UNIT-III

MAINTENANCE OF SAFETY
 Shop safety

Keeping hangars, shop, and the flight line

orderly and clean is essential to safety and
efficient maintenance.

The highest standards of orderly work

arrangements and cleanliness should be
observed during the maintenance of aircraft.
 Shop safety

Where continuous work shifts are established,

the outgoing shift should remove and properly
store personal tools, roll away boxes, all work
stands, maintenance stands, hoses, electrical
cords, hoists, crates, and boxes that were
needed for the work to be accomplished.
 Shop safety

Signs should be posted to indicate dangerous

equipment or hazardous conditions. There
should also be signs that provide the location
of first aid and fire equipment.
Safety lanes, pedestrian walkways, and fire
lanes should be painted around the perimeter
inside the hangars.
Safety Around Hazardous Materials
 Safety Around Hazardous Materials

As per MSDS:
RED- FLAMMABILITY
YELLOW- REACTIVITY
BLUE- HEALTH
WHITE- SPECIAL HAZARD
 Safety Around Hazardous
Materials

As per MSDS:
0- LITTLE HAZARD OR NO HAZARD
4- VERY HAZARDOUS

The letter W with a line through it stands for

high reactivity to water.
 Safety Around Hazardous
Materials

The special hazard segment contains a word or

abbreviation to represent the special hazard.
EX: RAD for radiation, ALK for alkali materials,
Acid for acidic materials, and CARC for
carcinogenic materials.
 Safety Around Machine Tools
PRECAUTIONS FOR DRILL PRESS:
• Wear eye protection.
• Securely clamp all work.
• Set the proper RPM for the material
used.
• Do not allow the spindle to feed beyond its limit of
travel while drilling.
• Stop the machine before adjusting work or
attempting to remove jammed work.
• Clean the area when finished.
 Safety Around Machine Tools
PRECAUTIONS FOR LATHE WORK:
• Wear eye protection.
• Use sharp cutting tools.
• Allow the chuck to stop on its own. Do not attempt
to stop the chuck by hand pressure.
• Examine tools and work for cracks or defects before
starting the work.
• Do not set tools on the lathe. Tools may be caught
by the work and thrown.
• Before measuring the work, allow it to stop in the
lathe.
 Safety Around Machine Tools
PRECAUTIONS FOR MILLING:
  .Wear eye protection.
• Clean the work bed prior to work.
• Secure the work to the bed to prevent
movement during milling.
• Select the proper tools for the job.
• Do not change the feed speed while
working.
 Safety Around Machine Tools
PRECAUTIONS DURING WELDING:
  • During welding operations, there should be
no open fuel tanks, and no work on fuel
systems should be in progress.
• No painting should be in progress.
• No aircraft are to be within 35 feet of the
welding operation.
• No flammable material should be in the area
around the welding operation.
 Safety Around Machine Tools
PRECAUTIONS DURING WELDING:
 • Only qualified welders should be permitted to
do the work.
• The welding area should be roped off and
placarded.
• Fire extinguishing equipment of a minimum
rating of 20B should be in the immediate area
with 80B rated equipment as a backup.
 Fire safety

Airport or other local fire departments can normally

be called upon to assist in training personnel and
helping to establish fire safety programs for the
hangar, shops, and flight line.
 Aircraft Cleaning Purpose

Certain chemicals found in many common cleaners

have alkaline properties that can have an adverse
effect on both paint and the aluminum itself. These
chemicals can contribute to hydrogen embrittlement
or structural weakening of highly stressed aluminum,
or in the case of sheet metal, a dulling of unpainted
surfaces, which promotes pitting and corrosion.
 Aircraft Cleaning Purpose

Cleaners such as Formula 409 and regular Simple

Green have no place in an aircraft cleaning kit.
 Aircraft Cleaning Purpose

Plexiglas must be cleaned in stages, with plenty of

water to keep any dirt flowing off the surfaces
 Aircraft Cleaning Purpose

Plexiglas must be cleaned in stages, with plenty of

water to keep any dirt flowing off the surfaces.
Avoid power washers.
Dirty belly- use pressure sprayers but not 1000 psi
variety.
 Taxiing Aircraft

As a general rule, only rated pilots and qualified

airframe and power plant technicians are authorized
to start, run up, and taxi aircraft. All taxiing
operations should be performed in accordance with
applicable local regulations.
Taxi Signals
Taxi Signals
 Safety precautions to be taken in
A/C hanger
Causes:
Fire
Acids
Machine
Electricity
Compressed/Explosive gases
Cryogenics
 Fire precautions
* waste: waste paper, oil rags or rags
impregnated with spirit, warnish or paint.
Smoking is prohibited.
Attention to packing of oil rags and waste oils.
 Fire precautions
Cleaning:
Petrol used only permitted for special purposes
during overhaul(cleaning magnetos)
Not used to clean engine tanks. Maintain a safe
distance from all inflammable material.
 Magnesium alloys
- Fine cuts to be avoided
- Tools used should be sharp
- When grinding it should be clearly marked for
identification process
- During hand finishing use glass paper in order
emery sheet
 Electrical precautions
• Marking- HIGH VOLTAGE
• Electrical wires: don’t use water on fire and
use co2 and dry powders
• Earthing properly
• Defects: wires, extension cables, switches and
connections check.
• Avoid Oil on rubber insulations
 Electrical precautions
• Carbon dust: Brush gear of rotary equipment
properly examines to avoid sparking.
• Fuses: proper replace if blown out.
• Heating apparatus: soldering iron, immersion
heater switched off immediately after use
 Electrical precautions
• Overheating: caused due to under rated wires
for heavy currents.
 Temperatures
• Electrolyte temperature:
Maximum temperature during charging 50
degree for batteries.
. Environmental temperature:
Not exceeding 27 degrees. If exceeds battery
will over flown
 Charging boards and benches
• Charging boards should be mounted directly
above the rear of the benches.
• Battery connecting cables-well insulated
• Power off- Connecting and de connecting
• Height should be visible
 Power supplies
• Transformers: fume free, dry and cool
position.
• Prefer separate room for transformers
 Storage
• Incoming unserviceable batteries and
outgoing serviceable batteries to be kept
separately.
 SCREW THREADS
All of the following devices have screw threads
in common.
NUTS
BOLTS
STUDS
SCREWS
LOCK NUTS
 SCREW THREADS
MALE THREAD(DIES)
A special groove cut on the surface of a round
bar.
FEMALE THREAD (TAPS)
A special groove cut on the surface of a
cylindrical hole
SCREW THREADS
 SCREW THREADS
• Major diameter – In an external thread like
the edges of a screw, major diameter refers to
the diameter of the overall shaft, including the
height of the raised helix.
• Minor diameter – Minor diameter measures
the diameter of the “root,” or innermost part
of the screw, not including the crests of the
helix.
 SCREW THREADS
• Pitch – The pitch is the distance between two
identical threads.
• Flank – The flank is the angle at which the
helix is raised to form a crest on the thread.
• Crest – The crest is the height at which an
external thread is raised, or the depth at
which an internal thread is indented
 SCREW THREADS
COARSE PITCH:
Few threads per inch
FINE PITCH:
Many threads per inch
 SCREW THREADS
• MINUS DIAMETER – when the external thread
is cut into normal diameter of thread.
• PLUS DIAMETER- Thread stands above the
surface.
 HARDWARE SPECIFICATIONS
BRITISH STANDARS:
AS (Society of British Aerospace Companies)
AGS ( Aircraft General Standards)
BSS (British Standard Specification)
DTD (Directorate of Technical Development)
 HARDWARE SPECIFICATIONS
AMERICAN STANDARD:
AN ( Air force- Navy)
NAS (National Aerospace Standard)
MS (Military Standard)
SAE (Society of Automobile Engineers)
AMS (Aeronautical Material Division)
FEDERAL SPECIFICATIONS
 COMMON THREADS
SQUARE THREAD:
X=Y=Z used in jacks and vices
ACME THREAD:
X=Y used in Lathe
BUTTRESS THREAD:
Greater pressure in only one direction.
Used in paper cutting machine
 COMMON THREADS
WORM THREAD:
They resemble ACME thread
NUCLE THREAD:
Rounded square threads. Used in Railway
couplings.
 NUTS

They are made in variety of shapes and sizes.

Made of carbon steel, stainless steel,
Anodised 2024T aluminium alloy.
Divided as (i) Non self locking (ii) Self locking
 NUTS IDENTIFICATION
They are identified by its
(i) Shape
(ii) Material made of
(iii) Size
(iv) Anti corrosive treatments given
(v) Left and right hand threaded
(vi) Nuts larger than British standard numbers
 NUTS IDENTIFICATION
SHAPE:
Ordinary nut
Slotted nut
Castle nut
Thin nuts
 NUTS IDENTIFICATION
SIZE:
In BA system: 2BA, 4BA..
In BSF system: infraction of inches
UNIFIED system: numbers and fractionless
 NUTS IDENTIFICATION
MATERIAL:
Brass
HTSS- high temperature stainless steel
ALAL- Aluminium alloy
LTS- low tensile steel
MTS- medium tensile steel
SS- stainless steel
 NUTS IDENTIFICATION
Anti corrosive treatments:
Cadmium finish
Anodic or Tinned
Left handed and Right handed:
Letter L and no letter
Identification of all types of fluid
line fittings

Aircraft fluid lines are usually made of metal

tubing or flexible hose. Metal tubing (also
called rigid fluid lines) is used in stationary
applications and where long, relatively straight
runs are possible. They are widely used in
aircraft for fuel, oil, coolant, oxygen,
instrument, and hydraulic lines.
Identification of all types of fluid
line fittings
Occasionally, it may be necessary to repair or
replace damaged aircraft fluid lines. Very often
the repair can be made simply by replacing
the tubing. However, if replacements are not
available, the needed parts may have to be
fabricated. Replacement tubing should be of
the same size and material as the original
tubing..
Identification of all types of fluid
line fittings

All tubing is pressure tested prior to initial

installation, and is designed to withstand
several times the normal operating pressure
to which it will be subjected
Identification of all types of fluid
line fittings
COPPER:
In the early days of aviation, copper tubing
was used extensively in aviation fluid
applications. In modern aircraft, aluminum
alloy, corrosion resistant steel or titanium
tubing have generally replaced copper tubing.
 Identification of all types of fluid
line fittings
Aluminum Alloy Tubing:
Tubing made from 1100 H14 (1/2-hard) or
3003 H14 (1/2-hard) is used for general
purpose lines of low or negligible fluid
pressures, such as instrument lines and
ventilating conduits. such as hydraulic and
pneumatic 1,000 to 1,500 psi systems, and
fuel and oil lines
 Identification of all types of fluid
line fittings
STEEL:
Corrosion resistant steel tubing, either
annealed CRES 304, CRES 321 or CRES 304-
1/8-hard, is used extensively in high pressure
hydraulic systems (3,000 psi or more) for the
operation of landing gear, flaps, brakes, and in
fire zones. Its higher tensile strength permits
the use of tubing with thinner walls.
Identification of all types of fluid
line fittings
Titanium 3AL-2.5V:
This type of tubing and fitting is used
extensively in transport category and high
performance aircraft hydraulic systems for
pressures above 1,500 psi. Titanium is 30
percent stronger than steel and 50 percent
lighter than steel. Cryofit fittings or swaged
fittings are used with titanium tubing.
Identification of all types of fluid
line fittings

Fluid lines in aircraft are often identified by

markers made up of color codes, words, and
geometric symbols. These markers identify
each line’s function, content, and primary
hazard.
Identification of all types of fluid
line fittings
Identification of all types of fluid
line fittings
 Fluid line end fittings
Depending on the type and use, fittings will
have either pipe threads or machine threads.
Pipe threads are similar to those used in
ordinary plumbing and are tapered, both
internal and external. External threads are
referred to as male threads and internal
threads are female threads.
 Fluid line end fittings
When two fittings are joined, a male into a
female, the thread taper forms a seal. Some
form of pipe thread lubricant approved for the
particular fluid application should be used
when joining pipe threads to prevent seizing
and high-pressure leakage. 
Do not use lubricants on oxygen lines
 Fluid line end fittings
Machine threads have no sealing capability
and are similar to those used on common nuts
and bolts. This type of fitting is used only to
draw connections together or for attachment
through bulkheads. A flared tube connection,
a crush washer, or a synthetic seal is used to
make the connection fluid tight.
 PLUMBING CONNECTORS

Plumbing connectors, or fittings, attach one

piece of tubing to another or to system units.
There are four types: (1) Flared fitting, (2)
flareless fitting, (3) bead and clamp, and (4)
swaged
 PLUMBING CONNECTORS
Flared fittings:
A flared tube fitting consists of a sleeve and a
nut. The nut fits over the sleeve and, when
tightened, draws the sleeve and tubing flare
tightly against a male fitting to form a seal.
Tubing used with this type of fitting must be
flared before installation.
PLUMBING CONNECTORS
PLUMBING CONNECTORS