Su p p lement

Internal/External
Maintenance and
Passenger
Entertainment
Systems
This supplement covers additional topics that were not
included in the other texts in the program but which are
equally important to all AMEs. Due to the variety of the
topics covered, the same level of continuity found in your
textbooks is absent in this supplement. Rather, the supple-
ment is designed to provide a cohesive component to the

Preface
program’s curriculum.

iii
AIRCRAFT GROOMING 1

INVENTORY CONTROL 3

Contents
FLOATS, HULLS, AND SKIS 5

CABIN PRESSURIZATION SYSTEM SAFETY

CONCERNS AND FUNCTIONAL TESTS 6

FLOATATION DEVICES 9

PASSENGER ENTERTAINMENT SYSTEMS 10

Fundamentals of Computerized Information
Input and Retrieval 12

v
Internal/External
Maintenance and Passenger
Entertainment Systems

AIRCRAFT GROOMING
An extremely important factor in maintaining an aircraft is
cleanliness. Cleaning is important preventative maintenance
because dirt can greatly accelerate corrosion, oxidation and
general deterioration of aircraft surfaces. Dirt on metal and
painted surfaces will attract and trap moisture and pollutants
onto the surface. The surfaces may then chemically react
with the moisture, dirt, and pollutants. Regular cleaning
will protect the exterior surfaces and reduce the chances of
corrosion and premature deterioration. If the aircraft cannot
be kept in a hangar or otherwise covered, it’s even more
important to try to keep the aircraft as clean as possible.
Although exact cleaning procedures may vary depending on
the different aircraft, the basic cleaning procedures are as
follows.
n The exterior of the aircraft should be cleaned with mild
soap and water, then rinsed with water. The surface can
be dried with a cloth or chamois. Harsh soaps or abra-
sives should never be used as they can scratch metal
and painted surfaces, and cause corrosion. Stubborn oil
and grease that is not removed by the soap and water
can be removed with a cloth and Stoddard solvent (also
called dry cleaning safety solvent).

n Some types of paint should be protected with wax that is

applied with a soft cloth or chamois. Leading edges and
surfaces suffer from more abrasion so they should
receive more wax than other surfaces.

1
 n Tires should be cleaned with soap or detergent and
water. Petroleum solvents should not be used because
they can cause rubber to breakdown. If a small amount
of petroleum solvent is used on a stubborn grease spot
on a tire then the solvent should be wiped away as
quickly as possible.

n Also clean de-icing boots with mild soap and water, and
then rinse thoroughly with clean water. Stubborn dirt
spots can be cleaned with isopropyl alcohol, then
washed with mild soap solution, and rinsed with water.
Rubber boot components are easily damaged by oil,
grease, and solvents so it is important to make sure that
they remain clean.

n Plastic windows and windshields can be easily scratched

if you wipe them while they are coated with abrasive dirt.
The plastic surface should first be thoroughly rinsed with
clean water to remove any dirt. After rinsing, the plastic
should be washed with a mild soap solution and a soft
cloth. Oil and grease should be removed with a cloth that
has been dampened with kerosene, naphtha, or metha-
nol. After cleaning, the plastic window should be waxed
to protect the surface and to prevent scratching.

n Plastic windows should never be cleaned with gasoline,

alcohol, anti-ice fluid, household glass cleaner, paint
thinner, or anything else that can dissolve plastic. These
solvents may cause fissure-like cracks to form on the
plastic surface (crazing) and the window will have a fog-
like haze to it.

n Care should be taken to avoid scratching from abrasive

dirt when cleaning all exterior surfaces, especially the
plastic windows. A dry cloth should never be used to
remove dirt from a surface. The cloth and the abrasive
dirt will scratch the surface (whether it is metal, a painted
surface, or a plastic window) as if it was fine sandpaper.

n Engines and engine accessories should be cleaned with

special solvents like Stoddard solvent, special water-based
alkaline detergents, or solvent based cleaners. Do not
use flammable materials, like gasoline, to wash an
engine. It’s best to follow the manufacturer’s guidelines

2 Internal/External Maintenance and Passenger Entertainment Systems

 for cleaning and for the use of these cleaning products.
Precautions must be used when cleaning because the
solvents can be toxic. You should wear gloves, goggles,
and protective clothing. Work in a ventilated area with
adequate firefighting and safety equipment.
n Take precautions to prevent the cleaning solution from
entering air intakes, vents, or other openings where it
could cause damage. Cleaning solutions can be sprayed on
with a low pressure. Use a stiff brush (not a steel brush)
to remove excess, or caked, grease and dirt. A large pan
should be placed under the engine to catch the dirty clean-
ing solution. Allow the solvent to remain on the engine
for the recommended period and then rinse the engine
clean with solvent and allow it to dry. You should not leave
cleaning solutions on the engine for too long a period of
time because it could accelerate corrosion and damage
seals. Dry the engine completely with compressed air.
n Landing gear can be cleaned with an emulsifying agent
and then rinsed clean with water. Any opening should
be covered prior to cleaning.
n The interior of the aircraft should also be cleaned period-
ically to maintain its condition. Dust and loose dirt can
be removed with a vacuum cleaner. Most spots can be
cleaned with standard commercial spot removers. Soiled
upholstery and carpet can be cleaned with detergent,
according to the manufacturer’s instructions, and then
vacuumed. Leather seats can be cleaned with a soft
cloth wetted with mild soap. Plastic components and the
instrument panel can be wiped clean with a damp cloth.

Above all, always follow the manufacturer’s exact cleaning

methods for a specific part of an aircraft.

INVENTORY CONTROL
Effective inventory control is essential in any organization
where a stock of parts and materials has to be maintained.
For an aircraft maintenance organization, the inventory sys-
tem has the added responsibility of maintaining control over
the items that are stocked to make sure that only conforming
approved parts are used when making repairs.

Internal/External Maintenance and Passenger Entertainment Systems 3

 To prevent abuse, misuse, damage, or deterioration, a system
must be implemented to provide for the identification, segre-
gation, handling, and storage of all parts and materials from
the time of receipt from a supplier or fabrication within the
facility. Secure storage areas or stock rooms should be avail-
able and all articles must be properly identified and protected
from intermingling or being contaminated prior to being
used. A review system should be established to provide for
the reporting of non-conformance or unapproved parts. All
nonconforming articles should be segregated and held in
quarantine areas (or be clearly identified) to prevent use
pending their final disposition.
Nonconforming parts and materials must be reviewed to
determine whether they should be reworked/repaired, or
scrapped. Articles which must be scrapped should be
segregated in quarantine until properly disposed of.
Conforming approved parts and materials are placed in a
defined secure area, referred to as “bonded stores,” pending
their eventual use.
Proper inventory control ensures that accurate information
is maintained on the number of parts and materials that
are in stock. All incoming parts and materials should be
segregated until they can be identified and inspected. Each
article should be checked against purchasing requirements
to ensure that it is the correct product, that it has been
properly identified, and that inspection data and proper
certification has been included with the shipment. Effective
inventory control facilitates accurate forecasting, timely
purchasing and efficient disposition all stock items. In
addition, it serves to minimize job delays at almost all levels
in the organization.
A variety of inventory control systems have been developed
and are used today. They include manual and automatic
card systems, and computerized inventory control systems.
Today, in almost all but the smallest organizations, an inven-
tory system will probably be computerized.
A manual inventory control system uses card files where
each individual stock item has a separate card. The quantity
on a card is adjusted when there is an addition or depletion
to a stock item. In this way, shop personnel can readily see
what is in stock.

4 Internal/External Maintenance and Passenger Entertainment Systems

Computerized inventory control systems are now the norm
in most organizations. The computer systems can maintain
a count of stock items as well as record other information
such as monthly and daily usage, who withdrew or added
stock, and the value of the inventory. The system can also
highlight items that have a limited shelf life. Usually modifi-
cations can be made to an inventory management software
program that can accommodate any additional information
that needs to be recorded. The computer can then be used to
generate specific information or complete inventory reports in
whatever format is required.
Regardless of the control method used, an inventory should
be manually counted and verified on a regular schedule,
perhaps every 6 months, in order to make sure that the
recorded numbers are accurate.

FLOATS, HULLS, AND SKIS

Airplanes that operate from water have floats mounted as
rigid landing gear. The actual configuration and construction
can vary between aircraft types but usually involves two
floats attached to the fuselage through a series of struts,
bars, and wires. For those airplanes that are actually flying
boats a hull is used for flotation and the wings have floats at
the tips to right the aircraft and maintain balance. For air-
craft that are amphibious, the floats or hull are used when
operating on water and retractable wheels are used when
operating from land.
Skis are used as landing gear when operating airplanes on
snow and ice. The skis may be made of wood, metal, or of a
composite material. If an aircraft operates on both snow and
ice and conventional runways it will need both skis and
wheels. The wheels will extend below the skis for conventional
runway operation.
Floats, hulls and ski can all find themselves subject to oper-
ating stresses not normally found on properly maintained
conventional runways. For water operation the waves can
add bumping shocks and torque-like stresses to those
stresses normally experienced during landing and takeoff.
Submerged and floating obstacles can create hazards that

Internal/External Maintenance and Passenger Entertainment Systems 5

 tear floats/hulls, and that can damage mounts and support-
ing structures. Ice is rarely completely smooth. It may be
coarse, pockmarked, and bumpy. Snow also has many tex-
tures that can make a ski landing bumpy. Snow-buried
obstacles can also pose a serious hazard. The friction drag
on the floats, hulls, and skis can be significantly higher than
what you would expect with wheels and a runway.
When inspecting floats, hulls, and skis, an examination
should be made for damage due to corrosion, collision with
objects, hard landings, and any other conditions that could
result in failure. Tubular structures for the gear should be
repaired or replaced, as required. Floats should be carefully
inspected for corrosion, especially if flown from salt water. If
corrosion exists it should be cleaned thoroughly and a coat of
corrosion inhibiting material applied. If the corrosion pene-
trated the material it should be patched. Wire fittings and
water-rudder control systems must also be inspected. The
floats and hull should be repaired according to the manufac-
turer’s recommended practice and must be tested to make
sure that it is waterproof.
Skis and their connecting fuselage attachments should be
inspected for their general condition and repaired according
to approved manufacturer’s instructions.

CABIN PRESSURIZATION
SYSTEMS SAFETY CONCERNS
AND FUNCTIONAL TESTS
A cabin pressurization system is designed to make the aircraft
comfortable for crew and passengers while allowing it to
operate efficiently at high altitudes. At higher altitudes
the aircraft can fly above turbulence with increased fuel
efficiency.
Cabin pressure should be maintained so that it does not
drop below the air pressure found at about 2430 m (8000
feet). At this pressure, crew and passengers don’t need
supplemental oxygen, and the air temperature can be easily
controlled to a comfortable level.

6 Internal/External Maintenance and Passenger Entertainment Systems

After takeoff, an aircraft normally climbs rapidly to its cruis-
ing altitude for maximum fuel efficiency. For the comfort of
the occupants, the cabin pressure is gradually changed to
match some lower altitude pressure. When landing, an air-
craft may descend quickly, but for the comfort of the
occupants the cabin pressure should be increased slowly so
as to reach the same pressure level as the ambient pressure
upon landing. In this way, the aircraft’s occupants are
spared the discomfort of rapid pressure changes.
The structural strength of the aircraft must be great enough
that it can withstand the stresses of being pressurized. The
difference between the ambient outside pressure and the
pressure inside the aircraft is called the cabin differential
pressure. The maximum altitude that an aircraft can fly is
limited to the maximum allowable cabin differential pressure.
Engines provide the power to pressurize an aircraft. Aircraft
with reciprocating engines supply pressure by a supercharger,
a turbocharger, or from an air pump. Part of the super-
charger or turbocharger airflow can be directed into the
cabin to provide pressurized air provided that the super-
charger (or turbocharger) is positioned in the induction
system before fuel is added to the airflow. When a super-
charger or turbocharger is not positioned in the induction
system before fuel is added to the airflow, it can seriously
reduce engine power output at high altitudes and the air can
become contaminated with engine fumes.
Aircraft with turbine engines use bleed air from the engine
compressor. This loss of compressor air does cause some
reduction in the total engine power.
Separate cabin compressors are used in some aircraft. These
pumps are driven from the engine accessory section or by
turbine engine bleed air.
Review pages 14-19 to 14-26 of the text A&P Technician
Airframe for the operation of the valves that regulate the
cabin pressure and maintain the safe operating levels of the
system.
The pressurization system must be properly maintained in
order to ensure that it safely controls the cabin pressure. If
the pressure is too high then structural damage may occur

Internal/External Maintenance and Passenger Entertainment Systems 7

 to the aircraft. If the pressure is too low then the cabin occu-
pants may find the flight uncomfortable, or they may even
require an emergency supplemental oxygen source to prevent
hypoxia.
The cabin pressurization system should be periodically
inspected for visible component defects. Particular attention
should be paid to heat exchangers for signs of structural
fatigue near welds. Ducting should be securely attached and
supported. Insulation around the ducts must be in good
shape and properly secured.
The pressurization system and the air conditioning system
should be ground checked with either the engines running or
with the necessary ground support equipment recommended
by the manufacturer.
n Check the pressure regulator by connecting an air test
stand and a manometer to the appropriate test adapter
fitting. Position the system controls as required to pres-
surize the cabin to the recommended test level found in
the manufacturer’s manual. Continue to pressurize the
cabin to see if the cabin pressure regulator maintains
this pressure.

n Check the pressure relief valve and the dump valve with
these three tests. First, with the test stand and manome-
ter connected to pressurize the cabin, position the cabin
pressure selector switch to dump the cabin air. If the
cabin pressure decreases to less than 0.3 in. Hg through
both the pressure relief and dump valves then the valves
are releasing the pressure properly. Second, re-pressurize
the cabin and then position the manual dump valve to
dump. A lowering of the pressure to 0.3 in. Hg and an
airflow through the pressure relief valve and the dump
valve indicate that the manual dumping function is
working. Third, position the master pressure regulator
shutoff valve to the “all off” position (this position is for
tests only). Then use the air test stand to pressurize the
cabin to the manufacturer’s recommended test level
(often about 7.5 in. Hg). Operating the pressure relief
and dump valves maintains a pressure that indicates the
relief function of these valves is good.

8 Internal/External Maintenance and Passenger Entertainment Systems

 n The cabin static pressure test checks the fuselage for
structural integrity. Connect the air test stand and pres-
surize the fuselage to the manufacturer’s recommended
pressure for this test. Check the aircraft skin for cracks,
bulging, distortions, and rivet condition.

n Perform a dynamic pressure test to check the fuselage

for air leakage. To do this check, the cabin must be
pressurized to the specific manufacturer’s recommended
pressure using an air test stand. With a manometer,
determine the rate at which the air pressure decreases
due to leakage within a certain time period specified by
the maintenance manual. Large leaks can be located by
sounds or by feeling for the leak. Small leaks can be
detected using a soap solution and looking for bubbles,
or by using a cabin leakage detector.

When washing or working on the aircraft exterior, an effort

should be made to look for signs of pressure leakage (espe-
cially around rivets and seams) and for small skin cracks.
Often the skin will be discoloured or stained around the
leak area.
Manufacturers often provide troubleshooting charts to help
establish the cause and remedy for the more common prob-
lems that can cause the pressurization system to fail or
become uncontrollable. These charts list the most common
system failures and the proper corrective action to be taken.

FLOATATION DEVICES
Aircraft that operate over or near water must carry individual
floatation devices for all passengers and crew. There are two
categories of individual floatation devices: inflatable and
noninflatable.
Inflatable devices are inflated by the release of a compressed
gas contained in a cylinder into the inflation chamber. The
cartridge is activated by a trigger that is clearly marked for
this purpose. The floatation chamber must also be capable
of being inflated by mouth in case of the failure of the gas
cartridge.

Internal/External Maintenance and Passenger Entertainment Systems 9

 Noninflatable devices could include seat cushions, head
rests, arm rests, and pillows, as well as devices specifically
intended as floatation devices—provided that they fulfill the
minimum requirements for safety and performance. It is
important that since these items fulfill other purposes
besides floatation devices, compression through extended
service, perspiration and periodic cleaning must not reduce
their buoyancy characteristics below the minimum
prescribed level.
The device must be able to provide at least 6.4 Kg (14 pounds)
of buoyancy in fresh water at 29°C for 8 hours.
The device should be easy to use and should include clear
instructions concerning proper use that are visible under
emergency lighting conditions. The materials used in the
device should not be susceptible to fungus growth. Metal
parts should be corrosion resistant. The device should also
be flame resistant. The materials must also be able to with-
stand the extreme range of temperatures that the equipment
may have to operate in (typically –40°C to 60°C).
The device should be adaptable for children as well as adults.
The attachment straps should be simple and obvious to use,
but must not pass between the user’s legs, and should not
restrict breathing or blood circulation.

PASSENGER ENTERTAINMENT
SYSTEMS
The passenger address and entertainment system can vary
greatly from aircraft to aircraft. It can simply be a means for
flight crew announcements and recorded music to be directed
to the passengers through a loudspeaker while the airplane
is in flight. Or, it can be as complicated as a network of DVD
players displaying movies and other prerecorded materials on
personal displays to each individual passenger.
The passenger entertainment systems on large full-service
aircrafts will have multiplexed audio, visual, and service func-
tions signals that are interfaced together. Multiplexing means
that the different signals are transmitted on the same wiring
at the same time but they will be encoded at different
frequencies and then decoded at the receiving end where the

1 0 Internal/External Maintenance and Passenger Entertainment Systems

passenger is. By transmitting several services on the same
lines there is a great reduction in the amount of wiring
required. Among the signals that could be multiplexed are
audio/visuals signals from VCRs and DVD players, stereo
music, passenger-to-attendant calls and remote control lights.
Some carriers may offer 10 or more channels of entertainment
on the system.
The multiplexed entertainment system has to meet the
demands of each passenger’s personal selections and on a
large aircraft the system can get quite complicated. Typical
components for an aircraft with 140 passengers can include:
n Compartment controllers for timing and synchronization

n 140 seat units that provide the passengers with their

selections and the demultiplexing of signals

n 140 decoders to provide the decoding of individual

passenger selections

n Multiplexer(s) to convert the various audio and visual

signals

n Video players and microphones

n Several submultiplexers to distribute the output from

the main multiplexer to the each seat

n Compartment or individual seat back video displays

n Wiring network between the seats and the main control

system

n Built-in redundancy so that partial system failures can

be compensated for

n Power supplies

n Built-in test equipment to provide a means for rapidly

isolating faults and providing service

n On some aircraft there are enhanced services offered to

passengers who pay a higher class fare and these extra
services can further complicate the system. Extra features
can include video libraries, television programs, sports
and regional news, power ports for laptop computers, a
very wide selection of music choices, and private phones.

Internal/External Maintenance and Passenger Entertainment Systems 1 1

 Fundamentals of Computerized
Information Input and Retrieval
A computer is a complex machine, but its purpose is
straightforward; it’s simply a tool for handling information. A
computer is used to store and organize information. The
computer can also be used to conveniently communicate the
information to others.
A computer system can take on several forms from a rela-
tively simple stand alone PC (personal computer) on one end
of the spectrum, to a complex network of PCs and mainframe
computers sharing resources and information on the other
end. When we talk about computers we really mean several
pieces of equipment, which together make up the computer.
In a small PC these pieces of equipment can fit on your desk.
The physical parts of the computer are known as the hard-
ware. The basic hardware components are:
n Keyboard, for typing data and instructions into the
computer

n Monitor, similar to a television screen to display text and

graphics output

n Mouse, which lets you point and select text from the
video monitor instead of typing instructions on the
keyboard

n System unit, performs all of the data processing and

control functions. This is the central component of the
system.

n Wireless and wired network capability, to equip the com-

puter to communicate with other computers, networks,
and the Internet.

The system unit houses the memory, the disk drives, and all
of the electronics to support the other hardware.
A laptop is a portable computer that includes all of the basic
hardware components, along with a battery power supply.
Additional hardware options increase the capabilities of the
computer. These options include:

1 2 Internal/External Maintenance and Passenger Entertainment Systems

 n Scanner, lets you convert pictures and documents into
electronic files that can be saved and shared with other
computers.

n Printer, lets you create paper copies of work performed

on the computer.

n Camera, microphone, speakers, and headset, to provide

visual and audio capability.

Although the hardware is the part of the computer that most

people are familiar with, hardware alone can’t perform any
functions. The hardware needs programming instructions, or
software, to tell it what to do. Most software can be placed
into one of three major classifications: operating system, util-
ity, and application.
Operating system software tells the computer how to func-
tion and how to use the disk drives and other devices
connected to the computer. Microsoft Windows is a very pop-
ular operating system software. Utility software is a general
classification for software that improves the efficiency of the
computer or that performs special tasks, like diagnostics or
recovering lost data.
Of most importance to the computer users is application
software, which includes the tools that help people do their
work. Some application software tasks include:
n Word processing

n Spreadsheet

n Database

n Desktop publishing

n Software development programs

n Educational software

n Games and other entertainment

n Financial

n Inventory control

n Data communication

n Desktop accessories

Internal/External Maintenance and Passenger Entertainment Systems 1 3

 n Internet browsers and e-mail

n Web page development programs

n Drafting programs

The most popular business applications are word processing,

spread sheets, and databases. Word processing software
allows you to use the computer to write, edit, store, and print
documents. Common word processing programs include
Microsoft Word and Corel WordPerfect.
A spreadsheet consists of a table of horizontal rows and
vertical columns used to hold data for calculations and
comparisons. Often spreadsheets are used to calculate and
analyze all sorts of numerical data. Each piece of individual
data is placed in a cell, which is the spot on the spreadsheet
where a row and a column intersect. Related data can be
placed all in one column or row for easy comparison, or to
facilitate quick calculations. Data in the spreadsheet can also
be redisplayed in different formats, like bar and pie charts.
Data in the spreadsheet can also be manipulated to help in
forecasting analysis and to anticipate outcomes based on
possible future scenarios. A widely used spreadsheet pro-
gram is Microsoft Excel.
Database software allows you to collect, sort, and store a
wide variety of information. Among other tasks, it can be
used to record the names, amounts, and other particulars for
all of a company’s business transactions. Or, it could be
used to file the part name, part number, location, and num-
ber in stock for every inventory item in a warehouse. Widely
used database programs include Microsoft Access and
Oracle.
Database software is especially important for businesses and
organizations that often need to keep track of many different
kinds of information. This software can draw on data from
several places and create one document from it. Once the
data is stored it can be used for any number of purposes.
n The data can be sorted in different ways.

n Using search and query techniques you can locate select

records from the database.

1 4 Internal/External Maintenance and Passenger Entertainment Systems

 n Calculations can be performed, similar to spreadsheet
software.

n Reports can be generated from the data.

n And of course the database can be displayed to view the

information that it contains.

There are commercial software applications designed to meet

the computer processing requirements of almost all types of
jobs. There are also specialty programs designed by compa-
nies and individuals to meet special needs. New software is
being developed all the time and old applications are revised
to improve their capabilities. Although many programs have
similar functionality, there are differences that can only be
appreciated by using the software.

Internal/External Maintenance and Passenger Entertainment Systems 1 5