01 GENERAL.pdf

SINGLE AISLE
TECHNICAL TRAINING MANUAL
MAINTENANCE COURSE - T1
GENERAL

This document must be used for training purposes only
Under no circumstances should this document be used as a reference
It will not be updated.
All rights reserved
No part of this manual may be reproduced in any form,
by photostat, microfilm, retrieval system, or any other means,
without the prior written permission of AIRBUS S.A.S.

GENERAL
Structure General (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Structural Breakdown and Zoning (3) . . . . . . . . . . . . . . . . . . . . . . . . 18
Ground Handling (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrostatic Discharge (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Computer Removal and Installation (3) . . . . . . . . . . . . . . . . . . . . . . 56
Maintenance External Visit (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
01 - GENERAL TABLE OF CONTENTS
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STRUCTURE GENERAL (1)
AIRCRAFT MATERIALS
METALLIC MATERIALS
The basic A/C structure is made of aluminum alloys with stainless
steel and titanium alloys in specific areas.
COMPOSITE MATERIALS
Composite materials are used for primary and secondary structure.
Composite materials represent about 15% of theA/C structural weight.
Carbon Fiber Reinforced Plastic (CFRP) is mainly used for primary
structures, whilst Aramid Fiber Reinforced Plastic (AFRP) and Glass
Fiber Reinforced Plastic (GFRP) are only used for secondary
structures.
01 - GENERAL STRUCTURE GENERAL (1)
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AIRCRAFT MATERIALS / COMPOSITE MATERIALS
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STRUCTURE PROTECTION
AIRCRAFT DRAINAGE
Wings and fuselage have different types of drains. Holes and gaps are
meant to be used for a natural drainage of the fluid collection points.
Drain holes are drilled before application of pretreatments. Remote
drains are used when natural drainage is not possible.
SURFACE PRETREATMENT
The protection of the structure against corrosion is achieved by means
of appropriate surface pretreatment of the metallic parts.
Aluminum alloys: the primary protection is generally a pure aluminum
cladding. The main pretreatment used is the unsealed chromic acid
anodizing.
Titanium alloys: surface interfaying with aluminum alloy parts are
zinc sprayed. The other titanium alloy surfaces are left bare. Titanium
fasteners are either sulphuric acid anodized or aluminum coated.
Composite materials are left bare.
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STRUCTURE PROTECTION / SURFACE PRETREATMENT
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STRUCTURE PROTECTION (continued)
PAINT SYSTEM
Before the final paint system, all aluminum parts are primed. The
paint system used includes polyurethane primers and paint on the
external surfaces, and epoxy primers and polyurethane paint on the
internal surfaces. Anti-slip paint is the overwing escape zones.
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STRUCTURE PROTECTION / PAINT SYSTEM
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STRUCTURE PROTECTION (continued)
NO STEP AREAS
Protective mats are required on the horizontal stabilizer as it is a carbon
fiber structure.
JACKING POINTS
Three jacking points are provided, one below each wing outboard of the
pylon and one in front of the NLG bay.
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JACKING POINTS
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A318 STRUCTURE DIFFERENCES
The Main structure differences between the A319/A320/A321 and the
A318 are due to the reduced length of the fuselage. There are several
general structure changes, laser beam welded structures and the vertical
stabilizer fin tip extension.
GENERAL STRUCTURE CHANGES
The main general structure changes are:
- on section 17, due to reduced length of the fuselage, the longitudinal
beams, the seat rails and the Z-profiles are replaced by new ones. The
crossbeams at FRame 52, FR53 and FR54 are removed. New
crossbeams are installed between FR55 to FR64,
- due to its location in the non-cylindrical part of the fuselage, a new
cargo sill box replaces the A319/A320/A321 one's, in section 17,
- on section 15, theA319/A320/A321 skin panels have been modified.
For weight reduction the A318 skin panels are thinner than the
A319/A320/A321 one's,
- the aft part of the belly fairing is modified due to an overlap with
non-cylindrical part of the fuselage. To avoid interference with cargo
compartment door, the A318 belly fairing is two panels shorter than
the A319/A320/A321 one's.
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A318 STRUCTURE DIFFERENCES / GENERAL STRUCTURE CHANGES
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A318 STRUCTURE DIFFERENCES (continued)
VERTICAL STABILIZER
Compared with A319/A320/A321 A/Cs, the A318 vertical stabilizer
fin tip is 750 mm (29,5 in.) longer.
The new developed tip is completely made of GFRP. There is an
additional fin leading edge panel. There is a new spar and a new CFRP
adaptor box, between the fin base and the fin tip.
The metallic rudder tip is longer by 100 mm in vertical direction. The
rudder trailing edge is increased in width by 50 mm.
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A318 STRUCTURE DIFFERENCES / VERTICAL STABILIZER
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LASER BEAM WELDING
The technology used for the A319/A320/A321 A/Cs is riveted
skin/stringer. On the A318, the skin/stringer connections are welded.
The new laser beam welded skin panels are installed in:
- the sections 13/14, FR24 to FR35, stringers 18 to 32,
- the sections 16/17, FR47/54 to FR64, stringers 32 to 41.
The skin panels are made thicker where the stringers are welded onto
them.
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A318 STRUCTURE DIFFERENCES / LASER BEAM WELDING
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CARGO DOORS
The A318 forward and aft cargo doors are smaller. The new cargo
door width is reduced from 1.82 m (71.5 in) to 1.28 m (50.5 in). The
under-floor cargo offers a usable volume of 21.21 m3
. There is no
containerized cargo system option.
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A318 STRUCTURE DIFFERENCES / CARGO DOORS
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STRUCTURAL BREAKDOWN AND ZONING (3)
REFERENCE AXES
The structure elements are installed according to the following reference
axes. The X axis in the longitudinal direction of the fuselage, the Y axis
in the direction of the wing span and the Z axis in the vertical direction.
The cross section P presents a typical fuselage section at frame 47.
NOTE: Note: The reference (station 0) for all structural measurements
for the X axis is set at 100 in (254 cm) forward of theA/C nose.
01 - GENERAL STRUCTURAL BREAKDOWN AND ZONING (3)
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REFERENCE AXES
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ATA CHAPTERS
The A/C structure is divided according to the ATA 100 specifications.
SECTION NUMBERS
Each major part of the A/C receives a section number. The fuselage
section base number is 10. The fuselage is divided into various sections
for manufacturing reasons.
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SECTION NUMBERS
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SECTION NUMBERS (continued)
WING AND TAIL PLANE
The general wing section base number is 20. The general tail plane
section base number is 30.
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SECTION NUMBERS / WING AND TAIL PLANE
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SECTION NUMBERS (continued)
ENGINE, LANDING GEAR AND BELLY FAIRING
The engine section base number is 40. The L/G section base number
is 50. The general belly fairing section base number is 60.
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SECTION NUMBERS / ENGINE, LANDING GEAR AND BELLY FAIRING
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STATION NUMBERS
FUSELAGE
The STAtion number is the distance in centimeters of a cross-section
from a reference point. The station/frame numbers shown agree with
the section boundaries.
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STATION NUMBERS / FUSELAGE
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STATION NUMBERS (continued)
VERTICAL STABILIZER
For the vertical stabilizer the reference station is Z=0 at the vertical
Z-axis. Due to the fin tip extension, the A318 station numbers have
changed. The new additional rib 12N is on the STA597.
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STATION NUMBERS / VERTICAL STABILIZER
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STATION NUMBERS (continued)
HORIZONTAL STABILIZER, ENGINE AND WING
For the horizontal stabilizer the reference station is y=0 at the A/C Y
axis. For the wings, the reference station is the wing reference axis
(WY). WY is located at 1868 mm (73.54 in) from the A/C X axis.
For the engines, station numbers are different depending on the
version.
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STATION NUMBERS / HORIZONTAL STABILIZER, ENGINE AND WING
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ZONES NUMBERS
There are 8 major zones for the A/C. Each major zone is identified by
the first digit of a three digits number. The even numbers identify the
zones on the RH side of the A/C, while odd numbers identify the zones
on the LH side of the A/C. The sub-zone 320 identifies the vertical
stabilizer.
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ZONES NUMBERS
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ZONES NUMBERS (continued)
WING (UPPER SURFACE) AND HORIZONTAL
STABILIZER
The 500 numbers identify the LH wing zones, while the 600 numbers
identify the RH wing zones. The sub-zones 330 and 340 identify the
LH and RH side of the horizontal stabilizer.
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ZONES NUMBERS / WING (UPPER SURFACE) AND HORIZONTAL STABILIZER
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WING (LOWER SURFACE), BELLY FAIRING AND
LANDING GEAR
The sub-zone 710 identifies the NLG. The sub-zones 730 and 740
identify the LH and RH MLG.
The sub-zone 190 indicates the belly fairing. 734 and 744 are the
MLG door zone numbers.
Access doors and panels are identified by the number of the zone in
which the panel is installed followed by a two letter suffix. These two
letters are used to indicate the doors and panels. The first letter
indicates which access door or panel it is, starting from the reference
axis (A=first, B=second, ..., G=seventh, etc...). The second letter
indicates the access door or panel location:
- T=top (upper) surface,
- B=bottom (lower) surface,
- R=right side,
- L=left side,
- Z=internal,
- F=floor panel,
- W=sidewall panel,
- C=ceiling panel.
Here is an example of access panels on the left wing lower surface.
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ZONES NUMBERS / WING (LOWER SURFACE), BELLY FAIRING AND LANDING GEAR
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NACELLE, PYLON, ENGINE AND DOOR
The difference between the LH and RH pylon and nacelle is made
with the ten digits of the zone number 400. The difference between
the LH side and RH side is identified by the last digit (Tens digit: odd
for he left and even for the right). Within one engine, an odd zone
number indicates the LH side and an even zone number indicates the
RH side of the engine. The major zone 800 identifies the doors.
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ZONES NUMBERS / NACELLE, PYLON, ENGINE AND DOOR
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GROUND HANDLING (1)
SERVICING POINTS
The ground service connections layout is the same on theAIRBUSA318
and A319.The main difference between A320 and A321 servicing point
is a second potable water draining panel in the center of the A/C on the
A320.
01 - GENERAL GROUND HANDLING (1)
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SERVICING POINTS
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GROUND HANDLING (1)
A/C SERVICING ARRANGEMENT
On the A318, note that special care must be taken during manual cargo
loading and unloading of the forward cargo compartment, because of the
close proximity of the engine air intake to the cargo loading vehicles
(conveyor belt).
NOTE: Note: The use of a self-propelled conveyor belt is not
recommended by Airbus Industrie.
The main difference between the A318/A319 and the A320/A321
servicing arrangement is that the A320 and A321 can have a bulk loader
on the bulk cargo door.
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A/C SERVICING ARRANGEMENT
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GROUND HANDLING (1)
TURNING RADII
The different turning radii are shown on a steering diagram. "Y" is the
distance between the centerline of theA/C longitudinal axis (X-axis) and
the theoretical center of turn for turning radius. "A" matches the minimum
turning width for a 180° turn. "Y, A" and the radii "R3, R4, R5 and R6"
values depend on two parameters: effective turn angle and steering angle.
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TURNING RADII
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ELECTROSTATIC DISCHARGE (3)
ELECTROSTATIC DISCHARGE PROBLEMS
Electro Static Discharge (ESD) is generated by rubbing materials with
each other. By moving over plastic materials (synthetic fibers), wearing
synthetic fiber clothing, electrical charges build up on the body. Thus
voltages of 12000 to 35000 volts can develop on a person. Touching
connector pins of computer units, a discharge path is formed through
wiring and components. Integrated Circuit (IC) chips can be partly
damaged or totally destroyed. Rubbing materials from the "tribo-electris"
series against each other and then separating them from each other causes
a build-up of electrostatic charges. If the materials are far apart in the
series, there will be a higher electric charge.
01 - GENERAL ELECTROSTATIC DISCHARGE (3)
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ELECTROSTATIC DISCHARGE PROBLEMS
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ELECTROSTATIC DISCHARGE PROTECTION
Here are some precautions to avoid damage of electronic equipment by
ESD. Line Replaceable Units (LRUs) that are sensitive to ESD are
identified by a black and yellow label on equipment face.
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ELECTROSTATIC DISCHARGE PROTECTION
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LRU REMOVAL
Replacing an LRU bearing the black and yellow label requires these
precautions.
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LRU REMOVAL
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LRU TEST
Testing of installed LRUs requires the following precautions.
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LRU TEST
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WORK STATION
The removal and testing of printed-circuit boards from an LRU bearing
the black and yellow label, is carried out as follows.
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WORK STATION
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COMPUTER REMOVAL AND INSTALLATION (3)
COMPUTER REMOVAL/INSTALLATION
Before starting a computer removal/installation procedure, the A/C has
to be set-up for maintenance. The first task is to make sure that the ground
service network is energized and the access door is open and accessible.
Then make sure that the C/Bs listed in the removal of the computer
procedure of Aircraft Maintenance Manual (AMM) is open. The first
action is to loosen the nut and then to lower the nut. When the nut is
lowered, pull the computer on its rack to disconnect the electrical
connectors and remove the computer from its rack. Before starting a
computer installation procedure, clean and do a visual inspection of the
component interface and of the adjacent area. First remove the blanking
caps from the electrical connectors and make sure that the electrical
connectors are clean and in the correct condition. Then install the
computer on its rack and push it on its rack to connect the electrical
connectors. Now you can engage the nuts on the studs and tighten them.
The installation is finished. You can close the C/B. The last actions of
the computer installation are to do a test through the MCDU and to close
the access. Make sure that the work area is clean and clear of tools and
other items, close the access door and remove the access platform.
01 - GENERAL COMPUTER REMOVAL AND INSTALLATION (3)
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COMPUTER REMOVAL/INSTALLATION
01 - GENERAL COMPUTER REMOVAL AND INSTALLATION (3)
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MAINTENANCE EXTERNAL VISIT (3)
PRESENTATION
This film presents the A321 outside safety inspection and cockpit
Check-List (CL) to be performed before powering the A/C for
maintenance purposes. Various main stations have been defined. The
inspection starts with the nose station. First verify that the NLG chocks
are in place. Then, observe that the NLG doors are closed. Make sure
that the NLG safety pin is installed. The NLG steering pin must be as
required. Finally, verify that theA/C is electrically grounded. The second
step consists of inspecting the right MLG. Start by checking that the
MLG door is closed. Then, verify that the MLG safety sleeve is installed.
Lastly, observe that the MLG chocks are in place. Let us continue with
the right engine station, the first thing to do is to make sure that the engine
right side access doors are secured. The same must be done for the left
side. Check that the engine fan cowls and thrust reverser cowls are
secured. The right wing is the 4th
station. Observe the position of the slats
and then, the flaps. The spoilers must be retracted. Then move to the left
wing station. Here again observe the position of the flaps and then, the
slats. Although make sure that the spoilers are retracted. The next step
is the left engine station. Check that the engine right side access doors
are secured. Then pass around the engine to verify that the left side access
doors are secured. Make sure that the engine fan cowls and thrust reverser
cowls are secured. Proceed with the left MLG station. The Ram Air
Turbine (RAT) safety device must be in the stowed position. Continue
by checking that the MLG door is closed and that the MLG safety sleeve
is installed. Before moving on, observe that the MLG chocks are in place.
In the A/C area station you have to make sure that the A/C area is clean
and clear of tools and any other items. Now you have to check the 9th
station: the external power receptacle. Verify that the external power is
connected and available. Finally enter the cockpit for the last station.
Start by checking the rear and the overhead circuit breaker, then have a
look to the emergency equipment. This consists in: verifying that the
escape ropes are present, observing that the fire extinguisher is in position,
making sure that the cockpit is equipped with smoke hoods, checking
that the fire protective gloves are present, ensuring the crash axe is in
position, checking that the cockpit is equipped with life vest, verifying
that the oxygen masks are present, observing that the flash lights are in
position. You must then make sure that the wipers are off. BATtery 1
and 2 P/BSW must be off and their voltage should be about 25 volts.
Proceed by setting the BAT1 P/BSW to AUTO. Then, set the BAT2
P/BSW to AUTO, check that the right hand dome light is on. Verify that
the speed brake handle is in the RETract disarm position. If the speed
brake handle disagrees with the surface position maintenance action is
due. On the center pedestal make sure that the thrust levers are in the idle
position. Engine master switches 1 and 2 must be in the OFF position
and the engine ignition mode selector in the NORMal position. Observe
that the flap handle is set according to surface position. If engine reverse
cowls have to be opened for maintenance action, the slats must to be
retracted. Still on the center pedestal, check that the radar is off, also
verify that the ATC transponder is off. Make sure that the gravity gear
extension crank handle is in the reset stowed position. On the instrument
panel observe that the three green triangles on the LanDinG GEAR panel
are on. The control safety check list should now have been accomplished.
On the overhead panel set the EXTernal PoWeR P/BSW to ON, also set
the GENerator 1 P/BSW to on and the GEN2 P/SW to ON. Scan and
check that no amber lights are on except GEN1 and 2 FAULT light on
panel 44VU. The GALY & CAB P/BSW should be as required. Finally
verify that there is no light on the VENTilation panel. The A/C is now
ready for maintenance.
NOTE: This film shows an A321 but the procedure is also valid for
A318, A319 and A320 aircrafts.
01 - GENERAL MAINTENANCE EXTERNAL VISIT (3)
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PRESENTATION
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STEP BY STEP
The following topics develop step by step the previous film presentation.
NOSE STATION AND EXTERNAL POWER RECEPTACLE
To the station 1, in first, verify that the NLG chocks are in place. Then,
observe that the NLG doors are closed. Make sure that the NLG safety
pin is installed. The steering pin must be as required. Finally, verify that
the A/C is electrically grounded.
NOTE: Note: The A/C can also be grounded from the MLG.
For the station 9, verify that the external power is connected and available.
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NOSE STATION AND EXTERNAL POWER RECEPTACLE
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RIGHT AND LEFT MLG STATION
The station 2 and 7 consist of inspecting the Right (R) and Left (L) MLG.
Start by checking that the MLG door is closed. Then, verify that the MLG
safety sleeve is installed. Finally, observe that the MLG chocks are in
place.
To the left station, the Ram Air Turbine (RAT) stowed position safety
device must be installed.
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RIGHT AND LEFT MLG STATION
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RIGHT AND LEFT ENGINE STATION
RIGHT AND LEFT ENGINE SIDE ACCESS DOORS
On station 3, the first thing to do is to make sure that the engine right
and left side access doors are secured. The same must be done on
station 6.
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RIGHT AND LEFT ENGINE STATION / RIGHT AND LEFT ENGINE SIDE ACCESS DOORS
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RIGHT AND LEFT ENGINE STATION (continued)
ENGINE FAN COWLS AND THRUST REVERSER
COWLS
Check that the engine fan cowls and thrust reverser cowls are secured.
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RIGHT AND LEFT ENGINE STATION / ENGINE FAN COWLS AND THRUST REVERSER COWLS
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RIGHT AND LEFT WING STATION
The R and L wing are the 4 and 5 stations. Confirm the position of the
slats and then, the flaps. The spoilers must be retracted.
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RIGHT AND LEFT WING STATION
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AIRCRAFT AREA
In theA/C area station 8, you have to make sure that theA/C area is clean
and clear of tools, other items and FOD.
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AIRCRAFT AREA
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COCKPIT STATION
REAR AND OVERHEAD C/B PANELS
Start by checking that the rear C/Bs and the overhead C/Bs are in
closed position.
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COCKPIT STATION / REAR AND OVERHEAD C/B PANELS
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COCKPIT STATION (continued)
EMERGENCY EQUIPMENT
Then, have a look the emergency equipment. This consists in verifying
that the escape ropes are present, observing that the fire extinguisher
is in position, making sure that the cockpit is equipped with smoke
hoods, checking that the fire protective gloves are present, ensuring
that the crash axe is in position, checking that the cockpit is equipped
with life vests, verifying that the oxygen masks are present and
observing that the flash lights are in position.
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COCKPIT STATION / EMERGENCY EQUIPMENT
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PEDESTAL PANEL CHECK LIST
On the center pedestal, verify that the speed brake handle is in the
retract/disarm position. If the speed brake handle disagrees with the
surface position, maintenance action is due. Make sure that the thrust
levers are in the IDLE position.
ENG MASTER SWs 1 and 2 must be in the OFF position and the
engine ignition mode selector in the NORMal position.
Observe that the flap handle is set according to surface position.
If engine reverser cowls have to be opened for maintenance action,
the slats must be retracted.
Check that the radar is off. Also, verify that the Air Traffic Control
(ATC) transponder is off.
Make sure that the gravity gear extension handle is in the reset and
stowed position.
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COCKPIT STATION / PEDESTAL PANEL CHECK LIST
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OVERHEAD PANEL CHECK LIST AND A/C POWER
SUPPLY
You must then make sure that the wipers are off. BATteries 1 & 2
P/BSWs must be OFF and the voltage should be about 25 volts.
Proceed by setting the BAT 1 P/BSW to AUTO position. Then, set
the BAT 2 P/BSW to AUTO position.
NOTE: Note: if BAT voltage is below 25V, a charging cycle of 20
minutes is required.
Check that the right hand dome light is on.
A/C power supply procedure:
On the overhead panel, set the EXTernal PoWeR P/BSW to ON.Also,
set the GEN 1 P/BSW to ON and the GEN 2 P/BSW to ON.
Scan and check that no amber lights are on except GENerator (GEN)
1 and GEN 2 FAULT lights on panel 35VU.
The GALY & CAB P/BSW should be as required. Finally, verify
there is no light on the ventilation panel.
The A/C is now ready to maintenance.
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COCKPIT STATION / OVERHEAD PANEL CHECK LIST AND A/C POWER SUPPLY
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MAIN INSTRUMENT PANEL CHECK LIST AND
CONTROLS SAFETY CHECK LIST COMPLETED
On the instrument panel, make sure that the L/G lever is in the down
position and confirm that the three green arrows on the L/G panel are
on. The control safety CL should now have been accomplished.
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COCKPIT STATION / MAIN INSTRUMENT PANEL CHECK LIST AND CONTROLS SAFETY CHECK LIST COMPLETED
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01 GENERAL.pdf

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01 GENERAL.pdf