Aircraft Maintenance and Repair, Seventh Edition

726 Pages·2013·30.1 MB·English

by  Michael Kroes, William Watkins, Frank Delp, Ronald Sterkenburg

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Maintenance and Repair
Seventh Edition
Michael J. Kroes
William A. Watkins (Deceased)
Frank Delp (Deceased)
Ronald Sterkenburg
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Copyright © 2013 by The McGraw-Hill Companies, Inc. All rights reserved. Except as permitted under the United States Copyright Act of 1976, no part
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ISBN: 978-0-07-180151-5
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About the Authors
Michael J. Kroes has been an aviation practitioner and educator for over 35 years. He has
held various FAA certifications, including Airframe and Powerplant Mechanic, Inspection
Authorization, Designated Mechanic Examiner, and Designated Engineering Representative,
and he holds a commercial pilot license. Mr. Kroes has worked for some of the leading
aviation companies, including Raytheon and Allied Signal, and has also spent 25 years as a
professor and department head at Purdue University. Recognized as a leading expert on FAA
technician certification, he authored a comprehensive study funded by the FAA. This study was
used to develop new FAA technician certification content and guidelines. Mr. Kroes resides in
Pinehurst, North Carolina.
Ronald Sterkenburg is a professor in the Aviation Technology Department at Purdue
University. He is a certificated Airframe and Powerplant (A&P) Mechanic, holds an Inspection
Authorization (IA), and is a Designated Mechanic Examiner (DME). Although his main research
interests are in advanced composite materials for aerospace vehicles, he has published many
articles, book chapters, and books on all types of aviation maintenance topics. Dr. Sterkenburg
resides in West Lafayette, Indiana.
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Contents
Preface to the Seventh Edition xiii
Preface to the Sixth Edition xv
1. Hazardous Materials and Safety Practices 1
Hazardous Materials 1
OSHA’s Hazardous Communications Standards 5
Disposal and Accidental Releases of Hazardous Materials 14
Review Questions 16
2. Aircraft Structures 17
Aircraft Structural Design 17
Principal Aircraft Structures 19
Aircraft Station Numbers 19
Zoning 24
Nomenclature and Definitions 25
Fuselages 27
Cockpits, Cabins, and Compartments 37
Wings 46
Tail and Control Surfaces 55
Landing Gear 57
Powerplant Structures 57
Rotorcraft Structures 63
Review Questions 68
3. Fabrication and Repair of Wood Structures 69
Aircraft Woods 69
Adhesives and Bonding Procedures 73
Construction and Repair of Wood Structures 75
Care of Aircraft with Wood Structures 84
Inspection of Airplanes Having Wood Structures 85
Review Questions 87
4. Fabric Coverings 89
Fabric Types and Terminology 89
Dopes and Finishing Materials 94
Facilities and Equipment for Aircraft Covering 97
Selection of Fabric Covering Material 98
Application of Fabric Covers for Aircraft 99
vii
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Fabric Inspection 105
Repair of Fabric Coverings 106
Review Questions 108
5. Aircraft Painting and Markings 111
Aircraft Finishing Materials 111
Spray-Paint Equipment 115
Finishing Metal Aircraft and Parts 121
Registration Marks for Aircraft 127
Review Questions 129
6. Welding Equipment and Techniques 131
Fundamentals of Welding 131
Oxyacetylene Welding 137
Gas Welding Techniques 148
Electric-Arc Welding 157
Inert-Gas Welding 162
Conclusion 177
Review Questions 177
7. Welded Aircraft Structures and Repair 179
Construction of Steel-Tube Assemblies by Welding 179
Inspection of Steel-Tube Structures 182
Aircraft Tubing Repair 182
Special Welding Repairs 194
Soldering and Brazing 197
Review Questions 201
8. Sheet-Metal Construction 203
Design Philosophies 203
Factors Affecting Sheet-Metal Part and Joint Design 205
Fundamental Calculations for Structures 213
Bending Metals 214
Preparation for Layout Work 228
Hand Tools for Sheet-Metal Work 229
Floor and Bench Machinery for Sheet-Metal Work 234
Fabrication of Sheet-Metal Parts 244
Riveting 248
Review Questions 255
9. Sheet-Metal Inspection and Repair 257
Sheet-Metal Inspection 257
Sheet-Metal Repair 258
Repair Practices 263
Rivet-Repair Design 269
Review Questions 280
10. Plastics 283
Fundamentals of Plastic Materials 283
Working with Plastic Materials 284
viii Contents
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Installation, Maintenance, and Repair of Plastic Materials 286
Review Questions 290
11. Advanced Composite Materials 291
Laminated Structures 291
Major Components of a Laminate 292
Strength Characteristics 292
Description of Sandwich Structures 299
Review Questions 326
12. Assembly and Rigging 327
Aircraft Assembly 327
Aircraft Rigging 329
Fixed-Surface Alignment 332
Aircraft Flight Controls 338
Secondary Flight-Control Surfaces 342
Control-System Components 350
Control Surface Rigging 366
Balancing Control Surfaces 369
Inspection and Maintenance 371
Helicopter Flight Controls 373
Review Questions 381
13. Aircraft Fluid Power Systems 383
Principles of Hydraulics 383
Hydraulic Fluids 386
Hydraulic Reservoirs 387
Hydraulic Filters 390
Hydraulic Pumps 392
Pressure-Control Devices 397
Pressure-Reducing Valves 400
Accumulators 402
Selector Valves 403
Automatic-Operating Control Valves 406
Hydraulic Actuators 412
Hydraulic Plumbing Components 415
Hydraulic Systems for Aircraft 417
Hydraulic System for the Boeing 777 Airliner 423
Hydraulic System for the Airbus 380 430
Hydraulic System for the Bell 214ST Helicopter 432
Pneumatic Systems for Aircraft 435
Summary of Hydraulic System Maintenance Practices 440
Review Questions 442
14. Aircraft Landing-Gear Systems 445
Landing-Gear Configurations 445
Classification of Landing Gear 445
Landing-Gear Components 449
Steering Systems 457
Retraction Systems 458
Contents ix
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Transport Aircraft Landing-Gear Systems 464
Inspection and Maintenance of Landing Gear 478
Tires and Wheels 483
Design and Operation of Brake Assemblies 492
Aircraft Brake Systems 499
Brake Maintenance 507
Review Questions 508
15. Aircraft Fuel Systems 511
Requirements for Fuel Systems 511
Fuel Tanks 513
Fuel-System Components 520
Types of Fuel Systems 528
Fuel Subsystems 529
Typical Aircraft Fuel Systems 534
Inspection, Maintenance, and Repair of Fuel Systems 548
Troubleshooting 553
Review Questions 554
16. Environmental Systems 555
Heating Systems 555
Cabin-Cooling Systems 560
Cabin-Pressurization Systems 570
Cabin Environmental System for a Jet Airliner 579
Summary of Pressurization and Air-Conditioning Systems 585
Oxygen Systems 587
Review Questions 603
17. Aircraft Instruments and Instrument Systems 605
Principles of Instrument Operations 606
Flight Instruments 612
Flight Instrument Systems 635
Engine Instruments 638
Fuel-Quantity Indicators 641
Fuel-System-Monitoring Instruments 643
Miscellaneous Instruments 644
Electronic Instruments 646
Installation and Maintenance of Instruments 651
Review Questions 657
18. Auxiliary Systems 659
Fire Protection Systems 659
Ice Protection Systems 671
Rain-Removal Systems 681
Water and Waste Systems 683
Position and Warning Systems 684
Auxiliary Power Units 688
Review Questions 692
x Contents
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19. Troubleshooting Theory and Practice 693
The Troubleshooting Process 693
Format of Troubleshooting Charts 697
Review Questions 702
Index 705
Contents xi
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