FACULTY OF ENGINEERING AND

TECHNOLOGY (FoET)

SCHOOL OF AIRCRAFT MAINTENANCE

DIPLOMA IN AIRCRAFT MAINTENANCE

ENGINEERING

EK 2111
AIRCRAFT HYDRAULIC AND
PNEUMATIC SYSTEMS

STUDENT WORKBOOK
ACADEMIC YEAR: 2023

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CONTENTS

Week Lesson Topic

Week 1 Lesson 1 :
Hydraulic System, Fluids and Seals
Week 2 Lesson 2 : Hydraulic Power Systems - I

Week 3 Lesson 3 : Hydraulic Power Systems - II

Week 4 Lesson 4 : Pressure Generation: Electrical, Mechanical and Pneumatic

Week 5 Lesson 5 : Emergency Pressure Generation

Week 6 Lesson 6 : Regulation of Hydraulic Pressure - I

Week 7 Lesson 7 : Regulation of Hydraulic Pressure - II

Week 8 Lesson 8 : Power Distribution - I

Week 9 Lesson 9 : Power Distribution - II

Week 10 Lesson 10 : Indication and Warning Systems

Week 11 Lesson 11 : Maintenance of Hydraulic Systems

Week 12 Lesson 12 : Pneumatic/Vacuum System

Week 13 Lesson 13 : Ice and Rain Protection

Week 14 Lesson 14 : EASA Revision

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 Lesson 1: Hydraulic System, Fluids and Seals

1.1 Introduction

In this lesson, you will learn about hydraulic system, fluids and seals.

1.2 Learning Outcomes

At the end of the topic the student will be able to:

• describe the various types, physical characteristics and standard identification
designator of aviation hydraulic fluids and where each type of fluid is likely to
be found;

• describe the different types of seals, construction, sealing operation and

compatibility of materials in different types of hydraulic fluid.

1.3 Exercises

1. What are three basic types of hydraulic fluids used in aircraft hydraulic
system?
o Mineral-based hydraulic fluids.
o Phosphate Ester hydraulic fluids.
o Vegetable-based hydraulic fluids.

2. What is Pascal’s law? Pascal's Law states that, “A change in pressure applied to
an enclosed fluid is transmitted undiminished to all portions of the fluid and
to the walls of its container”

3. Discuss the principles of hydraulic system?

• Pascal’s law
• Fluid conservation
• Mechanical advantage.

4. What are the ideal properties of hydraulic fluid?

• Incompressibility.
• Lubricating properties.
• Stability at high temperatures.
• Resistance to foaming.
• Compatibility with system materials.
• Corrosion resistance.
• Low volatility.

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 • Good viscosity characteristics.

5. Why the different types of hydraulic fluid cannot mix? Mixing different types
of hydraulic fluids can lead to chemical incompatibility, resulting in reduced
performance, increased wear, potential damage to seals and components, and
compromised system integrity.

6. What are the most common types of seals? O-rings, Lip seals, V-ring seals, T-
seals, U-cup seals, Wiper seals.

7. Vegetable (Castor oil) base hydraulic system can be flushed with kerosene.

8. Mineral base hydraulic system can be flushed with mineral spirits or kerosene.

9. Describe the application and materials of seals in hydraulic components.

Seals are used in hydraulic components to prevent the escape of fluid and to
maintain pressure within the system. They ensure proper functioning by
preventing leaks and contamination.

Seals are made from various materials depending on the specific application
and compatibility requirements:
1. Nitrile (Buna-N): Common for general-purpose seals.
2. Fluorocarbon (Viton): Resistant to high temperatures and chemicals.
3. Polyurethane: Provides good abrasion resistance.
4. Ethylene Propylene Diene Monomer (EPDM): Suitable for applications
with exposure to weather and ozone.
5. Polytetrafluoroethylene (PTFE): Known for low friction and chemical
resistance.
6. Silicone: Resistant to extreme temperatures.
7. Leather: Used historically, but less common in modern applications.

The choice of seal material depends on factors such as fluid compatibility,

temperature, pressure, and the specific conditions of the hydraulic system.

1. 4 Summary

In this lesson, you have learned about hydraulic system, fluids and seals.

1. 5 Key Terms

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Hydraulic flush flushing a hydraulic system is to eliminate sludge, varnish,
debris and contaminated or degraded fluid from conductor
walls and other internal surfaces and system dead spots

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 Lesson 2: Hydraulic Power Systems I

2.1 Introduction

In this lesson, you will learn about the layout and operation principles of hydraulic
power systems.

2.2 Learning Outcomes

At the end of the topic the student will be able to:

• describe the basic lay out of a typical, modern jet and turbo prop aircraft
hydraulic system;

• discuss the types, operation and components of hydraulic system.

2.3 Exercises

1. Discuss the power system transmission lines of hydraulic system?

In a hydraulic system, power transmission is achieved through fluid pressure.
The main components involved in power transmission are:

1. Pump: Converts mechanical power (usually from the aircraft engine) into
hydraulic fluid flow, creating pressure.

2. Actuators: Devices that use the hydraulic pressure to perform mechanical

work. Examples include hydraulic cylinders and hydraulic motors.

3. Valves: Control the flow and direction of hydraulic fluid, regulating the
operation of actuators.

4. Reservoir: Stores hydraulic fluid and helps in maintaining the proper fluid
level.

5. Filters: Ensure the cleanliness of hydraulic fluid, preventing contamination

that could damage components.

6. Lines and Hoses: Transmit hydraulic fluid between components, forming

the fluid circuit.

The power transmission in a hydraulic system involves the conversion of

mechanical power into hydraulic pressure, the transmission of this pressure
through the fluid, and the utilization of this pressure to perform work through
actuators.

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 2. Discuss the differences between open and closed centre system?
Open-Center Hydraulic System:
1. Fluid Flow: Fluid continuously flows from the pump to the control valve and
back to the reservoir, even when actuators are not in use.
2. Pressure: The pump maintains constant pressure, and excess flow returns to
the reservoir.
3. Efficiency: Less efficient as energy is not conserved when actuators are not
engaged.
4. Common Usage: Found in applications where constant hydraulic power is
required, such as tractors and earthmoving equipment.

Closed-Center Hydraulic System:

1. Fluid Flow: Fluid is pumped from the reservoir to the control valve only
when actuators are in use, and excess flow is directed back to the reservoir.
2. Pressure: Maintains variable pressure depending on the demand from
actuators, making it more energy-efficient.
3. Efficiency: More energy-efficient as the pump varies its output based on the
load requirements.
4. Common Usage: Used in applications where precise control and energy
efficiency are critical, such as in modern industrial machinery and some
aircraft systems.

3. List down components that consist on simple hydraulic system? Reservoir,

pump, valve(s), actuator, lines/hoses, filter, fluid, fittings/connectors, pressure
relief valve, check valve.

4. How positive pressure in the system was maintained when it is not operating?
Positive pressure in the system is maintained through check valve.

5. What is the purpose of unloading valve? To divert excess fluid from the pump
to the reservoir to prevent overpressurization.

6. An accumulator is installed to store and release hydraulic energy.

7. The accumulator has two compartments separated by a movable piston or

diaphragm.

8. One compartment of accumulator if charged with nitrogen gas or hydraulic

fluid through a charging valve.

2. 4 Summary

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In this lesson, you have learned about hydraulic power systems.

2. 5 Key Terms

System interconnect to allow the crew to port fluid from a good hydraulic system
into a system that has failed due to a supply pump failure

System isolation to prevent fluid entering any non-essential items that could
have a leak so preserving the fluid remaining for the essential
systems such as brake and nose wheel steering

Lesson 3: Hydraulic Power Systems II

3.1 Introduction

In this lesson, you will learn about hydraulic power systems.

3.2 Learning Outcomes

At the end of the topic the student will be able to:

• Describe the construction and operation of hydraulic components.

3.3 Exercises

1. Discuss the differences between vented and pressurised reservoir?

Vented Reservoir:

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 1. Design: Open to the atmosphere, allowing air to freely enter and exit the
reservoir.
2. Pressure: Operates at atmospheric pressure.
3. Use: Common in low-pressure systems where fluid is not pressurized
significantly.
4. Purpose: Prevents vacuum formation and allows air exchange to
accommodate fluid level changes.

Pressurized Reservoir:
1. Design: Sealed to maintain a positive pressure, often pressurized with
nitrogen.
2. Pressure: Operates at a constant positive pressure, preventing fluid
cavitation.
3. Use: Common in high-performance systems where maintaining fluid
pressure is critical.
4. Purpose: Ensures a consistent pressure head for the pump, preventing
aeration and cavitation.

In summary, the key difference lies in whether the reservoir is open to the
atmosphere (vented) or sealed and pressurized (pressurized).

2. Accumulator is located at a higher level than the EDP’s to ensure a positive

“head of pressure” supply of fluid throughout all normal flight manoeuvres.

3. Describe the common methods which used to pressurise the pressure

reservoir? This is by using a pre-charged gas, often nitrogen, introduced into
the reservoir.

4. On modern Jet and Turbo-prop aircraft it is common practice to install a

remote servicing point in a convenient place, with easy access from ground
level for maintenance personnel to carry out replenishment of the hydraulic
fluid level. What are the components usually consists at the service point?
Reservoir fill port, breather/air vent, fluid level sight glass/dipstick, drain valve,
pressure relief valve, filtration system, placards/labels.

5. Explain the operations of filter in hydraulic system? Filters in hydraulic systems

remove contaminants, preventing debris from reaching critical components,
maintaining fluid cleanliness, and enhancing system reliability.

6. Discuss the different types of accumulator? Bladder, Piston, and Diaphragm

are common types of accumulators.

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 3. 4 Summary

In this lesson, you have learned about hydraulic power systems.

3. 5 Key Terms

Inline Reservoir has its own welded aluminium alloy housing, is complete within
itself and is connected with other components in system by
tubing or hose
Integral Reservoir no housing of its own but merely a space set aside within some
major component to hold a supply of operational fluid

Lesson 4: Pressure Generation: Electrical, Mechanical and Pneumatic

4.1 Introduction

In this lesson, you will learn about different methods of pressure generation in
hydraulic systems

4.2 Learning Outcomes

At the end of the topic the student will be able to:

• familiarize the different types of hydraulic pump;

• describe the purpose, uses and principles of operation of hydraulic pump.

4.3 Exercises

1. Discuss the differences between single action and double action operated
hand pump?
Single Action Hand Pump:
- Operates in one direction (either compression or extension).
- Typically used for applications where force is required in one direction only.
- Examples include hydraulic presses.

Double Action Operated Hand Pump:

- Operates in both directions (compression and extension).
- Allows for fluid delivery on both the up and down strokes.
- Commonly used for tasks where force is needed in both directions.
- Provides more efficiency in certain applications.

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 2. Which type of hand pump called as “Piston rod displacement pump”?
Reciprocating or piston type pump.

3. Suction boost pump located at near the fuel tank.

4. Explain the operation and function of suction boost pump? The suction boost
pump operates to assist in lifting fuel from the aircraft's fuel tank to the
engine-driven pump, ensuring a consistent fuel supply to the engine. It
prevents cavitation and ensures a positive pressure head for the engine-
driven pump, especially during low fuel levels or high-altitude conditions.

5. What are the two basic types of powered operated pump?

1. Electric Motor-Driven Pump: Uses an electric motor to drive the pump.
2. Hydraulic Motor-Driven Pump: Utilizes a hydraulic motor to power the
pump.

6. Discuss the differences between constant volume and fixed displacement

(Non-self-idling) and constant pressure/ variable displacement (Self-idling).
Constant Volume and Fixed Displacement (Non-Self-Idling):
- Operation: Delivers a constant volume of fluid per revolution, regardless of
load.
- Characteristics: Does not automatically adjust to varying load demands.
- Application: Typically used in applications with consistent load
requirements.

Constant Pressure/Variable Displacement (Self-Idling):

- Operation: Maintains a constant pressure in the system by automatically
adjusting displacement based on load demand.
- Characteristics: Adjusts to varying load demands, making it more efficient.
- Application: Common in systems where pressure regulation is crucial,
adapting to changing operational conditions.

7. Which type of pump consists of a bronze cylinder block, rotated by a splined

drive shaft driven by the engine, through a universal link? A gear pump.

8. Which type of fixed volume pump, the cylinders are arranged radially around
an eccentric crankshaft? A radial piston pump.

4. 4 Summary

In this lesson, you have learned about pressure generation: electrical, mechanical and
pneumatic.

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 4. 5 Key Terms

Safety measure on Drive shaft of almost all powered pumps especially EDP has a
Powered pump necked down or waisted portion called shear section, that will
break or shear under excessive load if the system pressure relief
valve fails or pump seizes. This is to protect the engine
accessory drive
EDP Engine Driven Pump

Lesson 5: Emergency Pressure Generation

5.1 Introduction

In this lesson, you will learn about the different methods of emergency pressure
generation.

5.2 Learning Outcomes

At the end of the topic the student will be able to:

• describe the principles of operation and components associated with

emergency hydraulic systems fitted to modern jet and turbo prop air
transport aircraft;

• identify how and where fluid in the hydraulic system for auxiliary or
emergency pump operation.

5.3 Exercises

1. Discuss the several methods which provide hydraulic during emergency when
normal hydraulic supply failed?
1. Emergency Hand Pump:
- Operation: Manual pumping by the crew to pressurize the hydraulic
system.
- Use: Backup during power loss in normal hydraulic systems.

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 2. Emergency Power Assist (EPA) System:
- Operation: Uses alternative power sources (such as the aircraft's RAT -
Ram Air Turbine) to generate hydraulic power.
- Use: Provides emergency power for critical flight controls.

3. Accumulator-Based Systems:
- Operation: Utilizes stored hydraulic energy in accumulators to power
essential functions.
- Use: Ensures limited functionality during power loss.

4. Residual Pressure Check Valve:

- Operation: Retains residual hydraulic pressure in critical systems after
engine shutdown.
- Use: Enables limited hydraulic operation for a short duration in
emergencies.

5. RAT (Ram Air Turbine):

- Operation: Deploys a small turbine exposed to oncoming air to generate
hydraulic power.
- Use: Supplies emergency power for critical flight controls and systems.

These methods provide a means to maintain essential hydraulic functions

during emergencies when the normal hydraulic supply fails.

2. The hand-pump is connected in parallel with the engine driven pump but has
an independent fluid supply line from the reservoir

3. Describe the purpose of duplication of hydraulic supply in modern aircrafts?

The duplication of hydraulic supply in modern aircraft serves as a redundancy
measure to enhance safety and reliability. It ensures that if one hydraulic
system fails or is compromised, there is an alternative system available to
operate critical functions such as flight control surfaces, landing gear, and
braking systems. Duplication minimizes the risk of total hydraulic failure,
contributing to the overall safety and performance of the aircraft.

4. It is common practice to install an Auxiliary Power Unit (APU) primarily as a

backup to the EDP when system demand is high, but also to provide hydraulic
power in case of engine driven pump or engine failure.

5. Discuss the electric motor driven pump in emergency hydraulic systems,

In an emergency hydraulic system, an electric motor-driven pump serves as a

backup power source to ensure the availability of hydraulic power in critical
situations. Here's a brief overview:

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 1. Functionality:
- The electric motor-driven pump is activated automatically or manually
during an emergency.
- It provides hydraulic pressure to essential functions, such as flight control
surfaces, landing gear, or brakes.

2. Power Source:
- Powered by the aircraft's electrical system or a dedicated emergency
power source.
- Ensures independence from engine-driven pumps or hydraulically
powered systems.

3. Redundancy:
- Offers redundancy in case of primary hydraulic system failure or loss of the
main engine-driven pump.
- Enhances overall system reliability and safety.

4. Installation Location:
- Typically installed in a centralized location for easy access and efficient
hydraulic distribution.

5. Activation Mechanism:
- Activated automatically when certain criteria, such as loss of hydraulic
pressure, are detected.
- Manual activation is also possible in some designs.

6. Limited Operation:
- Designed for limited-duration operation to address critical needs during
emergencies.
- Ensures that hydraulic power is available for essential functions until a safe
landing or resolution of the emergency.

The electric motor-driven pump in an emergency hydraulic system provides

an additional layer of safety and control, allowing the aircraft to respond to
critical situations even if primary hydraulic systems are compromised.

6. Discuss the operation principles of air-turbine driven pumps when the main
hydraulics system is failed.
Air-turbine-driven pumps, often found in aircraft as part of the emergency
hydraulic system, operate on the principle of utilizing ram air to generate hydraulic
power. Here's a brief overview:

1. Activation:
- Engages automatically or manually during an emergency when the main hydraulic
system fails.

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2. Ram Air Turbine (RAT):
- The system typically includes a small turbine, known as a Ram Air Turbine (RAT),
mounted externally.
- RAT deploys into the airflow, usually from the aircraft's fuselage, to capture
oncoming air.

3. Hydraulic Power Generation:

- The airflow drives the RAT's turbine, which, in turn, powers a hydraulic pump.
- The hydraulic pump generates hydraulic pressure.

4. Emergency Functions:
- The hydraulic pressure produced by the air-turbine-driven pump is used to
operate critical functions, such as flight control surfaces and landing gear.

5. Independence from Engine-Driven Pumps:

- Provides an independent source of hydraulic power, separate from engine-driven
pumps or the main hydraulic system.

6. Limited Duration:
- Typically designed for short-duration operation to address immediate emergency
needs.
- Allows the aircraft to perform essential maneuvers and safely land in the event of
a main hydraulic system failure.

The air-turbine-driven pump serves as a crucial component of the emergency

hydraulic system, ensuring that the aircraft retains some hydraulic functionality even
when the main hydraulic system is compromised.

7. What is the purpose of power transfer unit? Its primary purpose is to ensure
that in the event of a failure or imbalance in one hydraulic system, hydraulic
power can be transferred from another system to maintain essential functions,
such as controlling flight surfaces and landing gear deployment. The PTU
enhances system redundancy and contributes to the overall reliability and
safety of the aircraft.

8. Explain the operations of ram air turbine (RAT).

The Ram Air Turbine (RAT) deploys into oncoming air during emergencies. It
spins, generating hydraulic power to operate critical systems, ensuring
essential functions like flight control surfaces and landing gear can be
controlled even if the main power sources fail.

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 5. 4 Summary

In this lesson, you have learned about emergency pressure generation.

5. 5 Key Terms

PTU Power Transfer Unit

RAT Ram Air Turbine
ATM Air Turbine Motor

Lesson 6: Regulation of Hydraulic Pressure I

6.1 Introduction

In this lesson, you will learn about the hydraulic power pack, flow and control valve.

6.2 Learning Outcomes

At the end of the topic the student will be able to:

• describe the operations of hydraulic power pack in the systems;

• describe the construction, operation, location and functions of flow and

pressure control valve.

6.3 Exercises

1. Discuss the operation and function of components in a hydraulic pack.

A hydraulic pack is a self-contained unit that includes various components to
generate and control hydraulic power. Here's the operation and function of
components commonly found in a hydraulic pack:

1. Electric Motor:
- Operation: Converts electrical energy into mechanical energy.
- Function: Drives the hydraulic pump to generate hydraulic pressure.

2. Hydraulic Pump:
- Operation: Converts mechanical energy from the motor into hydraulic
energy.
- Function: Pressurizes hydraulic fluid for system operation.

3. Reservoir:
- Operation: Stores hydraulic fluid.
- Function: Provides a source of hydraulic fluid for the system.

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 4. Valves:
- Operation: Control the flow and direction of hydraulic fluid.
- Function: Regulate and direct hydraulic pressure to specific components.

5. Filters:
- Operation: Remove contaminants from hydraulic fluid.
- Function: Maintain fluid cleanliness to prevent damage to components.

6. Accumulator:
- Operation: Stores hydraulic energy in the form of pressurized fluid.
- Function: Provides additional power during peak demand or emergency
situations.

7. Heat Exchanger/Cooler:
- Operation: Dissipates heat generated during hydraulic system operation.
- Function: Prevents overheating and ensures optimal system performance.

8. Sensors:
- Operation: Monitor system parameters.
- Function: Provide feedback for system control and diagnostics.

9. Control Unit:
- Operation: Receives input from sensors and controls system components.
- Function: Regulates and coordinates the operation of the hydraulic pack.

10. Pressure Relief Valve:

- Operation: Releases excess pressure to prevent overpressurization.
- Function: Safeguards the system and components from damage.

The hydraulic pack integrates these components to generate, control, and

distribute hydraulic power for various applications, contributing to the overall
functionality and reliability of hydraulic systems in aircraft and other
machinery.

2. The valves used in hydraulic systems may be divided into pressure control and
directional control valves.

3. A pressure relief valve adjusts, regulates and/or limits the amount of pressure
in
the power supply system or any component circuit.

4. A directional control valve selects and directs the flow of fluid through the
system or circuit in a particular direction and is not normally concerned with
the pressure.

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 5. A thermal relief valve is designed to relieve excessive pressure caused by
expansion of the hydraulic fluid due to increase in temperature.

6. Explain the operation of pressure reducing valve in hydraulic system?

A pressure reducing valve in a hydraulic system operates by maintaining a
preset lower pressure in a branch of the hydraulic circuit. When the pressure
exceeds the set limit, the valve opens to allow excess fluid to bypass, ensuring
that downstream components receive the desired reduced pressure.

7. Directional control valves in hydraulic systems controls fluid flow and the
direction of flow.

8. What valve is allow the fluid flow in one direction? Check valve.

6. 4 Summary

In this lesson, you have learned about the hydraulic power pack, flow and control
valve.

6. 5 Key Terms

Flow control valve Select and direct the fluid flow through the system or circuit in
a particular direction

Pressure control valve Adjust, regulate and /or limit the amount of pressure in the
power supply system or component circuit

Lesson 7: Regulation of Hydraulic Pressure II

7.1 Introduction

In this lesson, you will learn about the flow and pressure control valve.

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 7.2 Learning Outcomes

At the end of the topic the student will be able to:

• describe the construction, operation, location and functions of flow and

pressure control valve.

7.3 Exercises

1. What is the purpose of hydraulic fuse? The purpose of a hydraulic fuse is to

protect hydraulic systems from overpressure by disconnecting or isolating a
component in the event of a sudden pressure increase. This helps prevent
damage to the system and its components, ensuring safety and reliability.

2. Explain the different types of hydraulic fuse?

Hydraulic fuses are safety devices designed to protect hydraulic systems
from overpressure. There are different types of hydraulic fuses, each serving
specific purposes:

1. Check Valve-Type Hydraulic Fuse:

- Operation: Normally closed valve that opens when the pressure exceeds a
predetermined level.
- Application: Protects against pressure spikes in hydraulic cylinders or
actuators.

2. Flapper-Nozzle-Type Hydraulic Fuse:

- Operation: Uses a flapper and nozzle mechanism to sense pressure
changes.
- Application: Commonly used in hydraulic lines to isolate components
during overpressure events.

3. Restrictor-Type Hydraulic Fuse:

- Operation: Utilizes a controlled restrictor that opens under normal
pressure but closes in the event of overpressure.
- Application: Protects hydraulic circuits by limiting flow during excessive
pressure conditions.

4. Proportional Flow Control Valve-Type Hydraulic Fuse:

- Operation: Employs a proportional flow control valve that restricts flow
proportionally to the pressure increase.
- Application: Offers fine control in applications where precise pressure
regulation is crucial.

5. Differential Area Piston-Type Hydraulic Fuse:

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 - Operation: Uses a piston with different areas exposed to system and
control pressures to sense pressure changes.
- Application: Commonly employed in mobile hydraulic systems for safety.

The choice of hydraulic fuse depends on the specific requirements and

characteristics of the hydraulic system.

3. Describe the operation of pressure sensing fuse valve?

A pressure sensing fuse valve is a safety device designed to protect
hydraulic systems from overpressure conditions. Here's a brief description of
its operation:

1. Normal Operation:
- During normal operation, the valve is in a closed or sealed position.
- Fluid flows through the valve unrestricted, allowing the hydraulic system to
function as intended.

2. Pressure Sensing Mechanism:

- The pressure sensing fuse valve is equipped with a mechanism that
constantly monitors the hydraulic pressure.
- This mechanism is often a spring-loaded piston or similar device.

3. Overpressure Event:
- If the hydraulic pressure exceeds a predetermined threshold due to a
sudden increase or other factors, the pressure sensing mechanism is activated.

4. Opening of the Valve:

- The pressure sensing mechanism activates the opening of the valve.
- As the valve opens, it interrupts the flow of hydraulic fluid, preventing
further pressure increase downstream.

5. Isolation of the Circuit:

- By opening, the valve effectively isolates the affected circuit or component
from the rest of the hydraulic system.
- This prevents overpressure from causing damage to downstream
components.

6. Reset or Replacement:
- After activation, the pressure sensing fuse valve may need to be reset or
replaced, depending on the design.
- Some designs allow for manual resetting, while others may require the
replacement of the entire valve.

The pressure sensing fuse valve acts as a safety measure, preventing

catastrophic failure and protecting hydraulic components from damage
during overpressure events

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 4. Explain the operation of flow sensing fuse valve?
A flow sensing fuse valve operates by monitoring the flow rate of hydraulic
fluid. If the flow rate exceeds a preset limit, indicative of a potential system
failure or leakage, the valve actuates to restrict or block the flow, preventing
further damage to the hydraulic system.

5. What is the function of Pressure De-Booster? The function of a Pressure De-

Booster is to reduce or de-boost the pressure in a hydraulic system. It is
commonly used to supply lower pressure to specific components or
subsystems that require reduced operating pressure. The Pressure De-Booster
helps regulate pressure levels, ensuring that different parts of the hydraulic
system receive the appropriate pressure for their optimal performance and
safety.

6. What is the purpose of Pressure Booster? The purpose of a Pressure Booster is

to increase or boost the pressure in a hydraulic system. It is typically used to
elevate the pressure level of hydraulic fluid to meet the requirements of
specific components or subsystems that demand higher operating pressure.
The Pressure Booster enhances the system's capability to deliver sufficient
force and power to critical components, ensuring proper functionality and
performance.

7. What is the function of throttling valve? The function of a throttling valve is to

control or regulate the flow of fluid in a hydraulic system. By adjusting the
valve opening or position, the throttling valve can vary the flow rate of
hydraulic fluid, thereby controlling the speed of an actuator or the rate of
fluid movement through a particular system. Throttling valves are commonly
used to manage the speed and precision of hydraulic components in various
applications.

8. What is the purpose of shuttle valve? The purpose of a shuttle valve is to

direct the flow of hydraulic fluid from one of two sources to a common outlet.
It allows fluid to flow from the active source while blocking flow from the
inactive source. A shuttle valve is commonly used in hydraulic systems to
ensure a continuous and uninterrupted supply of fluid, especially in
applications where redundancy or switching between different sources is
required.

7. 4 Summary

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In this lesson, you have learned about the flow and pressure control valve.

7. 5 Key Terms

Pressure Relief Valve - The cracking pressure setting will approximately 150 – 250 psi
System Relief Valve above pressure regulator

Pressure Relief Valve - The cracking pressure setting above than relief valve cracking
Thermal Relief Valve pressure (approximately 150% of system pressure)

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 Lesson 8: Power Distribution I

8.1 Introduction

In this lesson, you will learn about self and non-self-idling hydraulic systems.

8.2 Learning Outcomes

At the end of the topic the student will be able to:

• describe the operations of hydraulic supply in a different service of hydraulic

systems;

• identify the self and non-self-idling hydraulic systems.

8.3 Exercises

1. Describe the operations of hydraulic supply in different services of hydraulic

systems.
The hydraulic supply in different services of hydraulic systems is designed to
meet specific requirements for various components and functions. Here's a
brief description of the operations of hydraulic supply in different services:

1. Primary Flight Controls:

- Operation: Hydraulic power is supplied to primary flight control surfaces,
such as ailerons, elevators, and rudders.
- Function: Ensures precise and responsive control of the aircraft during
flight maneuvers.

2. Secondary Flight Controls:

- Operation: Hydraulic power is directed to secondary flight control surfaces,
including flaps and slats.
- Function: Controls the aircraft's lift characteristics and aerodynamic
configuration during takeoff, landing, and other flight phases.

3. Landing Gear System:

- Operation: Hydraulic power is utilized to raise and lower the landing gear.
- Function: Enables safe and controlled extension and retraction of the
landing gear during takeoff and landing.

4. Braking System:

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 - Operation: Hydraulic power is applied to actuate the aircraft's brake
system.
- Function: Provides controlled and effective braking for the aircraft during
landing and ground operations.

5. Thrust Reversers:
- Operation: Hydraulic power is employed to deploy thrust reversers.
- Function: Assists in decelerating the aircraft after landing by redirecting
engine thrust.

6. Flap Systems:
- Operation: Hydraulic power is used to extend and retract flaps.
- Function: Alters the wing's lift and drag characteristics, enhancing takeoff
and landing performance.

7. Cargo Handling Systems (if applicable):

- Operation: Hydraulic power facilitates cargo door operation and other
cargo-handling mechanisms.
- Function: Supports the loading and unloading of cargo in cargo aircraft.

8. Auxiliary Systems:
- Operation: Hydraulic power is supplied to various auxiliary systems, such
as avionics cooling and nosewheel steering.
- Function: Supports non-flight-critical functions and systems to ensure
overall aircraft operation.

These diverse hydraulic services cater to specific aircraft functions, providing

the necessary power and control for safe and efficient operation during
different phases of flight and ground handling.

2. The complete hydraulic system consists of a power source (typically a

hydraulic pump), a fluid (hydraulic fluid or oil), and a network of hydraulic
components such as valves, cylinders, motors, and actuators.

3. Discuss the difference of self and non-self-idling hydraulic systems.

Self-Idling Hydraulic Systems:
- Definition: Self-idling hydraulic systems have components or features that
automatically regulate or reduce the hydraulic pressure when the system is
not actively engaged.
- Operation: The system is designed to idle or reduce pressure on its own
without external intervention.
- Advantages: Energy-efficient as it avoids unnecessary pressure build-up,
reducing heat generation and wear on components.
- Examples: Some variable displacement pumps have self-idling features.

18
 Non-Self-Idling Hydraulic Systems:
- Definition: Non-self-idling hydraulic systems require external devices or
components to control or reduce hydraulic pressure when the system is not in
use.
- Operation: Without external intervention, these systems may maintain
pressure or require additional components for pressure reduction.
- Considerations: May experience energy loss and increased wear if pressure
is not actively managed during idle periods.
- Examples: Fixed displacement pumps often require additional valves or
devices for pressure regulation.

In summary, the key difference lies in whether the hydraulic system has
inherent features (self-idling) that automatically regulate pressure during idle
periods or relies on external components (non-self-idling) for pressure
control.

4. What is the function of throttling valve? The function of a throttling valve is to

control or regulate the flow of fluid in a hydraulic system. By adjusting the
valve opening or position, the throttling valve can vary the flow rate of
hydraulic fluid, thereby controlling the speed of an actuator or the rate of
fluid movement through a particular system.

5. Discuss the operation of synchronisation on aircraft hydraulic system?

Synchronization refers to the coordinated movement of multiple actuators or
control surfaces to ensure they move simultaneously and maintain proper
alignment. Here's a discussion of the operation of synchronization in aircraft
hydraulic systems:

1. Multiple Actuators:
- Aircraft often have multiple actuators controlling the same function, such
as multiple hydraulic cylinders for moving a control surface like an elevator or
aileron.

2. Synchronization Mechanism:
- Synchronization is achieved through a mechanism that ensures all
actuators move in harmony.
- This mechanism can include mechanical linkages, electronic sensors, or
hydraulic circuits designed to equalize pressure and movement.

3. Alignment of Control Surfaces:

- The goal of synchronization is to align control surfaces precisely,
preventing any unintended differential movement between them.

4. Methods of Synchronization:

19
 - Mechanical Linkages: Physical connections between actuators can
mechanically synchronize their movement.
- Electronic Sensors: Sensors detect the position of each actuator and send
signals to adjust their movement to maintain alignment.
- Hydraulic Circuits: Specialized hydraulic circuits can distribute pressure
evenly to ensure uniform movement of actuators.

5. Benefits:
- Synchronization prevents one part of a control surface from moving ahead
or lagging behind, ensuring smooth and coordinated aircraft control.
- This is crucial for maintaining stability and control during flight.

6. Examples:
- In an aircraft with multiple engines, synchronization mechanisms may be
employed to ensure that thrust levers move together, maintaining balanced
power settings.
- In the case of control surfaces like elevators, synchronizing mechanisms
prevent asymmetrical movement during pitch control.

7. Redundancy and Safety:

- Synchronization systems may incorporate redundancy to ensure continued
operation even if one part of the system fails.
- Safety features are often integrated to prevent unintended movements
and ensure proper functioning.

Synchronization in aircraft hydraulic systems is essential for the safe and

efficient control of the aircraft, contributing to stability and coordinated
movement of control surfaces.

8. 4 Summary

In this lesson, you have learned about self and non-self-idling hydraulic systems.

8. 5 Key Terms

Primary Flight Elevators, ailerons, rudder and roll spoilers

Controls

Secondary Flight Leading and trailing edge high lift devices Spoilers/Lift
Controls dumpers Speed brakes/Air brakes

20
 Lesson 9: Power Distribution II

9.1 Introduction

In this lesson, you will learn about typical pressure, contents and temperature
indicating systems of hydraulic system.

9.2 Learning Outcomes

At the end of the topic the student will be able to:

• explain the typical pressure, contents and temperature indicating systems and
their respective components.
.

9.3 Exercises

1. Explain the operations of temperature and pressure sensor in hydraulic

system.
Temperature Sensor:
- Function: Monitors the temperature of the hydraulic fluid.
- Operation: Converts the temperature into an electrical signal.
- Use: Provides feedback to the aircraft's systems to ensure hydraulic fluid
operates within safe temperature ranges.

Pressure Sensor:
- Function: Measures the hydraulic pressure in the system.
- Operation: Converts the pressure into an electrical signal.
- Use: Sends signals to the aircraft's systems to monitor and maintain
hydraulic pressure within specified limits.

2. Identify the location of pressure and temperature sensor in hydraulic

components. Pressure and temperature sensors are typically located in the
hydraulic components, such as pumps, actuators, or reservoirs, to directly
monitor the conditions of the hydraulic fluid within those components.

3. Discuss in detail, how to prevent an over heat occurring on electrically

operated power pumps.

21
 To prevent overheating in electrically operated power pumps, ensure proper
cooling, maintain fluid within specified temperature limits, and monitor
system conditions closely for timely intervention if temperatures approach
critical levels.

4. What are three general parameters that provided for hydraulic systems
monitoring?
o Pressure.
o Temperature.
o Fluid Quantity.

9. 4 Summary

In this lesson, you have learned about typical pressure, contents and temperature
indicating systems of hydraulic system.

9. 5 Key Terms
Accumulator gas Gauges are fitted to accumulators, to indicate the pre-charge
pressure base gas (nitrogen) pressure when all hydraulic pressure has
been dissipated. These simple direct reading analogue gauges
will show the approximate system pressure when the hydraulic
pumps are running

Lesson 10: Indication and Warning Systems

10.1 Introduction

22
In this lesson, you will learn about indication and warning systems for hydraulic
systems monitoring.

10.2 Learning Outcomes

At the end of the topic the student will be able to:

• familiarize the procedures in indication and warning;

• explain the typical pressure, contents and temperature indicating systems and
their respective components.

10.3 Exercises

1. Generally the information comprises actual hydraulic pressure and quantity in

normal indications.

2. In abnormal conditions the indication will display the warnings of low

pressure and quantity or system malfunctions.

3. ECAM stand for Electronic Centralized Aircraft Monitor.

4. To avoid the inherent risk of hydraulic oil leaking onto electronic equipment,
hydraulic oil is not routed directly to the flight deck instruments

5. On all modern aircraft, pressure transducers fitted in the hydraulic bay, relay
pressure information for each system to the flight deck.

6. Why the electro-hydraulic transducers fitted in the hydraulic bay, which

usually away from cockpit? To avoid the risk of hydraulic fluid leaks reaching
sensitive electronic equipment in the cockpit.

7. Explain the difference between float switch and capacitance type detector
which fitted in the reservoir?
- Precision: Capacitance type detectors provide continuous and more precise
fluid level information, while float switches typically offer basic on/off
indications.
- Mechanical vs. Electronic: Float switches use a mechanical float, while
capacitance type detectors rely on electronic capacitance measurement.
- Continuous Monitoring: Capacitance type detectors can monitor fluid levels
continuously, whereas float switches provide discrete on/off signals.

23
 - Sensitivity: Capacitance type detectors may be more sensitive to changes in
fluid properties.

10. 4 Summary

In this lesson, you have learned about indication and warning systems.

10. 5 Key Terms

CWP Central Warning Panel

Lesson 11: Maintenance of Hydraulic Systems

11.1 Introduction

In this lesson, you will learn about maintenance of hydraulic systems.

11.2 Learning Outcomes

At the end of the topic the student will be able to:

• perform the maintenance and servicing of hydraulic systems.

11.3 Exercises

1. List general guidelines should be followed in order to minimise the risk of

hydraulic systems contamination?
• Maintain cleanliness
• Follow proper handling procedures,
• Use filtered hydraulic fluid,
• Seal open components,
• Avoid mixing fluids & keep fluid containers sealed

2. What happen to hydraulic seals when incorrect hydraulic fluid serviced?

Hydraulic seals can degrade or fail when incorrect hydraulic fluid is used.

24
 3. Fault finding check is carried out to detect external leaks and internal leaks on
hydraulic system.

4. Provide three examples cause of hydraulic contamination in term of

maintenance practices?

• Poor cleanliness during maintenance.

• Use of contaminated tools and equipment.
• Inadequate sealing of components during maintenance.

5. What is the function of magnetic chip detector? Detects and collects metallic
particles in the hydraulic fluid to indicate potential wear or damage in the
system.

6. Discuss the differences between draining and flushing on hydraulic system?

Draining removes fluid from the system, while flushing involves actively
replacing and cleaning the fluid by running a cleaning agent through the
system.

7. Explain in general, how to carry out hydraulic flushing.

Flushing involves circulating a cleaning fluid through the hydraulic system to
remove contaminants. This is done by connecting the flushing unit to the
system, circulating the fluid, and draining it, repeating until the system is
clean.

11. 4 Summary

In this lesson, you have learned about maintenance of hydraulic systems.

11. 5 Key Terms

Sluggish, slow or Indicate aeration of fluid or excessive internal leakage

erratic operation

AMM Aircraft Maintenance Manual

Lesson 12: Pneumatic and Vacuum System

25
 12.1 Introduction

In this lesson, you will learn about operation and maintenance of pneumatic and
vacuum system.

12.2 Learning Outcomes

At the end of the topic the student will be able to:

• describe the components and operation of pneumatics system;

• differentiate between high, medium and low pressure pneumatic systems.

12.3 Exercises

1. State three the safety precautions, when working on bleed air system?

• Bleed air is hot. It’s to be taken care with pipes and ducts
• Replace crush seals when replacing joints.
• Tighten clamps to the figures laid down in the AMM.
• Never lever against ducts as dents will cause hot spots.

2. Discuss the advantages of using compressed air?

• It is universally available in unlimited supply
• It is simple and lightweight
• It has no return lines are needed saving weight
• There is no fire hazard and the danger of explosion is slight
• Contamination is minimised by the use of filters.

3. Vacuum systems supply of air at a negative pressure.

4. Discuss the different sources of air for pneumatic systems?

• Engine Bleed Air:
- Air tapped from the aircraft engine's compressor.

• APU Bleed Air:

- Air taken from the Auxiliary Power Unit.

• Ram Air:
- Air collected directly from the aircraft's forward motion.

• Ground Compressed Air:

- Air supplied when the aircraft is on the ground, often from ground
support equipment.

26
 • External Compressed Air:
- Air supplied externally for ground testing or maintenance.

• Bottle Compressed Air:

- Stored compressed air in bottles or reservoirs for emergency use.

These sources provide the necessary compressed air for various pneumatic systems in
an aircraft.

5. Engine bleed air is used in turbo jet aircraft in which hot air is bled of from the
engine to pressurize the cabin.

6. At low engine rpm the low-pressure compressor air is of insufficient pressure

for use in the pneumatic systems, so air will be tapped from the intermediate
or high-pressure compressor stages.

7. APU stand for Auxiliary Power Unit.

8. Au Auxiliary Power Unit (APU) is basically a small gas turbine engine that
provides air and other service whilst the aircraft is on the ground with its main
engines stopped.

9. Ground Power Unit (GPU) used on the ground when the engines are not
running; this unit will run until the aircraft is independent of the ground
supply trolley.

10. The ground cart is basically a compressor driven by an engine, usually a

diesel engine as burning agent.

11. What standard practices apply to pneumatic and vacuum systems? Standard
practices for pneumatic and vacuum systems in aircraft maintenance are
outlined in Aircraft Maintenance Manual which provides detailed instructions
for maintenance, repair and operations for specific aircraft models.

12. What can this air are used for? Pressurization, environmental control and anti-
ice systems, breaking systems, APU e.t.c

13. What does a shuttle valve allow you to do? A shuttle valve allows the
redirection of fluid or air flow in a pneumatic or hydraulic system, enabling
the system to draw from one of two sources. It permits the transfer of fluid or
air in one direction while blocking it in the opposite direction. This function is
often used to provide a backup or alternative source of fluid or air in case of
system failure or for specific operational requirements.

27
 14. With a conventional gas turbine aeroplane, where can the air come from (clue:
on the ground and in the air)? On the ground air come from APU and in the
air (during flights) air comes from the engine inlets.

12. 4 Summary

In this lesson, you have learned about operation and maintenance of pneumatic and
vacuum system.
.

12. 5 Key Terms

LP Low pressure

IP Intermediate Pressure

HP High Pressure

Lesson 13: Ice and Rain Protection

13.1 Introduction

In this lesson, you will learn about operation principles and methods for ice and rain
protection.

13.2 Learning Outcomes

At the end of the topic the student will be able to:

• identify the type of ice formation and rain protection on an aircraft;

• describe the parts of an aircraft susceptible to ice formation.

13.3 Exercises

1. What is the standard pipeline identification for ice protection systems?

2. Which fluid system is used only on windscreens (and as there are only two
types, which one is used on aerofoils)?

28
3. What are the main types (methods) of ice detection and how do they all
work?

4. What are the four main category’s of ice removal.

5. What are the main types of ice formation and which is the most dangerous to
aeroplanes (and why)?

6. When are ice detection systems switched on?

7. What precautions must be used during the maintenance of windscreen

wipers?

8. How can the operation of a wiper arm be adjusted?

9. What are the normal modes of operation of windscreen wipers?

10. When selected off what position do wiper arms adopt?

11. List three ice formation protected areas in aircraft?

29
 12. Discuss the effects on aircraft due to ice formation.

13. List three types of ice formation

14. Which type of ice that builds up on the leading edge, but does not extend far
back along the chord?

15. Explain the blue ice that formed in an aircraft.

13.4 Summary

In this lesson, you have learned about operation principles and methods for ice and
rain protection.

13.5 Key Terms

SRM Structure Repair Manual

Windshield wipers An operator shall not operate an aeroplane with a maximum

certificated take-off mass of more than 5700 kg unless it is
equipped at each pilot station with a windshield wiper or

30
 equivalent means to maintain a clear portion of the windshield
during precipitation.
FOD Foreign Object Damage

Lesson 14: EASA Revision

14.1 Introduction

In this lesson, you will learn about questions of EASA PART 66, MODULE 11 aircraft
hydraulic, pneumatic system, ice and rain protection. Module 11 MCQ – Duration 175
Minutes – Total no of questions - 140

14.2 Learning Outcomes

At the end of the topic the student will be able to:

• familiarise on EASA Module 11 examination on aircraft hydraulic, pneumatic

system, ice and rain protection.

14.3 Exercises

1. In aircraft hydraulic systems, it is permissible to use

A. only the specified fluid.
B. any fluid of the same specific gravity.
C. any hydraulic fluid available.

2. The chemical stability of hydraulic fluids will give

A. liquid to resist oxidation and long periods of deterioration.
B. excessive temperatures.
C. poor performance.

3. The depth of “O” ring seal groove should be

A. equal to diameter of seal.
B. 10% less than seal diameter.
C. 10% greater than seal diameter.

4. Why the reservoir of an aircraft designed for high-altitude operations must be

pressurized?
A. To maintain a positive suction pressure to the pump.
B. To use atmospheric pressure to assist fluid flow.
C. To vent the system during periods of high fluid.

31
5. What is the main purpose of a de-booster valve?
A. To decrease the volume of fluid going to the brakes.
B. To reduce the flow rate of the fluid.
C. To reduce the hydraulic pressure

6. Parameters will be monitor by flight crews in hydraulic systems are

A. pressure and temperature.
B. fluid quantity, pressure and temperature.
C. temperature and fluid quantity.

7. If hydraulic fluids is contaminated, the procedure is to

A. drain and flush the liquid with solutions.
B. operate the hydraulic systems until they mixed together.
C. remove the hydraulic component have been contaminated.

8. What is the difference between a hydraulic sequence valve and a priority

valve?
A. Mechanical contact opens a priority valve.
B. Sequence valves are electrically actuated.
C. Priority valves are opened by hydraulic pressure.

9. Glaze ice can be identified as

A. small rough ice crystals.
B. clear layer of heavy and dense ice.
C. round shape golf ball size ice falling from the sky.

10. Prior to the testing of windshield wiper movement, the windscreen must be
A. cooled.
B. heated.
C. wetted.

11. Which valve enables the safe maintenance of high pressure pneumatic system
without the release of all the compressed air from the system?
A. Reducing valve
B. Isolation valve
C. Regulating valve

12. Pneumatic air is supplied from which component in flight?

A. APU and or Main Engine compressors or Airblowers
B. APU and or Airblowers
C. APU and or Main Engine Turbine

13. What is the purpose of the diffuser fitted to some reservoirs?

A. To trap a reserve of fluid for emergency use

32
 B. To pressurize the fluid
C. To minimise agitation of the fluid

14. Hydraulic fluid sampling is necessary

A. whenever a component is charged.
B. as specified in the maintenance manual & whenever contamination is
suspected.
C. whenever air is found in the system.

15. In a hydraulic system, what factor dictates the fluid to be used?

A. The make-up of the seals, hoses and other non-metallic parts

B. The fluids supplied by the aircraft operator
C. The fluid identified by National Legislation

16. Characteristics of Skydrol Hydraulic Fluid are:

A. Petroleum based, Synthetic rubber seals

B. Phosphate Ester based, fire resistant, Butyl Rubber seals
C. Phosphate Ester based, fire resistant, red in colour

17. Which of the following lists the desirable properties of a good hydraulic fluid?

A. Low viscosity, good chemical stability, high flash point, high fire point
B. High flash point, low viscosity, good chemical stability, low fire point
C. Low flash point, low fire point, good chemical stability, high viscosity

18. Hydraulic accumulator gas pressure is checked:

A. with the hydraulic system pressurised only

B. at any time provided fluid contents in reservoir is normal
C. with the hydraulic system de-pressurised only

19. Many hydraulic reservoirs contain a small quantity of fluid which is not
available to the main engine driven pumps. This is to:

A. provide fluid for an emergency system

B. supply fluid to the accumulator
C. maintain a positive head of pressure

20. Some large aircraft have a reservoir fitted with a booster pump. Its purpose is
to

A. prevent reservoir foaming

B. prevent cavitation of the engine driven pumps
C. increase engine driven pump output pressure

33
 21. Before removing an aircraft hydraulic component, it is necessary to relieve the
hydraulic system pressure. This is normally done by:

A. Opening a convenient bleed valve in the system

B. Disconnecting a pipeline at a convenient point
C. Operating a circuit until pressure is zero

22. An air turbine driven hydraulic pump is driven by:

A. Bleed air from the turbine stage of the engine

B. Air from the air conditioning system
C. Ram air

23. If a red button or plunger is protruding from a high pressure hydraulic filter
body

A. the filter should be replaced or cleaned before the next flight

B. no action is necessary since it is the normal safe indication
C. the accumulator gas pressure is likely to be low and should be
checked

24. A shuttle valve in a hydraulic circuit is

A. pilot controlled to ensure an emergency system is working
B. operated automatically to allow an alternate system to operate a
component
C. operated automatically to permit two system to operate a component
simultaneously

25. Self-sealing couplings are used in an aircraft hydraulic system primarily

to:
A. blank-off pipelines after they are removed from the aircraft
B. allow the system to be disconnected at specific points for maintenance
without fluid loss
C. minimise leaks at high operating pressures. A rubber seal swells to
block leaks as they occur

14.4 Summary

In this lesson, you have learned about questions of EASA PART 66, MODULE 11
aircraft hydraulic, pneumatic system, ice and rain protection.

14.5 Key Terms

EDP Engine Driven Pump

34
PTU Power Transfer Unit

ATM Air turbine Motor

EMDP Electrical Motor Driven Pump

SRM Structure Repair Manual

FOD Foreign Object Damage

35