Riveting Procedure (Reaction).......................................................................................................274 Precautions during Riveting .......................................................................................................................274 Pneumatic Driving ..................................................................................................................................274 Formed Rivet Dimensions ..........................................................................................................................276 Rivet Failures ..............................................................................................................................................276 Shear Failure...........................................................................................................................................276 Bearing Failure .......................................................................................................................................277

Issue 1. Effective date 2017-02-28

FOR TRAINING PURPOSES ONLY

Page 11 of 280

Category B1/B2 according Part-66 Appendix 1

Module 7 Maintenance Practices

Head Failure ........................................................................................................................................... 277 Rivet Installation Faults.............................................................................................................................. 277 Rivet Inspection ......................................................................................................................................... 278 Removing Rivets......................................................................................................................................... 279

Removal of Snap-head Rivet .................................................................................................................. 280

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FOR TRAINING PURPOSES ONLY

Page 12 of 280

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