inspections followings major maintenance activities and major components changed

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)

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.

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

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.

AS 355 STRUCTURAL PARTS

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

POST INSTALLATION INSPECTION
SOME 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.

FLYING CONTROL REPLACEMENT
FLYING 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.

EXAMPLE OF FLYING CONTROL REPLACEMENT – MAIN
ROTOR SERVO

MAIN ROTOR SERVO ON SA330J

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.

EVEN 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.

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.

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;

inspections followings major maintenance activities and major components changed

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