Ojt Avionics Renewed 2017

REGIONAL INSTITUTE OF
AVIATION
PALLICHAL
VEDIVACHAN KOVIL (PO)
THIRUVANANTHAPURAM
KERALA-695501
OJT MANUAL
(Approved by Deputy Director General (Southern Region)
Vide Letter No. -----------------------. Dated---------------------)
Controlled Copy No. …………………
SECTION : 01 GENERAL
Regional Institute of Aviation
Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHAPTER : 01 RECORD OF REVISIONS Page : 1.1.01
REVISION AFFECTED INCORPORATED

NO DATE SECTION PAGE NO ON BY
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5 02 5.2.132 1 DEC.2010 1 FEB2013
5 02 5.2.133 1 DEC.2010 0 DEC.2010
5 02 5.2.134 1 DEC.2010 0 DEC.2010
5 02 5.2.135 1 DEC.2010 1 FEB2013
5 02 5.2.136 1 DEC.2010 0 DEC.2010
5 02 5.2.137 1 DEC.2010 0 DEC.2010
5 02 5.2.138 1 DEC.2010 1 FEB2013
5 02 5.2.139 1 DEC.2010 0 DEC.2010
5 02 5.2.140 1 DEC.2010 1 FEB2013
5 02 5.2.141 1 DEC.2010 0 DEC.2010
5 02 5.2.142 1 DEC.2010 0 DEC.2010
5 02 5.2.143 1 DEC.2010 1 FEB2013
5 02 5.2.144 1 DEC.2010 0 DEC.2010
5 02 5.2.145 1 DEC.2010 0 DEC.2010

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OJT MANUAL
OJT MANUAL
CHAPTER : 03 INDEX Page :1.3.01
SECTION CHAPTER CONTENTS PAGE NO.

1-GENERAL 01 RECORD OF REVISIONS 1.1.01 -1.1.04
02 LIST OF EFFECTIVE PAGES 1.2.01 – 1.2.10
03 INDEX 1.3.01
04 INTRODUCTION 1.4.01
05 TRAINING 1.5.01 – 1.5.02
06 REVISION OF THE MANUAL 1.6.01
07 DISTRIBUTION OF THE MANUAL 1.7.01
2-FACILITIES 01 GENERAL FACILITIES 2.1.01
02 PERSONNEL 2.2.01 – 2.2.02
03 LITERATURE 2.3.01
04 GROUND EQUIPMENT’S 2.4.01
05 SPECIAL EQUIPMENT’S 2.5.01
06 TOOLS 2.6.01 – 2.6.02
3-SYLLABUS 01 MECHANICAL STREAM 3.1.01 – 3.1.06
02 AVIONICS STREAM 3.2.01 – 3.2.06
03 LIST OF PROCEDURE SHEETS 3.3.01 – 3.3.08
4-KNOWLEDGE EVALUATION AND ISSUE OF CERTIFICATE 4.1.01
01 CERTIFICATE 4.1.02 – 4.1.03
5-APPENDIX 01 MECHANICAL 5.1.01 – 5.1.186
02 AVIONICS 5.2.01 – 5.2.145

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OJT MANUAL
CHAPTER : 04 INTRODUCTION Page : 1.4.01
Òn-Job Training’ (OJT) shall be mandatory for completion of AME training course as
per the approved system of training under CAR section 2 series E category `G’. OJT
will be given for a continuous period of 6 months on the aircraft owned by the institute,
if facilities are acceptable to DGCA as specified in Appendix `V’ of CAR section 2
series E part VIII exist.
Regional Institute Of Aviation, Thiruvananthapuram is approved by DGCA to conduct

AME course in Mechanical Stream (Aero plane & Power plants) comprising of Light
Aero planes (LA), Heavy Aero planes (HA), Piston Engines (PE) And Jet Engines (JE)
and Avionics Stream comprising of Electrical System (ES), Instrument System (IS) And
Radio Navigation System (RN). The college shall provide OJT to the students after
completion of five semesters of classroom training.
Regional Institute Of Aviation, Thiruvananthapuram have one Merlin 2B, pressurized

aircraft, fitted with two Garrett Turbo prop engines in running condition, one Cessna
150, light aircraft fitted with Continental engine in running condition, and one Cessna
152 light aircraft fitted with Lycoming Model engine. Merlin 2B and Cessna 150 aircraft
are with their primary instruments and systems in working condition. The institute has
suitably qualified and experienced instructors for providing OJT on the above aircrafts.
The institute will provide OJT to its students after completion of Fifth semester for a
continuous period of six months, on the airplane owned by the institute.
The training is conducted as per syllabus in Section 3 of this manual to provide sufficient
hand on experience and skill development on a variety of maintenance activities. The
training will be for a period of six months covering 700 hours each of instructions/
training for Mechanical and Avionics. The students should have minimum of 80%
attendance. In charge OJT shall maintain an attendance register to mark attendance of
students undergoing OJT.

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OJT MANUAL
OJT MANUAL
CHAPTER : 05 TRAINING Page : 1.5.01
OBJECTIVE
Objective of OJT is to provide opportunity to the students, who have learned aircraft
systems and procedures to practically apply their knowledge and actually carryout
maintenance works on aircraft/systems/simulated projects/equipments under
supervision of qualified /experienced instructors. Practical experience is provided to
the students covering different aspects of actual aircraft maintenance under simulated
field conditions of airlines/general aviation operation. The training exercise will cover
actual/ maintenance tasks based on OJT Syllabus.
On job training facility of Regional Institute of Aviation will be utilized only to

provide on job training to its students, after completion of the fifth semester.
STANDARD OF ACCOMPLISHMENT:
During this experience phase of training, the standard is a function of the variety of
exercises completed and the time spent in workshop training. The trainee/student may
work individually or in a team.
THE OJT TRAINING
The OJT training will be conducted as per OJT syllabus given in Chapter 3 of this
manual. An OJT In-charge will control the complete OJT activities. The In – charge of
OJT will ensure that the programme is carried out as per the syllabus and students
logbooks are maintained. He will prepare a date wise schedule for the conduct of the
entire course of OJT, as per the syllabus. OJT will be carried out individually or in
small groups not exceeding 05 students depending up on the type of the practical
work. The students are to record activities performed by them in their individual
logbooks and the entries will be signed by the instructor who supervised the job.

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OJT MANUAL
CHAPTER : 05 TRAINING Page : 1.5.02
ADMISSION TO OJT
Admission to OJT is limited to the students of Regional Institute of Aviation. Students
who have completed the first five semesters and have passed all the subjects in each
semester are eligible for admission to OJT. OJT will be provided, as far as possible, in a
continuous manner till the syllabus is completely covered by the Student.
TRAINING AT OTHER APPROVED ORGANISATIONS

All students of this institute are advised to undergo OJT in this institute itself. However
in an exceptional case, based on the merit a candidate may be permitted to apply for
OJT in any other AMO with special permission.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHAPTER : 06 REVISION OF MANUAL Page : 1.6.01
In order to maintain the contents of this Manual up to date, revisions will be prepared
by the OJT In-charge from time to time. The prepared such revisions, will be forwarded
to the Regional Airworthiness Office in triplicate along with an application stating the
reasons for the revision and requesting their approval. After obtaining approval of the
revisions the master copy of the manual in the office of the OJT In charge will be
revised. Copies of the revision will be distributed to the holders of this manual, and
they will be solely responsible for incorporating the revision in the copies of manual
held by them. Then revision status card in the manual will be updated and signed by
the concerned person. The removed page(s) will be destroyed.
This manual will be revised or amended under the following circumstances:-
1. On change of Training policy/ procedure in the institute

2. As and when any revision to the CAR/ Rule/ AAC affecting OJT programme is
issued.
3. Under the directives of the Director General of Civil Aviation
4. On revision of Training programme affecting OJT
The revision will be identified by a VERTICAL BAR in the left side margin.

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OJT MANUAL
OJT MANUAL
CHAPTER : 07 DISTRIBUTION OF MANUAL Page : 1.7.01
The copies of the manual will be controlled with serial numbers and distributed according
to the following distribution record.
CONTROLLED COPY NO: 1 :OJT IN- CHARGE
CONTROLLED COPY NO: 2 :DGCA, NEW DELHI
CONTROLLED COPY NO: 3 :DY.DGCA (SR),
CONTROLLED COPY NO: 4 : ASST.DIRECTOR 0F AIRWORTHINES, KOCHI
CONTROLLED COPY NO: 5 :ACCOUNTABLE MANAGER
CONTROLLED COPY NO: 6 :AME INSTRUCTOR’S LIBRARY
SECTION : 02 FACILITIES
CHAPTER : 01 GENERAL FACILITIES Page : 2.1.01
The institute has all the general facilities required for the conduct of OJT. The institute
has appropriate hanger and workshop for housing the aero planes and servicing them. It
has an apron for ground run of the engines. It has the manuals, tools and equipment’s

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
required for the servicing and maintenance. It has the necessary manpower for providing
OJT.
The Institute has the following aircraft and engines for OJT.
1. Merlin 2B installed with Garrett TPE331-1/2 engines and all major systems in
working condition.
2. Cessna 150 installed with Continental O-200A engine and all systems in working
condition.
3. Cessna 152 installed with AVCO LYCOMING Model O-235 L2C engine.
CHAPTER : 02 PERSONNEL Page : 2.2.01
List of Instructors

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
OJT IN CHARGE
Experience
SL Trained
Name & Initials Qualification
No. on Aviation Instructional
BAMEC Cessna
Sqn Ldr KV Ramaswamy
1. HA, LA, CP,& & 47 years 12 Years
AE (M) (Retd)
CT Merlin2B
INSTRUCTORS MECHANICAL
Experience
SL
Name & Initials Qualification Trained on
No. Aviation Instructional
Jet Engine, Piston

Engine, Cessna A/C,
1. Mr. K.P.S.Suresh DME 24 years 4 years
Merlin 2B & competent
to give ground run.
LA,CP,HA,CT,RA,,OJTT
rained on Dornier-
228,HS-748&Comptent
Mr.Arvind Singh AME to give ground run on 9 Years 6 Years
2. Beech Bonanza-A-
35,Robinson R-
22&Lear Jet 25-B
Heavy Aircraft, Light
DME Aircraft, Cessna A/C & 25years 2years
3. Mr. Satheesh Kumar
Merlin 2B

4. Mr. N.Harikuttan Nair DME Aircraft, Cessna A/C & 20years 2 years
Merlin 2B
CHAPTER : 02 PERSONNEL Page : 2.2.02
INSTRUCTORS AVIONICS

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OJT MANUAL
OJT MANUAL
Experience
SL
Name & Initials Qualification Trained on
No. Aviation Instructional
Aircraft Electrical
1. Mr.Anil James 20 years 4 years
DEE Systems, Cessna A/C
& Merlin 2B

Aircraft Instrument 22 years 2 years
2. Mr.K.Venugopal DEE
Systems, Cessna A/C
& Merlin 2B
Aircraft Radio
3.
Mr. Mathew K Oommen DEE Navigation Systems, 25Years 3 years
Cessna A/C & Merlin
2B
CHAPTER : 03 LITERATURE Page : 2.3.01

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OJT MANUAL
OJT MANUAL
The institute has be following technical literature for conducting OJT Merlin 2B and
Cessna 152
Literature for Merlin 2B

1. Flight manual
2. Maintenance manual
3. Illustrated parts catalog
4. Engine maintenance manual
5. Aircraft wiring diagram
6. Training manual
Literature for Cessna 152

a. Maintenance manual
b. Parts catalog
c. Flight manual

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OJT MANUAL
OJT MANUAL
CHAPTER : 04 GROUND EQUIPMENT’S Page : 2.4.01
The institute has all the necessary support equipment’s for the maintenance and servicing of
the aero planes for the purpose of providing OJT under actual / simulated operating
conditions.
The support equipment’s include the following.
SL.No MERLIN 2B CESSNA

1. Jacks for lifting Aircraft
External ground power unit to provide
2. Bottle jacks for aircraft.
24 V, DC power supply to aircraft.
3. Ladders, Trestles, Trolleys, Trays. Ladders, Trestles, Trolleys, Trays.
4. Engine lifting sling. Engine lifting sling.
5. Mobile hoist. Mobile hoist.
6. Air compressor- low pressure. Air compressor- low pressure.
7. Towing arm. Towing arm.
8. Tail support. Tail support.
9. Wing Trestles. Wing Trestles.

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OJT MANUAL
OJT MANUAL
CHAPTER : 05 SPECIAL EQUIPMENT’S Page : 2.5.01
Special equipment required for the servicing and maintenance covered under OJT are
available in the Institute for general and specific maintenance works.
They include the following.
SL.No MERLIN 2B CESSNA

1. Straight Edge Straight Edge
2. Spirit Level Spirit Level
3. Wheel Spanner Wheel Spanner
4. Cable tension meter Cable tension meter
5. Torque wrenches Torque wrenches
1. 10-50 Lb Ft, 14-68Nm, 1-7 kg mts 1. 10-50 Lb Ft, 14-68Nm, 1-7 kg mts
2. 0-150 Ft metlb, 0-25 Meter kg 2. 0-150 Ft metlb, 0-25 Meter kg
6. Magnifying Glass – 4x & 6x Magnifying Glass – 4x & 6x
7. Inspection Mirror Inspection Mirror
8. TPG – Range 0-120 PSI TPG – Range 0-120 PSI
9. Rigging Boards
a. Incidence Board
b. Dihedral Board

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OJT MANUAL
OJT MANUAL
CHAPTER : 06 TOOLS Page : 2.6.01
The required tools for the conduct of OJT are available in the institution; the following
tools are required for the conducts of OJT as per the syllabus are available.
01. Pliers
02. Diagonal cutter
03. Wire twister
04. Steel rule
05. Screw Driver – Common – 6”
09. Screw Driver Philips – 6”
13. Hammer B/P
14. Hammer – Plastic
15. Small Socket – set one
16. Deep Socket – set one
17. Ratchet Handle
18. Spanner D/E – 3/8 x 5/16
19. Spanner D/E – 3/16 x ¼
20. Spanner D/E – 7/16 x ½
21. Snap-on combination 1/4”
33. Snap-on combination 1”
34. Snap-on combination 1 ¼”

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CHAPTER : 06 TOOLS Page : 2.6.02
Continued……….
35. Ring Spanner set – 1/4”

47. Ring Spanner set – 1”
48. Ring Spanner set – 1¼”
49. Allen key set

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OJT MANUAL
OJT MANUAL
SECTION : 03 SYLLABUS
CHAPTER : 01 MECHANICAL STREAM Page : 3.1.01
The syllabus for OJT in the institute will be of 700 hours/six months covering Merlin
2B flitted with Garrett engine and Cessna 150 fitted with Continental engine and
Cessna 152 installed with AVCO LYCOMING Model O-235 L2C engine. The syllabus
will cover general study of the aircraft and mechanical systems, ground handling, line
maintenance, periodic maintenance and special inspections and their documentation
works. The details are given below.
1. Familiarization of aircraft.
Cessna Merlin 2B
Cessna 150 / Merlin2B
a. Leading particulars and construction 10 Hrs 30 Hrs
details
2. Ground handling of aircraft

Cessna / Merlin2B
a. Mooring 03 Hrs 05 Hrs
b. Towing 03 Hrs 05 Hrs
c. Refueling / Defueling 03 Hrs 05 Hrs
05 Hrs
d. Jacking
3. Study of aircraft systems :

Cessna / Merlin 2B 07 Hrs 15 Hrs
1. Engine system 07Hrs 15 Hrs
2. Airframe system 07 Hrs 15 Hrs
3. Electrical system 07 Hrs 15 Hrs
4. Instrument system 07 Hrs 15 Hrs
5. Communication & Navigation system

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OJT MANUAL
OJT MANUAL
Practicals Cessna 152 / Merlin 2B
SL GROUP
PROCEDURE PROCEDURE SHEET No. Hrs
No. SIZE
1 Mooring RIA/PS/MECH/CES/01 03 03
2 Towing/Steering of aircraft RIA/PS/MECH/CES/02 03 05
3 Refueling/Defueling RIA/PS/MECH/CES/03 03 04
4 Main wheel change RIA/PS/MECH/CES/04 03 03
5 Main wheel assembly RIA/PS/MECH/CES/05 03 03
6 Brake bleeding RIA/PS/MECH/CES/06 03 03
7 Elevator removal and installation RIA/PS/MECH/CES/07 03 03
8 Aileron removal and installation RIA/PS/MECH/CES/08 03 03
9 Flap removal and installation RIA/PS/MECH/CES/09 03 03
10 Flap motor and gear box removal RIA/PS/MECH/CES/10 03
03
and installation
11 Engine Change RIA/PS/MECH/CES/11 10 05
12 Starter removal and installation RIA/PS/MECH/CES/12 03 02
13 Magneto removal and installation RIA/PS/MECH/CES/13 03 02
14 Spark plug removal and installation RIA/PS/MECH/CES/14 02 02
15 Oil filter removal and installation RIA/PS/MECH/CES/15 02 02
16 Induction system removal and RIA/PS/MECH/CES/16 03 02
installation
17 Exhaust system removal and RIA/PS/MECH/CES/17 03 02
installation
18 Carburetor removal and installation RIA/PS/MECH/CES/18 03 02
19 Fuel Filter removal and installation RIA/PS/MECH/CES/19 03 02
20 Inspection of starter motor and RIA/PS/MECH/CES/20 02 02
generator


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OJT MANUAL
Continued…..
SL GROUP
No. SIZE
21 Inspection of engine wiring RIA/PS/MECH/CES/21 04 02
22 Inspection of electrical RIA/PS/MECH/CES/22 04 02
components on engine bay
23 Inspection of Hoses and RIA/PS/MECH/CES/23 02 02
connection to and from
Instrument
24 Air speed indicator RIA/PS/MECH/CES/24 02
02
removal & installation
25 Vertical Speed indicator RIA/PS/MECH/CES/25 02
02
Altimeter removal & RIA/PS/MECH/CES/26 02
26 02
installation
Aircraft clock checking, RIA/PS/MECH/CES/27 02
27 02
removal & fitment
28 Removal, testing and RIA/PS/MECH/CES/28 04
02
installation of VHF/ VOR
29 Removal, testing and RIA/PS/MECH/CES/29 02
02
installation of Transponder
30 Elevator control rigging RIA/PS/MECH/CES/30 05 03
31 Aileron control rigging RIA/PS/MECH/CES/31 05 03
32 Preflight Inspection RIA/PS/MECH/CES/32 05 02
33 Overnight Inspection RIA/PS/MECH/CES/33
05 02
schedule
34 50/100 Hrs Servicing RIA/PS/MECH/CES/34 15 05
35 Mooring RIA/PS/MECH/MER/01 05 03
36 Jacking Up RIA/PS/MECH/MER/02 05 04
37. Towing of aircraft RIA/PS/MECH/MER/03 05 05

SL PROCEDURE A/C TYPE PROCEDURE SHEET No. Hrs GROUP
No. SIZE
SL PROCEDURE A/C TYPE PROCEDURE SHEET No. Hrs GROUP
55
No. Shutoff valve and Plumbing Merlin2B RIA/PS/MECH/MER/21 02
SIZE
10
38. Refueling / DefuelingRegional Institute of Aviation
56 Engine control rigging
39 Bleeding of break system
Merlin2B RIA/PS/MECH/MER/04
Merlin2B RIA/PS/MECH/MER/22 20
05
05
04
04
03
40 Charging of nose and main LG Thiruvananthapuram
Merlin2B RIA/PS/MECH/MER/06 5 03
57 Preflight Inspection OJT MANUAL OJT
Merlin2B MANUAL
RIA/PS/MECH/MER/23 05 02
shock absorber
41 Flap removal
CHAPTER : 01 andMECHANICAL
installation Merlin2B RIA/PS/MECH/MER/07 Page
STREAM 10: 3.1.04
03
58 Overnight Inspection
42 Cock pit seats removal & Merlin2B RIA/PS/MECH/MER/24
05 02
02
installation
59 50 Hrs
43 Main Servicing
landing gear wheel removal Merlin2B
RIA/PS/MECH/MER/09 155 04
03
& installation
60 100 Hrs Servicing
44 Elevator removal & installation Merlin2B
RIA/PS/MECH/MER/10 20
10 04
03
45 Aileron removal & installation Merlin2B RIA/PS/MECH/MER/11 10 03
61 200 Hrs Servicing Merlin2B RIA/PS/MECH/MER/27 20 04
46 Brake Master Cylinder removal Merlin2B RIA/PS/MECH/MER/12 5 03
62 &400
installation
Hrs Servicing Merlin2B RIA/PS/MECH/MER/28 20 04
47 Shuttle valve operation Merlin2B RIA/PS/MECH/MER/13 05 02
48
63 Brake unit removal
Hard/Over & installation
weight landing Merlin2B IA/PS/MECH/MER/29
20 03
04
49 Oil cooler removal & installation Merlin2B RIA/PS/MECH/MER/15 10 02
50 Fuel filter removal & installation Merlin2B RIA/PS/MECH/MER/16 10 02
Removal ,inspection& installation Merlin2B RIA/PS/MECH/MER/17 02
51 10
of starter generator
Oil filter and adapter removal & Merlin2B RIA/PS/MECH/MER/18 02
52 15
installation
53 Propeller greasing Merlin2B RIA/PS/MECH/MER/19 10 02
54 Removal, inspection & Merlin2B RIA/PS/MECH/MER/20 04
installation Fuel Manifold & 20
Nozzle Assemblies
Continued…..
Continued…..

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OJT MANUAL
OJT MANUAL
Continued…..
5. Trouble Shooting, analysis & rectification Cessna Merlin 2B

a. Airframe system: At least 5 tech log to be complied 10 Hrs 15 Hrs
5 Hrs 15 Hrs
b. Engine system: At least 5 tech log to be complied
6. Documentation of aircraft Cessna

a. QC records: Sample from old documents will be 2.30 Hrs 15 Hrs
shown to students and all columns will be explained
with information related to the documentation and
reference. 2.30 Hrs 10 Hrs
b. Defect records 2.30 Hrs 10 Hrs
c. Fuel oil uplift records 2.30 Hrs 10Hrs
d. Life limited component records 200 Hrs 500 Hrs
Total Hours Cessna/Merlin 700 Hrs
Total Hrs Mechanical
* b, c & d : The format from old aircraft documents will be explained and practical of
the documentation will be carried out.
Upkeep of records periodicity

Note 1: All procedure sheets will have the name and number of students.
Note 2: All procedure sheets of the practical work carried out by the students will be
preserved for 5 years from the date of practical completed.

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OJT MANUAL
OJT MANUAL
CHAPTER : 02 AVIONICS STREAM Page : 3.2.01
The syllabus for OJT in the institute will be of 700 hours/six months covering Merlin
2B flitted with Garrett engine and Cessna 150 fitted with Continental engine and
Cessna 152 installed with AVCO LYCOMING Model O-235 L2C engine and electrical
systems, instruments system and radio navigation system. The syllabus will cover
general study of the aircraft avionic systems, ground handling, line maintenance,
periodic maintenance and documentation works. The details are given below.
1. Familiarization of aircraft Cessna/Merlin 2B Cessna Merlin 2B
a. Leading particulars and construction details 10 Hrs 30 Hrs
2. Ground handling of aircraft Cessna/Merlin 2B

a. Mooring 03 Hrs 05 Hrs
b. Towing 03 Hrs 05 Hrs
3. Study of aircraft systems of aircraft Cessna/Merlin 2B

07 Hrs 15 Hrs
a. Communication, Navigation system
07 Hrs 15 Hrs
b. Electrical system 07 Hrs 15 Hrs
c. Instrument system 07 Hrs 15 Hrs
d. Engine system 07 Hrs 15 Hrs
e. Airframe system
4.

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PRACTICALS CESSNA 152 / MERLIN 2B AVIONICS
SL GROUP
No. SIZE
Mooring RIA/PS/AVIO/CES/01
1 03 03
Towing/Steering of aircraft RIA/PS/AVIO/CES/02
2 03 05
Inspection of electrical cables and RIA/PS/AVIO/CES/03
3 wiring at cockpit, wing, fuselage and 04 02
tail area
4 Inspection of lighting systems RIA/PS/AVIO/CES/04 04 02
Inspection of electrical components RIA/PS/AVIO/CES/05
5 04 02
on engine bay
Removal, Inspection and Installation RIA/PS/AVIO/CES/06
6 04 02
of starter motor and generator
7 Inspection of engine wiring RIA/PS/AVIO/CES/07 04 02
Inspection of Hoses and Connection RIA/PS/AVIO/CES/08
8 04 02
to and from Instruments
Pitot & static head removal, Fitment RIA/PS/AVIO/CES/09
9 inspection and checking of heater 04 02
connections
10 Leak test of Pitot Static System RIA/PS/AVIO/CES/10 04 04
Air speed indicator removal & RIA/PS/AVIO/CES/11
11 03 02
installation
Vertical Speed indicator removal & RIA/PS/AVIO/CES/12
12 03 02
installation
13 Altimeter removal & installation RIA/PS/AVIO/CES/13 03 02
14 RPM indicator removal & installation RIA/PS/AVIO/CES/14 03 02
15 Direct reading compass Removal & RIA/PS/AVIO/CES/15 03 02

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OJT MANUAL
OJT MANUAL
GRO
SL No. PROCEDURE A/C TYPE PROCEDURE SHEET No. Hrs UP
SIZE
Turn and Bank indicator removal Cessna RIA/PS/AVIO/CES/16
16 03 02
& installation
Aircraft clock checking, removal Cessna RIA/PS/AVIO/CES/17
17 04 02
& fitment
Suction gauges removal & Cessna RIA/PS/AVIO/CES/18
18 05 02
installation
Removal, testing and installation Cessna RIA/PS/AVIO/CES/19
19 05 04
of VHF/ VOR
Removal, testing and installation Cessna RIA/PS/AVIO/CES/20
20 05 02
of Transponder
Flap motor and gear box removal Cessna RIA/PS/AVIO/CES/21
21 05 03
& installation
22 Starter removal and installation Cessna RIA/PS/AVIO/CES/22 05 02
Spark plug removal & Cessna RIA/PS/AVIO/CES/23
23 05 02
installation
24 Preflight Inspection Cessna RIA/PS/AVIO/CES/24 05 02
25 Overnight Inspection Cessna RIA/PS/AVIO/CES/25 05 02
26 50/100 Hrs Inspection Cessna RIA/PS/AVIO/CES/26 10 05
27 Mooring Merlin 2B RIA/PS/AVIO/MER/01 05 03
28 Towing Merlin 2B RIA/PS/AVIO/MER/02 05 05
29 Inspection of ignition system Merlin 2B RIA/PS/AVIO/MER/03 10 05
30 Inspection of fuel booster pumps Merlin 2B RIA/PS/AVIO/MER/04 10 02
Inspection of cockpit illumination Merlin 2B RIA/PS/AVIO/MER/05
31 10 02
& annunciates
Continued…..
Continued…..
SL GROUP
No. SIZE

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OJT MANUAL
OJT MANUAL
Inspection of start system RIA/PS/AVIO/MER/06
32 10 02
contactors
33 Inspection of static inverters RIA/PS/AVIO/MER/07 10 02
34 Inspection of fuel shutoff valve RIA/PS/AVIO/MER/08 10 02
Inspection of CB, switches & RIA/PS/AVIO/MER/09
35 10 02
wiring in cockpit
36 Standard electrical wiring practice RIA/PS/AVIO/MER/10 15 02
Inspection of Hoses and RIA/PS/AVIO/MER/11
37 Connection to and from 10
02
Instruments
Pitot & static head removal, RIA/PS/AVIO/MER/12
38 Fitment inspection and checking of 10 02
heater connections
39 Leak test of Pitot Static System RIA/PS/AVIO/MER/13 10 04
Air speed indicator removal & RIA/PS/AVIO/MER/14
40 5 02
installation
Vertical Speed indicator removal & RIA/PS/AVIO/MER/15
41 05 02
installation
42 Altimeter removal & installation RIA/PS/AVIO/MER/16 05 02
Direct reading compass Removal & RIA/PS/AVIO/MER/17 02
43 05
fitment
Turn & Bank indicator removal & RIA/PS/AVIO/MER/18
44 05 02
installation
Continued…..
SL GROUP
No. SIZE
Aircraft clock checking, removal & RIA/PS/AVIO/MER/19 05
45 02
fitment
Removal, testing and installation of RIA/PS/AVIO/MER/20
46 05 04
VHF Transceiver
Removal testing and installation of RIA/PS/AVIO/MER/21
47 05 04
VOR/ILS equipment
48 05 02
Marker receiver
49 05 02
Transponders

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50 05 04
Radio altimeter
51 05 04
weather radar
Removal, test and installation of RIA/PS/AVIO/MER/26
52 05 04
ADF
53 05 04
AIS
54 05 04
GPS
55 Cockpit seat removal & installation RIA/PS/AVIO/MER/29 05 02
Starter generator removal and RIA/PS/AVIO/MER/30
56 10 02
installation
Fuel Shutoff valve and plumping RIA/PS/AVIO/MER/31
57 10 02
Continued…..
SL GROUP
No. SIZE
58 Preflight Inspection RIA/PS/AVIO/MER/32
05 02
59 Overnight Inspection Schedule RIA/PS/AVIO/MER/33
10 02
60 50 Hrs Maintenance schedule RIA/PS/AVIO/MER/34 15 04

Cessna Merlin 2B
5. Trouble Shooting, analysis & rectification 05 Hrs 10 Hrs
10 Hrs 10 Hrs
10 Hrs 10 Hrs
05Hrs 10 Hrs
05Hrs 10 Hrs
Date :Dec 2010 Date5 Hrs 10Hrs
: Feb 2013
200 Hrs 500 Hrs
700 Hrs
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a. Communication system
b. Electrical system
c. Instrument system
6. Documentation of aircraft Cessna a. QC records:

Sample from old documents will be
shown to students and all columns will be explained
with information related to the documentation and
reference.
b. Defect records
c. Life limited component records
Total Hrs Cessna/Merlin

Total Hrs Avionics
* b & c: The format from old aircraft documents will be explained and practical of the
documentation will be carried out.
Upkeep of records periodicity

Note 1: All procedure sheets will have the name and number of students.
Note 2: All procedure sheets of the practical work carried out by the students will be
preserved for 5 years from the date of practical completed.
CHAPTER : 03 LIST OF PROCEDURE SHEET, MECHANICAL Page : 3.3.01
The list of procedure sheets is given below.

SL. Gang
Procedure Sheet No. Topics
No. Size
1. RIA/PS/MECH/CES/01 Mooring 03
2. RIA/PS/MECH/CES/02 Towing/Steering of aircraft 05
3. RIA/PS/MECH/CES/03 Refueling/Defueling 04
4. RIA/PS/MECH/CES/04 Main wheel change 03
5. RIA/PS/MECH/CES/05 Main wheel assembly 03
6. RIA/PS/MECH/CES/06 Brake bleeding 03
7. RIA/PS/MECH/CES/07 Elevator removal and installation 03
8. RIA/PS/MECH/CES/08 Aileron removal and installation 03
9. RIA/PS/MECH/CES/09 Flap removal and installation 03
10. RIA/PS/MECH/CES/10 Flap motor and gear box removal and installation 03
11. RIA/PS/MECH/CES/11 Engine Change 05
12. RIA/PS/MECH/CES/12 Starter removal and installation 02
13. RIA/PS/MECH/CES/13 Magneto removal and installation 02

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14. RIA/PS/MECH/CES/14 Spark plug removal and installation 02
15. RIA/PS/MECH/CES/15 Oil filter removal and installation 02
16. RIA/PS/MECH/CES/16 Induction system removal and installation 02
17. RIA/PS/MECH/CES/17 Exhaust system removal and installation 02
18. RIA/PS/MECH/CES/18 Carburetor removal and installation 02
19. RIA/PS/MECH/CES/19 Fuel Filter removal and installation 02
20. RIA/PS/MECH/CES/20 Inspection of starter motor and generator 02
21. RIA/PS/MECH/CES/21 Inspection of engine wiring 02
22. RIA/PS/MECH/CES/22 Inspection of electrical components on engine bay 02
23. RIA/PS/MECH/CES/23 Inspection of Hoses and Connection to and from
02
Instruments
CHAPTER : 03 LIST OF PROCEDURE SHEET, MECHANICAL Page : 3.3.02
Continued…….
24 RIA/PS/MECH/CES/24 Air speed indicator removal & installation 02

25 RIA/PS/MECH/CES/25 Vertical Speed indicator removal & installation 02
26 RIA/PS/MECH/CES/26 Altimeter removal & installation 02
27 RIA/PS/MECH/CES/27 Aircraft clock checking, removal & fitment 02
28 RIA/PS/MECH/CES/28 Removal, testing and installation of VHF/ VOR 04
29 RIA/PS/MECH/CES/29 Removal, testing and installation of Transponder 02
30 RIA/PS/MECH/CES/30 Elevator control rigging 03
31 RIA/PS/MECH/CES/31 Aileron control rigging 03
32 RIA/PS/MECH/CES/32 Preflight Inspection 02
33 RIA/PS/MECH/CES/33 Overnight Inspection schedule 02
34 RIA/PS/MECH/CES/34 50/100 Hrs Servicing 05

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CHAPTER : 03 LIST OF PROCEDURE SHEET , MECHANICAL Page : 3.3.03
SL. Procedure Sheet No. Topics Group
No. Size
1 RIA/PS/MECH/MER/01 Mooring 03
2 RIA/PS/MECH/MER/02 Jacking Up 04
3 RIA/PS/MECH/MER/03 Towing of aircraft 05
4 RIA/PS/MECH/MER/04 Refueling / Defueling 04
5 RIA/PS/MECH/MER/05 Bleeding of break system 03
6 RIA/PS/MECH/MER/06 Charging of nose and main LG shock absorber 03
7 RIA/PS/MECH/MER/07 Flap removal and installation 03
8 RIA/PS/MECH/MER/08 Cock pit seats removal & installation 02
9 RIA/PS/MECH/MER/09 Main landing gear wheel removal & installation 03
10 RIA/PS/MECH/MER/10 Elevator removal & installation 03
11 RIA/PS/MECH/MER/11 Aileron removal & installation 03
12 RIA/PS/MECH/MER/12 Brake Master Cylinder removal & installation 03
13 RIA/PS/MECH/MER/13 Shuttle valve operation 02
14 RIA/PS/MECH/MER/14 Brake unit removal & installation 03
15 RIA/PS/MECH/MER/15 Oil cooler removal & installation 02
16 RIA/PS/MECH/MER/16 Fuel filter removal & installation 02
17. RIA/PS/MECH/MER/17 Removal, inspection & installation of Starter 02
generator
18. RIA/PS/MECH/MER/18 Oil filter and adapter removal & installation 02
19. RIA/PS/MECH/MER/19 Propeller greasing 02
20. RIA/PS/MECH/MER/20 Removal, inspection & installation Fuel 04
Manifold & Nozzle Assemblies
21. RIA/PS/MECH/MER/21 Fuel Shutoff valve and Plumbing removal & 02
installation
22. RIA/PS/MECH/MER/22 Engine control Rigging 04
23. RIA/PS/MECH/MER/23 Preflight Inspection 02
CHAPTER : 03 LIST OF PROCEDURE SHEET, MECHANICAL Page :
3.3.04
Continued……..

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24 RIA/PS/MECH/MER/24 Overnight Inspection schedule 02
25. RIA/PS/MECH/MER/25 50 Hrs Maintenance schedule 04
29. RIA/PS/MECH/MER/29 Hard/Over weight landing 04

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CHAPTER : 03 LIST OF PROCEDURE SHEET, AVIONICS Page : 3.3.05

SL. Gang
Procedure Sheet No. Topics
No. Size
01 RIA/PS/AVIO/CES/01 Mooring 03
02 RIA/PS/AVIO/CES/02 Towing/Steering of aircraft 05
03 RIA/PS/AVIO/CES/03 Inspection of electrical cables and wiring at cockpit, 02
wing, fuselage and tail area
04. RIA/PS/AVIO/CES/04 Inspection of lighting systems 02
05. RIA/PS/AVIO/CES/05 Inspection of electrical components on engine bay 02
06. RIA/PS/AVIO/CES/06 Removal. Inspection and installation of starter 02
motor
07. RIA/PS/AVIO/CES/07 Inspection of engine wiring 02
08. RIA/PS/AVIO/CES/08 Inspection of Hoses and Connection to and from 02
Instruments
09. RIA/PS/AVIO/CES/09 Pilot & static head removal, Fitment inspection and 02
checking of heater connections
10. RIA/PS/AVIO/CES/10 Leak test of Pilot Static System 04
11. RIA/PS/AVIO/CES/11 Air speed indicator removal & installation 02
12. RIA/PS/AVIO/CES/12 Vertical Speed indicator removal & installation 02
13. RIA/PS/AVIO/CES/13 Altimeter removal & installation 02
14. RIA/PS/AVIO/CES/14 RPM indicator removal & installation 02
15. RIA/PS/AVIO/CES/15 Direct reading compass Removal & Installation 02
16. RIA/PS/AVIO/CES/16 Turn and Bank indicator removal & installation 02
17. RIA/PS/AVIO/CES/17 Aircraft clock checking, removal & fitment 02
18. RIA/PS/AVIO/CES/18 Suction gauges removal & installation 02
19. RIA/PS/AVIO/CES/19 Removal, testing and installation of VHF/ VOR 04
20. RIA/PS/AVIO/CES/20 Removal, testing and installation of Transponder 02

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Continued----------
21. RIA/PS/AVIO/CES/21 Flap motor and gear box removal and installation 03
22 RIA/PS/AVIO/CES/22 Starter removal and installation 02
23. RIA/PS/AVIO/CES/23 Spark plug removal and installation 02
24. RIA/PS/AVIO/CES/24 Preflight Inspection 02
25. RIA/PS/AVIO/CES/25 Overnight Inspection schedule 02
26. RIA/PS/AVIO/CES/26 50/100 Hrs Maintenance schedule 05

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SL. Procedure Sheet No. Topics Gang

No. Size
01 RIA/PS/AVIO/MER/01 Mooring 03
02 RIA/PS/AVIO/MER/02 Towing 05
03 RIA/PS/AVIO/MER/03 Inspection of ignition system 05
04 RIA/PS/AVIO/MER/04 Inspection of fuel booster pumps 02
05 RIA/PS/AVIO/MER/05 Inspection of Cockpit illumination and Annunciates 02
06 RIA/PS/AVIO/MER/06 Inspection of start system contactors 02
07 RIA/PS/AVIO/MER/07 Inspection of static invertors 02
08. RIA/PS/AVIO/MER/08 Inspection of fuel shutoff valve 02
09. RIA/PS/AVIO/MER/09 Inspection of CB, switches & wiring in cockpit 02
10. RIA/PS/AVIO/MER/10 Standard electrical wiring practice 02
11. RIA/PS/AVIO/MER/11 Inspection of Hoses and Connection to and from 02
Instruments
12. RIA/PS/AVIO/MER/12 Pitot & static head removal, Fitment inspection and 02
checking of heater connections
13. RIA/PS/AVIO/MER/13 Leak test of Pitot Static System 04
14. RIA/PS/AVIO/MER/14 Air speed indicator removal & installation 02
15. RIA/PS/AVIO/MER/15 Vertical Speed indicator removal & installation 02
16. RIA/PS/AVIO/MER/16 Altimeter removal & installation 02
17. RIA/PS/AVIO/MER/17 Direct reading compass Removal & fitment 02
18. RIA/PS/AVIO/MER/18 Turn and Bank indicator removal & installation 02
19. RIA/PS/AVIO/MER/19 Aircraft clock checking, removal & fitment 02
20. RIA/PS/AVIO/MER/20 Removal, test and installation of VHF Transceiver 04
21. RIA/PS/AVIO/MER/21 Removal, test and installation of VOR/ILS 04
equipment
Continued……….
22. RIA/PS/AVIO/MER/23 Removal, test and installation of Marker 02

receiver
23. RIA/PS/AVIO/MER/24 Removal, test and installation of Transponders 02
24. RIA/PS/AVIO/MER/25 Removal, test and installation of Radio altimeter 04

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25. RIA/PS/AVIO/MER/26 Removal, test and installation of weather radar 04
26. RIA/PS/AVIO/MER/27 Removal, test and installation of ADF 04
27. RIA/PS/AVIO/MER/28 Removal, test and installation of AIS 04
28. RIA/PS/AVIO/MER/29 Removal, test and installation of GPS 02
29. RIA/PS/AVIO/MER/30 Cock pit seats removal & installation 02
30. RIA/PS/AVIO/MER/31 Fuel Shutoff valve and Plumbing removal & 02
installation
31. RIA/PS/AVIO/MER/32 Preflight Inspection 02
32. RIA/PS/AVIO/MER/33 Overnight Inspection Schedule 02
33. RIA/PS/AVIO/MER/34 50 Hrs Maintenance schedule 04
34 RIA/PS/AVIO/MER/35 100 Hrs Maintenance schedule 04

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SECTION : 04 KNOWLEDGE EVALUATION AND ISSUE OF CERTIFICATE
CHAPTER : 01 Page : 4.1.01
A continuous evaluation system will be followed to judge a student’s progress through

the OJT. The students will be checked by oral as well as practical methods to evaluate
the students at different stages.
Instructor – in – charge OJT will maintain a register indicating the student’s progress
and grading. The students will be graded good, very good and outstanding. A page will
be allotted for each student. The page will. in addition, indicate details like
commencement and completion dates . The instructor- in – charge in responsible for
maintenance of the register and he will submit the register to OJT in – charge who
will review the performance and progress.
On completion of the OJT, OJT in-charge shall issue a certificate as per the format
given in appendix after ensuring that the student has recorded the practical training
exercises carried out by him in his log book and the entries are signed by the
Instructor.

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CHAPTER : 01 SPECIMEN CERTIFICATE – MECHANICAL Page : 4.1.02

PALLICHAL, VEDIVACHANKOIL, THIRUVANANTHAPURAM
(Approved by the Director General of Civil Aviation, Govt. of India,
Vide letter no. ……… …….. Date ………..)
CERTIFICATE
This is to certify that Mr./Ms/Mrs.……………………………................................

Son/Daughter of Mr.…………………………,………… Roll No. ………… Batch …….. has
successfully undergone six months ‘On the Job Training’ (OJT) in Mechanical stream (Aero
plane & Power plant) from …………………… to ……………………His/ Her On the Job
Training (OJT) was on Merlin 2B fitted with Garrett TPE331-1/2 engine ( Heavy Aero plane –
HA and Turbo prop Engine – JE) and Cessna 152 fitted with Lycoming O-235 engine, (Light
Aero plane – LA and Piston engine - PE).as per syllabus given in appendix V to CAR part VIII.
He/She is awarded with the grading of....................................on completion of the course.
……………………. ………………..
OJT in Charge Accountable manager

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CHAPTER : 01 SPECIMEN CERTIFICATE – AVIONICS Page : 4.1.03

PALLICHAL, VEDIVACHANKOIL, THIRUVANANTHAPURAM
(Approved by the Director General of Civil Aviation, Govt. of India,
Vide letter no. ……… …….. Date ………..)
CERTIFICATE
This is to certify that Mr/Ms/Mrs……………………………............................ Son/Daughter of

Mr.…………………………,………… Roll No. ………… Batch …….. has successfully
undergone six months ‘On the Job Training’ (OJT) in Avionics stream (Electrical System,
Instrument System & Radio Navigation system) from ………………to……………..His/ Her
On the Job Training (OJT) was on Merlin 2B fitted with Garrette engine (Heavy Aero plane –
HA and Turbo prop Engine – JE) and Cessna 152 fitted with Lycoming O-235 engine (Light
Aero plane – LA and Piston engine - PE).
He/She is awarded with the grading of....................................on completion of the course.
………………… ………………………….
OJT in Charge Accountable manager

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OJT MANUAL
SECTION : 05 APPENDIX
CHAPTER : 01 PROCEDURE SHEET, MECHANICAL Page : 5.1.01
PROCEDURE SHEET NO: -RIA/PS/MECH/CES/01 Group Size: 03
CESSNA 150: MOORING – 03 Hrs
AIRCRAFT SL NO :--------------- REG NO :-------------------------
DATE :----------------------------- AF HOURS:----------------------
SL SIGNATURE SIGNATURE
NO JOB MECH AME/APPRD
PERSON
1. Place the aircraft Nose to wind.
2. Put the control locks
3. Position two chocks in front and aft of each wheel.
4. Tie ropes, cables or chain (700 lbs tensile strength) to the
wing tie-down fittings located at the upper end of each
wing strut. Secure the opposite end of the rope to ground
anchors.
5. Secure the middle of a rope to the tail tie-down ring. Pull
each end of rope away at a 45° angle and secure to ground
anchors at each side of tail.
Caution: Do not set parking brakes when they are over
heated or during cold weather when accumulated moisture
may freeze them
DATE :----------------- SIGNATURE:---------------------------
AME NO:----------------------

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CESSNA150: MOORING EQUIPMENT AND TOOLS
Tools and consumables;-
1. Two pieces of Ropes
2. Six chocks

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PROCEDURE SHEET NO: - RIA/PS/MECH/CES/02 Group Size: 05
CESSNA 150: TOWING / STEERING OF AIRCRAFT – 03 Hrs
AIRCRAFT SL NO :--------------- REG NO :----------------------
DATE :----------------------------- AF HOURS:--------------------
SIGNATURE SIGNATURE
SL
JOB MECH AME/APPRD
NO
PERSON
Note:- Steering of aircraft has to be done only on a level
and Hard ground. Necessary clearance is to given by the
wing walkers and tail walkers.
1. Attach the towing bar to the nose strut.
2. Hold the towing bar steadily and ensure that the nose
wheel is not turned more than 30 degree.
3. Push the aircraft manually; by applying pressure on wing
struts and landing gear struts only.
DATE :----------------- SIGNATURE:-----------------------
AME NO:----------------------------

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OJT MANUAL
CESSNA 150: TOWING / STEERING OF AIRCRAFT

EQUIPMENT AND TOOLS
1. Tow Bar

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PROCEDURE SHEET NO:- RIA/PS/MECH/CES/03 Group Size: 04
CESSNA 150: REFUELING & DEFUELING PRECAUTIONS AND

PROCEDURE – 03 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Be sure that only the correct grade of fuel is put into an aircraft.
Remember that aviation gasoline comes in various grades and the
wrong grade can cause severe damage to the engine. Turbine fuel in
a reciprocating engine can cause severe detonation and engine
failure, and the improper use of aviation gasoline in a turbine engine
can also be harmful.
2. Bo sure that the fuel truck, or Servicer, is properly bonded to the
aircraft and the fuel nozzle is bonded to the structure before the
cover is taken from the fuel tank.
3. Wipe up spilled fuel or flood it with water. Do not sweep spilled
fuel with a dry broom.
4. Be sure that there are no open fires in the vicinity of the fueling or
defueling operations.
5. Be sure that fire extinguishers suitable for a Class B fire are
available. Either CO2 or dry-powder units are generally used.
6. Protect the aircraft structure from damage from the fuel hose and
from the nozzle.
7. Be sure that the radio or radar are not used during fueling or
defueling, and that no electrical equipment is turned on or off,
except for the equipment needed for the fueling operation.
8. When defueling, be sure that the fuel is not con-laminated if it is to
be used again.
9. Be sure that the filters in the tank truck or servicer remove all traces
of water and contamination and that the fuel pumped into an aircraft
is bright and clear.
10. If a biocidal additive is required, be sure that it is mixed with the
fuel in the proper concentration.
11. If the aircraft is being fueled in the rain, be sure that the tank
opening is covered to exclude water from the tank.

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Continued……….
12. Be sure that dust covers and caps are placed over the end of the fuel
nozzles and any open fuel lines when they are not in use.
13. Drive the tank truck parallel to the wing of the aircraft and be sure
that the parking brake is set so the truck cannot roll into an aircraft.
14, If any fuel is spilled on to your body, wash it off with soap and
water as soon as possible. Do not wear any clothing on which fuel
has been spilled.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA 152: MAIN WHEEL CHANGE – 03 Hrs
DATE :----------------------------- AF HOURS:--------------------
SIGNATURE SIGNATURE
SL
JOB MECH AME/APPRD
NO
PERSON
REMOVAL
1. Jack up the aircraft till wheels are cleared from ground.
2. Remove brake back plate from brake torque plate.
3. Remove cotter pin from axle nut.
4. Remove axle nut and remove the wheel with brake disc
After inspection, repair if any, lubrication etc..,
INSTALLATION
1. Position the wheel assembly along with brake disc.
2. Engage wheel axle nut and tighten with proper torque and
secure with cotter pin.
3. Refit the brake back plate onto brake unit.
4. Check up free rotation of wheel and brake application.
5. Ensure security, safety, locking and proper torque.
6. Lower the aircraft from jack.
DATE :----------------- SIGNATURE:-----------------------
AME NO:----------------------------

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OJT MANUAL
CESSNA 152: MAIN WHEEL CHANGE

EQUIPMENT AND TOOLS
TOOLS AND CONSUMABLES;-
1. 7/16 Spanner D/E

2. 7/16 socket
3. Ratchet drive
4. Torque wrench 80-90 lb in
5. Diagonal cutter
6. Pliers
7. Wheel spanner
8. Cotter pin 1/8 in
9. Wire locking 22swg
10. Grease general purpose
11. ½ “ open ended spanner & socket

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OJT MANUAL
CESSNA 152: MAIN WHEEL ASSEMBLY – 03 Hrs
AIRCRAFT SL NO :--------------- REG NO :---------------------------
DATE :----------------------------- AF HOURS:------------------------
SIGNATURE SIGNATURE
SL
JOB MECH AME/APPRD
NO
PERSON
DIS ASSEMBLING
1. Ensure wheel is removed from aircraft.
2. Deflate the tyre.
3. Break / loose tire bead
4. Remove nuts washers and bolts , Remove brake disc
5. Separate and remove the wheel halves from tire and tube
Note :- Never attempt to separate wheel halves with tire
and tube inflated
6. Remove bearing retaining ring
Bearing races are not to be removed from wheel
After cleaning,inspection,repair/replace, lubrication
corrosion treatment
ASSEMBLING
1. Assemble bearing and retaining ring , Position tire &tube
2. Position the wheel halves align valve stem, put bolts
through brake disc and engage nuts and washers. Inflate
tube with certain pressure to seat tire.
3. Do not use impact wrenches on thru bolts and nuts
Apply proper torque evenly and inflate tire with correct
pressure and required creep markings
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA 152: MAIN WHEEL ASSEMBLY

EQUIPMENT AND TOOLS
Equipment:-
TPG
Air pressure source
Tyre cage
Inspection tools
7/16 Spanner set D/E
7/16socket
Ratchet drive
T handle
Extension rod
Torque wrench
Grease general purpose
Cleaning brush
Cleaning materials
Yellow paint
Sand paper 400 grit
French chalk powder

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CHAPTER : 01 PROCEDURE SHEET, MECHANICA Page : 5.1.11
CESSNA 152: BRAKE BLEEDING – 03 Hrs
DATE :----------------------------- AF HOURS:------------------------
SIGNATURE SIGNATURE
SL
JOB MECH AME/APPRD
NO
PERSON
1. Remove brake master cylinder filler plug.
2. Screw flexible hose with appropriate fitting into the filler
hole at top of master cylinder
3. Immerse other end of hose in a container with enough
hyd. fluid to cover the end of hose
4. Connect a clean hyd. pressure source to the bleeder valve
in the wheel cylinder
5. As the fluid pump to the system ,observe the immersed
end of hose at BMC for evidence of air bubble
6. When bubbling stops, remove bleeder source and tight
the bleeder valve.
7. Check the free movement of wheel and correct operation
of brake
8. Ensure security, safety and locking.
DATE :----------------- SIGNATURE:------------------------
AME NO:-----------------------------

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OJT MANUAL
CESSNA 152: BRAKE BLEEDING

EQUIPMENT AND TOOLS
Equipment:-
Hydraulic pressure source

3/8 spanner set
Ratchet drive
T handle
Extension rod
Pliers
Transparent hose
Container
Torch
Hyd fluid
Wire locking 22 swg
Screw driver

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CESSNA 152: ELEVATOR REMOVAL AND INSTALLATION– 03 Hrs
AIRCRAFT SL NO :--------------- REG NO :--------------------------
DATE :----------------------------- AF HOURS:------------------------
SIGNATURE SIGNATURE
SL
JOB MECH AME/APPRD
NO
PERSON
Note:-A trim tab is fitted onto starboard elevator
No tab is fitted on port elevator
REMOVAL
1. Open the required access panels
2. Disconnect trim tab push pull tube at tab actuator
3. Remove bolts securing elevators to bell crank
4. Remove bolts from elevator hinges
5. Remove elevator ,keep on to a table & Store properly the
spares
6. To remove port elevator use same procedure
7. After inspection, repair if any, lubrication etc..,
INSTALLATION
1. Position the elevator engage the bolts and nuts with correct
torque
2. Engage the bolt and nut to the bell crank with correct
torque
3. Connect trim tab push pull tube at the actuator of stbd.
elevator
4. Ensure security , safety and locking
5. Close the access panels &check elevator travel and
alignment
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA 152: ELEVATOR REMOVAL AND INSTALLATION
EQUIPMENT AND TOOLS
Control column locking tool

3/8 ring
Spanner D/E 3/8
Spanner socket 3/8
Philips screw driver
Cotter pin 1/16
Oilcan
Oil lubrication

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OJT MANUAL
CESSNA 152: AILERON REMOVAL AND INSTALLATION– 03 Hrs
DATE :----------------------------- AF HOURS:-----------------------
SIGNATURE SIGNATURE
SL JOB MECH AME/APPRD
NO PERSON
REMOVAL
1. Open the required access panel.
2. Remove the blanking.
3. Disconnect push pull rod at aileron.
4. Remove screws and nuts attaching aileron hinges to trailing
edge of wing.
5. With care, pull aileron out and down to slide hinges from
under wing skin and auxiliary spar reinforcements.
6. Secure spare parts safely.
After inspection, repair if any, lubrication etc..
INSTALLATION
1. Position the aileron, engage the screws and nuts to trailing
edge of wing.
2. Attach push pull rod to aileron.
4. Close the access panels &check aileron travel and
alignment
DATE :----------------- SIGNATURE:------------------------
AME NO:-----------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 152: AILERON REMOVAL AND INSTALLATION

EQUIPMENT AND TOOLS

3/8 ring
3/8 spanner D/E
3/8 socket
Ratchet drive
T handle
Extension rod
Oil can
Oil general purpose

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OJT MANUAL
OJT MANUAL
CESSNA 152: FLAP REMOVAL AND INSTALLATION– 03 Hrs
DATE :----------------------------- AF HOURS:------------------------
SIGNATURE SIGNATURE
SL
JOB MECH AME/APPRD
NO
PERSON
REMOVAL
1. Lower the flaps fully
2. Remove access plates from top leading edge of flap
3. Disconnect push pull rod at flap bracket
4. Remove bolts at each flap track and remove the flap.
Retain all washers, bushings rollers safely
5. Place the flap on a table, Carry out inspection, repair if
any ,lubrication etc.,
INSTALLATION
1. Position the bushings rollers and spacers in the slot of flap
track & position the flap and engage the bolts , washer
and nut with proper torque
2. Position spacer ,nylon plug buttons as required
3. Connect push pull rod at flap bracket
4. Re install all access plates , operate flaps and ensure its
correct operation
5. Ensure security , safety and locking
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 152: FLAP REMOVAL AND INSTALLATION

EQUIPMENT AND TOOLS
T handle
3/8 ring
3/8set
3/8 Socket
Ratchet drive
Extension rod
Oilcan
Oil general purpose

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OJT MANUAL
OJT MANUAL
CESSNA 152: FLAP MOTOR AND GEAR BOX REMOVAL &

INSTALLATION – 03 Hrs
AIRCRAFT SL NO :--------------- REG NO: ---------------------------
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
2. Disconnect battery ground cable and insulate terminal
3. Remove access plates as required on stbd. wing
4. Note:-Flap motor, gear assembly, hinge assembly and
actuating tube are removed as a single unit. Remove bolt
securing actuating tube to drive pulley
5. Screw in actuating tube toward transmission as far as
possible by hand
6. Remove bolt securing flap motor hinge to wing
7. Disconnect motor electrical leads at quick disconnects ,
wiring at limit switch
8. Carefully take out the assembly from wing through the
access opening
9. Retain all spares for use on reinstallation. After inspection,
repair if any ,lubrication etc. ,If hinge assembly was
removed from transmission ensure that short end of
hinge is re installed towards top
Continued………….

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OJT MANUAL
INSTALLATION
1. Position back the assembly connect flap motor hinge to
wing
2. Connect motor electrical leads to quick connection
3. Connect wiring at limit switches
4. Connect actuating tube to drive pulley with bolt and nut
5. Ensure security , safety , locking and proper torque
correct operation
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 152: FLAP MOTOR AND GEAR BOX REMOVAL & INSTALLATION
EQUIPMENT AND TOOLS

Cable tensiometer
Torque wrench
7/16 Spanner D/E
7/16 socket
5/16 Spanner D/E
5 /16socket
Ratchet drive
T handle
Extension rod
Pliers
Oilcan
Oil gen.purpose
Grease gen.purpose
Cleaning material MEK

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/MECH/CES/11 Group Size: 05
CESSNA 152: ENGINE CHANGE – 10 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Place all cabin switches and the fuel shutoff valve in the
OFF position
2. Remove engine cowling.
3. Open battery circuit by disconnecting battery cable(s) at the
battery. Insulate cable terminal(s) as a safety precaution
4. Disconnect ignition switch primary (“P”) leads at the
magnetos.
5. Drain engine oil from sump.
6. Remove propeller and spinner.
7. Disconnect throttle and mixture control at carburetor. Pull
these controls free of engine and engine mount, using care
not to damage them by bending too sharply. Note position,
size and number attaching washers and spacers.
8. Disconnect carburetor heat control from arm on carburetor
air intake housing assembly. Remove clamps and pull
control aft clear of the engine.
9. Disconnect wires and cables as follows:
9.1 Starter electrical cable at starter.
9.2 Electrical wires and wire shielding ground at alternator.
9.3 Tachometer drive shaft at adapter on engine.
9.4 Remove all clamps attaching wires and cables to the engine
or engine mount. Pull all wires and cables aft to clear the
engine.

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OJT MANUAL
Continued……
10. Disconnect and cap or plug lines and hose as follows:
10.1Vacuum hose at firewall.
10.2Oil pressure hose at firewall.
10.3Oil temperature bulb at engine.
10.4Primer line to engine at firewall.
10.5Fuel hose to engine at fuel strainer on firewall.
10.6Remove all clamps attaching lines and hose to engine or
engine mount which interferes with engine removal from
engine mount.
11. Attach a tail stand to the tail tie-down fitting before
removing the engine.
12. Attach a hoist to the lifting lug on top of the engine weight
on hoist.
13. Remove bolts attaching engine to mount. Note direction of
bolt installation and position and numbers of washers.
Balance the engine by hand as the last of the bolts are
removed. Remove ground straps at lower mount leg bolts
are removed.
14. Carefully guide disconnected components out of engine
assembly.
INSTALLATION
1. Before installing the engine on the aircraft, install any items
which were removed from the engine or aircraft after the
engine was removed.
2. Remove all protective covers, plugs, caps and identification
tags as each item is connected or installed.
3. Hoist the engine to a point near the engine mount.
4. Install engine shock-mount pads.
5. Carefully lower engine slowly into place on the engine
mount. Route controls, lines, hoses and wires in place as
the engine is positioned on the engine mount.
6. Install engine mount bolts in the following sequence:
6.1 Install the upper right hand(locking forward) bolt, washer
and nut and tighten until one thread of the bolt is visible
past the nut
6.2 Install the lower right hand bolt, washer and nut and torque
bolt to 450 – 500 lb-in.

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OJT MANUAL
Continued……
6.3 Next install the upper left hand bolt, washer and nut and
tighten until one thread of the bolt is visible past the nut.
6.4 The lower left hand bolt, washer and nut are the last to be
installed.
6.5 Torque bolts mentioned in steps 1,3 and 4 to 450–500 lb-in.
7. Rout throttle, mixture and carburetor heat controls to the
carburetor and air box and connect. Secure controls in
position with clamps.
8. Connect lines and hoses as follows:
8.1 Connect oil cooler hoses at cooler.
8.2 Connect oil pressure line at firewall fitting.
8.3 Connect fuel supply hose at carburetor.
8.4 Connect primer line at firewall fitting.
8.5 Connect oil temperature bulb at adapter.
8.6 Connect engine breather hose at top of accessory case.
8.7 Connect vacuum hose at firewall fitting.
8.8 Install clamps and lacings attaching lines and hoses to
engine, engine mount and brackets.
9. Connect wires and cables as follows:
9.1 Connect electrical wires and wire shielding ground at
alternator.
9.2 Connect starter electrical cable at starter.
9.3 Connect tachometer drive shaft at adapter. Be sure drive
cable engages drive in adapter. Hand tighten housing attach
nut then tighten ¼ turn more.
9.4 Install clamps and lacings securing wires and cables to
engine, engine mount and brackets.
10. Install flexible duct to heater valve and engine baffle and
install clamps.
11. Install flexible duct to engine baffle and oil cooler and
install clamps.
12. Install propeller and spinner.
13. Complete a magneto switch ground-out and continuity
check, then connect primary lead wires to the magnetos.
Remove the temporary ground or connect spark plug leads,
whichever procedure was used during removal.

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OJT MANUAL
Continued……
14. Clean and install induction air filter.

15. Service engine with proper grade and quantity of engine oil.
16. Check all switches are in the OFF position, and connect battery
cables.
17. Rig engine controls.
18. Inspect engine installation for security, correct routing of
controls, lines, hoses and electrical wiring, proper safe tying and
tightness of all components.
19. Install engine cowling.
20. Perform an engine run up and make final adjustments on the
engine controls.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 152: ENGINE CHANGE
EQUIPMENT AND TOOLS
1. Philips screw driver

2. Common screw driver
3. Diagonal cutter
4. Pliers S/C
5. 3/8” spanner open end
9. ½” spanner open end
12. Torque wrench 452 – 500 lb/ft inch
13. Socket – D19- 16
14. ¾” Spanner open end
15. Hammer
16. ¼” Spanner open end
17. 7/8” Spanner open end
18. 1” Spanner open end
EQUIPMENTS
1. Tray and cotton waste
2. Engine lifting sling
3. Grease general purpose
4. Locking wire
5. Insulation tape
6. Tag

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OJT MANUAL
CESSNA 152: STARTER REMOVAL & INSTALLATION – 03 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Remove engine cowling
2. Disconnect starter cable. Do not permit starter terminal bolt
to rotate, which may eventually cause starter motor in
operative.
3. Disconnect starter power cable at starter. Insulate terminal
on power cable to prevent accidental shorting.
4. Remove the three nuts and washers and one bolt securing
starter to crankcase and remove starter.
INSTALLATION
1. Install starter by positioning starter on mounting pad, align
dowel pins in starter mounting pad with holes in mounting
pad on engine.
2. Secure starter with washes, lock washes and nut in three
place and install bolt and washes.
3. Tighten nuts and bolt evenly to a torque value of 150 lb in
4. Connect electrical cable to starter terminal and install
engine cowling.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CESSNA 152: STAETER REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL
1. SCREW DRIVER COMMON – ONE
2. SCREW DRIVER PHILIPS – ONE
3. SPANNER ¼ - ONE
4. SPANNER – 9/16 – ONE
5. SPANNER SET 3/8 – ONE
CESSNA 152: MAGNETO REMOVAL & INSTALLATION – 03 Hrs

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OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
Take proper precautions to make sure the engine can not
fire or start when the propeller is moved.
1. Remove high tension outlet plate.
2. Disconnect primary ‘P’ lead.
3. Remove nuts and washers which as securing magneto to
engine.
4. Note the approximate angular position at which the
magneto is installed, then remove the magneto.
INSTALLATION
1. Install the magneto with its timing marks correctly aligned
And in exact angular position with No.1 cylinder on its
compression stroke and No.1 piston at its advanced firing
position.
2. Time the magneto, by removing the timing plug from the
bottom of the magneto.
3. Rotate magneto shaft until timing mark on the vent plug
hole.
4. Establish that the magneto is at No.1 firing position.
5. Keep timing mark centered in vet plug hole during
installation.
6. Place gargets in its location and that the engine is in correct
firing position, then install magneto at the correct angular
position.

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OJT MANUAL
Continued……
7. Replace the washers and tighten the nuts whish are securing
magneto engine and then re-check timing.
8. Connect primary P-Lead.
9. Make sure both magnetos are set to fire at the same time.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA 152: MAGNETO REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
3. SPANNER ¼ - ONE

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OJT MANUAL
OJT MANUAL
CESSNA 152: SPARK PLUG REMOVAL & INSTALLATION – 02 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Remove the engine cowling.
1.1 Engine battery connection removed, masters and ignition
switch ‘OFF’.
2. Remove spark plug lead.
3. Remove spark plug and tag the cylinder No. and its
location.
4. Blank the spark plug openings using dummy spark plugs.
4.1. Protect the spark plug lead by proper covering.
INSTALLATION
1. Clean, Re-gap and test spark plugs prior to installation. It
satisfactory install.
2. Place the washers in its place, then install the spark plug.
3. Tighten the spark plugs to the required torque.
4. Connect spark plug leads.
5. Fit back the engine cowling.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 152: SPARK PLUG REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
3. SPANNER ¼ - ONE

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OJT MANUAL
OJT MANUAL
CESSNA 152: OIL FILTER REMOVAL & INSTALLATION – 02 Hrs
DATE :----------------------------- AF HOURS:----------------------
NO MECH AME/APPRD
JOB
PERSON
REMOVAL
2. Remove safety wire from filter.
3. Unscrew filter from adapter.
4. Remove oil filter gasket.
5. Remove the filter from spin-on oil filter assembly.
INSTALLATION
1. Prior to installation of filter, lightly lubricate gasket (oil
filter) with engine oil.
2. Install spin-on filter on the stud and torque to 19-29 lb.ft or
¾ to 1 full turn after gasket makes contact.
3. Safety wire filters to adapter.
4. After first engine run, check for oil leaks.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA 152: OIL FILTER REMOVAL & INSTALLATION
EQUIPMENT AND TOOLS
3. SPANNER ¼ - ONE
CESSNA 152: INDUCTION SYSTEM REMOVAL & INSTALLATION – 03 Hrs

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OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:----------------------
NO MECH AME/APPRD
JOB
PERSON
REMOVAL
2. Disconnect the carburetor heat control connection to the
induction air box.
3. Place fuel shut off valve in ‘OFF’ position.
4. Drain fuel from strainer and lines.
5. Disconnect throttle and mixture controls at carburetor.
6. Remove induction air box.
7. Remove nuts and washers attaching carburetor to intake
manifold and remove carburetor.
8. Remove intake pipes by disconnecting hose and removing
nuts and washers attaching pipes to cylinder.
INSTALLATION
1. Install intake pipes by connecting hose and tightening nuts
and washer to attaching pipes to cylinders.
2. Use new gaskets while installing carburetor to intake
manifold and tighten nuts and washers.
3. Connect throttle and mixture controls to carburetor and
ring.
4. Install induction air box
5. Connect carburetor heat control to the induction air box.
6. Re-install engine cowling.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CESSNA 152: INDUCTION SYSTEM REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL
3. SPANNER ¼ - ONE
CESSNA 152: EXHAUST SYSTEM REMOVAL & INSTALLATION – 03 Hrs

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OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:----------------------
NO MECH AME/APPRD
JOB
PERSON
REMOVAL
1. Remove engine cowling as required for access.
2. Disconnect flexible ducts from shrouds on muffler
assembly
3. Disconnect braces from muffler and tail pipe assemblies
4. Remove nuts and washers securing the exhaust stack
assemblies to the cylinder
5. Remove exhaust stack assy.
INSTALLATION
1. Install exhaust system, place one new copper-asbestos
gasket between each exhaust pipe and on its mounting pad
on the cylinder.
2. Tighten the nuts and washers securing the exhaust stack
assemblies to the cylinders.
3. Connect braces to muffler and tail pipe assemblies
4. Connect flexible ducts to shrouds on muffler assembly.
5. Make sure damps attaching muffler to exhaust pipes are
tight and all air ducts are installed.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CESSNA 152: EXHAUST SYSTEM REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL
3. SPANNER ¼ - ONE
CESSNA 152: CARBURETOR REMOVAL & INSTALLATION – 03 Hrs
DATE :----------------------------- AF HOURS:----------------------
NO MECH AME/APPRD
JOB
PERSON

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OJT MANUAL
OJT MANUAL
REMOVAL
1. Place fuel shut off valve in the OFF position
3. Drain fuel from strains and fuel lines. With strains drain
control.
4. Disconnect throttle and mixture controls at carbonator.
Note the EXACT position size and number of washers and
spacers for reference on reinstallation.
5. Disconnect and cap or plug fuel line at carburetor
6. Remove induction air box
7. Remove nuts and washers attaching carburetor to make
manifold and remove carburetor.
INSTALLATION
1. Install carburetor, attach carburetor to intake manifolds by
tightening the nuts and washers.
2. Install induction air box to carburetor
3. Connect fuel lines to carburetor
4. Connect throttle and mixture control to carburetor. Use
required number of washers, and spacers of the required
size and at exact position.
5. Put fuel shut off valve ‘ON’ and check for any leak.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA 152: CARBURETOR REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
1. SPANNER – ¾” – ONE
2. PLIER SIDE CUTTER – ONE
3. PHILIPS SCREW DRIVER – ONE
4. SOCKET ¼” 12 POINT – ONE
5. TORQUE WRENCH – 0 – 150 lb. in

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OJT MANUAL
CESSNA 152: FUEL FILTER REMOVAL & INSTALLATION – 03 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Place fuel shutoff valve in ‘OFF’ position, and drain fuel
from the drain tube.
2. Remove drain tube, safety wire, nut and washer at bottom
of filter bowl and remove bowl.
3. Carefully unscrew stand pipe and remove.
4. Remove filter screen and gasket.
INSTALLATION
1. Prior to installation of filter, clean the filter screen and bowl
with solvent and dry with compressed air.
2. Using a new gasket between filter screen and top assembly,
install screen and stand pipe. Tighten standpipe only finger
tight.
3. Using all new ‘O’ rings install bowl. Note that step washer
at bottom of bowl is installed so that steps seat against ‘O’
ring.
4. Turn shut off valve to ‘ON’ position. Check for leaks and
proper operation and safety wire.
5. Torque bottom nut to 25-30 lb.inch and safety wire to top
assembly of strainer. Wire must have right hand wrap, at
least 45 degree.
6. Connect drain tube.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA 152: FUEL FILTER REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
1. Plier side cutter – one
2. Spanner – 1 1/8 – one
3. Kerosene for cleaning
4. Compressed air
5. Magnifying glass - one
CHAPTER : 01 PROCEDURE SHEET, MECHANICAL Page :5.1.44

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OJT MANUAL
CESSNA150: INSPECTION OF STARTER MOTOR AND GENERATOR – 02Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Open the engine cowling and inspect the condition of
starter motor and generator
2. Check the cable connections and cable terminals to the
starter motor and generator.
3. Inspect the cables for any signs of overheat or insulation
deterioration and safety of routing.
4. Check the mountings of starter motor and generator.
5. Check the belt tension of generator.
6. Check the starter motor pinion for its condition.
7. Clean the starter motor and generator externally.
8. Close the engine cowling.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CESSNA150: INSPECTION OF STARTER MOTOR & GENERATOR

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL
1. CSD-8"
2. PSD-8"
3. Inspection lamp
4. Set spanner-12x13
PROCEDURE SHEET NO :- RIA/PS/MECH/CES/21 Group Size: 02
CESSNA150: INSPECTION OF ENGINE WIRING – 04 Hrs

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OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Open the engine cowling.
2. Inspect the condition of wiring harness and its routing.
3. Check the wiring for its safety and security of mountings.
4. Clean the electrical wiring harness around the engine.
5. Check the ignition leads for its condition, routing and
terminations.
6. Take proper corrective action if any abnormality is found.
7. Close engine cowling.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CESSNA150: INSPECTION OF ENGINE WIRING

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL
1. CSD-8"
2. PSD-8"
3. Inspection lamp
CESSNA150: INSPECTION OF ELECTRICAL COMPONENTS ON

ENGINE BAY – 04 Hrs

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OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:----------------------
PERSON
2. Visually inspect the condition of electrical components like
relays, contactors, voltage regulators etc…
3. Check the component for any mechanical damage; ensure
safety of cable routing and security of mounting.
4. Check the electrical cable terminations for its condition.
Tighten all the cable connections.
5. Inspect the electrical components and electrical cables for
the sign of overheat or damages.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL

ENGINE BAY EQUIPMENT AND TOOLS
1. CSD-8"
2. PSD-8"
3. Inspection lamp

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OJT MANUAL
PROCEDURE SHEET NO :- RIA/PS/MECH/CES/23 Group Size: 02
CESSNA150: INSPECTION OF HOSES & CONNECTIONS TO AND FROM

INSTRUMENTS – 02 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
1. Remove the hoses concerned to the Instrument system
2. Clean the hoses blow off with the compressed air. Connect
the hoses properly and check for the leakage
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL

INSTRUMENTS EQUIPMENT AND TOOLS
1. CSD-8"
2. PSD-8"
3. Inspection lamp

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OJT MANUAL
CESSNA150: AIR SPEED INDICATOR REMOVAL & INSTALLATION – 02 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
1. Lower the instrument panel by unscrewing the mounting
screws.
2. Unscrew the mounting screws which are holding the
Instruments.
3. Slowly slide the Instruments out of the instrument panel
and remove the connection from the rear side of the
instrument
4. Blank the pitot / static pipe lines on the aircraft installation
and instrument.
INSTALLATION
1. Install the Instruments in the reverse order of the removal
and carry out the leak test.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA150: AIR SPEED INDICATOR REMOVAL & INSTALLATION
EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers
7. Pilot/Static leak tester

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OJT MANUAL
CESSNA150: VERTICAL SPEED INDICATOR REMOVAL &
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
screws.
Instruments.
instrument
and instrument.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CESSNA150: VERTICAL SPEED INDICATOR REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers
7. Pitot/Static leak tester

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OJT MANUAL
CESSNA150: ALTIMETER REMOVAL & INSTALLATION – 02 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
screws.
Instruments.
instrument
and instrument.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA150: ALTIMETER REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers

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CESSNA150: AIRCRAFT CLOCK, CHECKING, REMOVAL &

DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
1. Remove the mounting screws from the bracket
Remove the instrument
2. Check the winding of the clock for the serviceability.
Visually inspect the dial and needle of the clock.
FITMENT
1. Install the instruments on the reverse order of the removal.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL

INSTALLATION EQUIPMENT AND TOOLS
CSD
PSD
Inspection lamp

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OJT MANUAL
CESSNA 150: REMOVAL, TESTING & INSTALLATION OF VHF/VOR – 02 Hrs
DATE :----------------------------- AF HOURS:----------------------
NO MECH AME/APPRD
JOB
PERSON
1. Remove VHF/VOR equipment from the instrument panel.
2. Check the plugs at the back of the equipment and at the
instrument panel.
3. Clean the plugs.
4. Check insulation of aerial cables
5. Install the equipment back and carry out functional check.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA 150: REMOVAL, TESTING & INSTALLATION OF VHF/VOR

EQUIPMENT AND TOOLS
Tools and consumables:-
1. Watt meter
2. Megger
3. Multimeter
4. Philips Screwdriver
5. Cutting Plier
6. Cleaning Brush

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CESSNA 150: REMOVAL, TESTING & INSTALLATION OF

TRANSPONDERS – 02 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Remove the transponder from the instrument panel.
2. Check the plugs for any possible damages.
3. Clean the plugs.
4. Check insulation of aerial cables.
5. Install the equipment back.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 150: REMOVAL, TESTING & INSTALLATION OF TRANSPONDER
EQUIPMENT AND TOOLS
1. Megger
2. Multimeter
4. Cutting Plier
5. Cleaning Brush

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OJT MANUAL
CESSNA 152: ELEVATOR CONTROL RIGGING - 05 Hrs
DATE :----------------------------- AF HOURS:--------------------
JOB
NO MECH AME/APPRD
PERSON
1. Remove seats, upholstery and access plates as required to
gain access to turn buckles.
2. Lock control column in neutral position by installing
neutral position rigging tool.
3. Streamline elevators to neutral with horizontal stabilizer.
4. Holding elevators in neutral (streamlined) position, adjust
cable tension by tightening turn buckle.
5. With elevators still in neutral position, mount an
inclinometer on one elevator and set to 00.
6. Remove control column neutral position rigging tool and
adjust travel on both the side.
7. Check all components for security, and turnbuckle to be
safe tied.
8. Reinstall all access panels.
9. Ensure the operation of elevator in correct direction.
If trim tab system is not adjusted, rigging of trim is not
required.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CESSNA 152: ELEVATOR CONTROL RIGGING

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL

Cable tensiometer
Torque wrench 40 lb in
3/8 ring
3/8 spanner D/E
3/8 socket
Ratchet
T handle
Extension rod
Plier
Diagonal cutter
Wire locking 0.040 in
Oilcan
Oil Lubricating

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OJT MANUAL
HAPTER : 01 PROCEDURE SHEET, MECHANICAL Page : 5.1.66
CESSNA 152: AILERON CONTROL RIGGING – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Ensure all required access panels, wing root fairings and
upholstery are removed.
2. Ensure positioning of control arm horizontal &install chain
with equal no. of links from drive sprocket.
3. Adjust turn buckle to remove slack from chain and
synchronize control wheel.
4. Adjust chain turn buckle to minimum tension required to
remove slack.
5. Tape a bar across both control wheels to hold in neutral
position.
6. Adjust turn buckle at bell crank to correct tension
7. Adjust push pull rod at each ailerons are in neutral with
reference to trailing edge of flap.
8. Note:- Be sure wing flaps are fully up
Remove bar from control wheel
9. Safety all turn buckle and install all removed items Be
sure ailerons are moving correct direction.
10. Mount an inclinometer on aileron trailing edge and set to
00 Measure aileron travel from DROOP position
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
CESSNA 152: AILERON CONTROL RIGGING

EQUIPMENT AND TOOLS

Cable tensiometer
Turn buckle clamp
3/8 ring
3/8 set
3/8 socket
Ratchet drive
T handle
Extension rod
Pliers
Diagonal cutter
cotter pin
Wire locking 0.040 in
Oilcan
Oil general purpose

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/MECH/CESS: 32 Group Size: 02
CESSNA 150: PREFLIGHT INSPECTION – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
ITEM MECH AME

NO ITEM
CABIN
1. Pilot's Operating Handbook – AVAILABLE IN'THE
AIRPLANE.
2. Parking: Brake - SET.
3. Control Wheel Lock - REMOVE.
4. Ignition Switch -- OFF.
5. Master Switch - ON.
WARNING
When turning on the master switch, using an external power
source or pulling the propeller through by hand, treat the
propeller as if the ignition switch were on. Do not stand, nor
allow anyone else to stand, within the arc of the propeller, since a
loose or broken wire, or a component malfunction, could cause
the propeller to rotate.
6. Fuel Quantity indicators - CHECK QUANTITY.
7. Avionics Cooling- Fan -- CHECK AUDIBLY FOR
OPERATION.
8. Low-Vacuum Warning Light -- CHECK ON.
9. Master Switch -- OFF.
10. Fuel Shutoff Valve - ON.
11. Door Release Pins — CHECK prior to aerobatic flight.
12. Seat Belts and Shoulder Harnesses -- CHECK condition and

security.
13. Seat Cushions -- STOW prior to aerobatic flight as required
EMPENNAGE
1. Rudder Gust Lock -- REMOVE.
2. Tail Tie-Down -- DISCONNECT.
3. Control Surfaces -- CHECK freedom of movement and security.
R1GHT WING Trailing Edge
1. Aileron -- CHECK freedom of movement and security.

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Continued………
RIGHT WING
1. Wing Tie-Down -- DISCONNECT.
2. Main Wheel Tire -- CHECK for proper inflation.
3. Fuel Line quick- Drain Valve (on bottom of fuselage near cabin
door) -- DRAIN at least a cupful of fuel (using sampler cup) to
check for water, sediment, and proper fuel grade before first fight
of day and after each refueling. If water is observed, lake further;
samples until clear and then gently rock wings and lower tail to
the ground to move any additional contaminants to the sampling
points. Take repeated samples from all drain points until all con-
tamination has been removed.
4. Fuel Tank Sump Quick-Drain Valve – DRAIN at least a cupful
of fuel (using sampler cup) to check for water, sediment and
proper fuel grade before first flight of day and after each
refueling. If water is observed, take further sampler until clear
and then gently rock wings and lower tail to the ground to move
any additional. contaminants to the sampling points. Take
repeated samples from, all drain points until all contamination
has been removed.
5. Fuel Quantity - CHECK VISUALLY for desired level.
6. Fuel Filler Cap - SECURE.
NOSE
1. Engine Oil Dipstick / Filler Cap -- CHECK oil level,
then check dipstick/filler cap SECURE- Do not operate with
less than four quarts. Fill to six quarts for extended flight.
2. Fuel Strainer Drain Knob -- PULL OUT for at least four seconds
to clear strainer of possible water and sediment before first flight
of day and after each refueling. Return drain knob full in and
check strainer drain CLOSED. If water is observed,
perform further draining at all drain points until clear and then
gently rock wings and lower tail to the ground to move any
additional contaminants to the sampling points. Take
repeated samples from all drain points until all
contamination has been, removed.
3. Propeller and Spinner -- CHECK for nicks and security.
4. Engine Cooling Air Inlets - CLEAR of obstructions.
5. Carburetor Air Filter -- CHECK for restrictions by dust or other
foreign matter.
6. Nose Wheel Strut and Tire -- CHECK for proper inflation.
7. Nose Tie-Down - DISCONNECT.
8 Static source opening (left side or fuselage) - CHECK for
stoppage.

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Continued………
LEFT WING
2. Fuel Filler Cap -- SECURE.
3. Fuel Tank Sump Quick-Drain Valve -- DRAIN at least a cupful

refueling. If water is observed, take further samples until clear
any additional contaminants to the sampling points. Take
repeated samples from all drain points until all contamination
has been removed.
4. Main Wheel Tire - CHECK for proper inflation.
LEFT WING Leading Edge

1. Pitot Tube Cover -- REMOVE and check opening for stoppage.
2. Stall Warning Opening -- CHECK for stoppage. To check the

system , place a clean handkerchief over the vent opening and
apply suction; a sound from the warning horn will confirm
system operation.
3. Fuel Tank Vent Opening - CHECK for stoppage.
4. Wing Tie Down - DISCONNECT.
5. Landing light(s) - CHECK for condition and cleanliness of lens.
LEFT WING Trailing Edge

DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
CHAPTER : 01 PERIODIC MAINTENANCE Page : 5.1.71
TOOLS & EQUIPMENTS RREQUIRED
TOOLS
1. C.S.D
2. Pliers
3. T.P.G
4. Smooth cloth
EQUIPMENTS REQUIRED
1. Fuel drain bowl

2. Water finding paste/ capsule
3. Compressed air Trolley
4. External Power supply
5. Fire extinguisher
REPLINISHMENT REQUIREMENT
1. Lubricant oil-SAE 40 OR SAE 50

2. Hydraulic fluid – Mil – H-5606
3. AVGAS .100LL(BLUE) or 100 Grade aviation fuel (Green)

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OJT MANUAL
CESSNA 150 OVERNIGHT INSPECTION - 5 Hrs
DATE :----------------------------- AF HOURS:----------------------
ITEM MECH AME

NO ITEM
1. GENERAL
001 Visually check air plane for general condition during walk
around.
002 Do refueling operation as per procedure and requirements
003 Check operation of all lights and ensure flash light is

available
2. CABIN
0101 Pilot operation hand book available in the airplane
0102 Parking brake –set
0103 Control wheel lock – engage
0104 Ignition switch – 0FF
0105 Master switch –ON
0106 Fuel quantity indicator , check quantity
0107 Avionic cooling fan-check for audibly operation
0108 Vacuum warming light check on
0109 Master switch OFF
0110 Fuel shut off valve –OFF
0111 Door release pin – insert

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OJT MANUAL
Continued…………..
ITEM MECH AME
NO ITEM
0112 Seat belts and shoulder harness- check condition and
security
0113 Seat cushion – check condition
02- EMPENNAGE
0201 Rudder gust lock- engaged
0202 Tail tie –Down – Connect
03- RIGHT WING TRAILING EDGE

0301 Aileron –check externally
04- RIGHT WING
0401 Wing tie down- Connect
0402 Main wheel Tire- check for condition
0403 Fuel line quick drain valve drain fuel to check for water
sediment and proper fuel grade before first of day and after
each refueling return drain knob full in and check strainer
drain closed
0404 Fuel quantity check visually for desired level
0405 Fuel filler cap-secure
05. ENGINE
0501 Engine oil dipstick/filler cap check oil level, then check
dipstick filler cap secure. Do not operate with less than four
quarts
0502 Fuel strainer drain knob ,pull out for about four seconds to
clear strainer of possible water and sediment before first
flight of day and after each refueling return drain knob full
in and check strainer drain closed .If water is observed the
fuel system may contain additional water, and further
draining of the system at the strainer fuel tank sump, and
fuel line drain valve must be accomplished
0503 Propeller and spinner. check for nicks and security
0504 Engine cooling air/ inlets and oil cooler –clear of
obstruction

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OJT MANUAL
ITEM MECH AME

NO ITEM
0505 Landing lights check for condition and cleanliness
0506 Carburetor Air filter –check fir registration by dust or other

from region matter.
0507 Nose wheel strut and Tire –check for condition
0508 Nose Tie down – Connect
0509 Static source opening (left side of fuselage –check for

blockage)
06. LEFT WING
0601 Fuel quantity –check visually for desired level
0603 Fuel tank sump quick drain valve Drain fuel to check for
water , sediment and proper fuel grade before each flight
0604 Main wheel Tire- check for condition
07. LEFT WING LEADING EDGE

0701 Pilot tube cover – Remove and check opening for blockage
0702 Stall warning opening –check for stoppage to check

stoppage, to check system, place a clean hand kerchief over
the vent opening and apply suction a sound from warning
horn will confirm system operation.
0703 Fuel tank vent opening check for blockage
0704 Wing Tie down – Connect
08- LEFT WING Trailing

0801 Aileron – check externally for any damage
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
TOOLS
1. C.S.D
2. Pliers
3. T.P.G
4. Smooth cloth
EQUIPMENTS REQUIRED
1. Fuel drain bowl


CESSNA 150: 50 /100 Hrs SERVICING – 15 Hrs

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OJT MANUAL
DATE :----------------------------- AF HOURS:----------------------
ITEM MECH AME

NO ITEM
GENERAL
001 Collect required tools, ground equipment and cleaning
material
002 Remove the access doors as required
101 Propeller – I
Spinner check for external damages
102 Check the propeller blades for nicks, dents and other
mechanical damages and erosion
Engine – 02
201 Engine compartment check for evidence of fuel and oil
leaks, clean the entire engine compartments, if needed
202 Engine oil check for correct grade and level, replenish if
required
203 Filler cap [check for safety and security]
204 Dipstick check for damages and security
205 Drain plugs check for safety and obstructions
206 Induction air filler, check for cleanliness and damages
207 Induction air box, air valves doors and controls check for
any external damages air valves, door and controls for
proper operation.
208 Cold and hot air hoses, check for condition and any leak
ensure that there is no kink on the hose length
209 Engine baffles check for any damages and inflation

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OJT MANUAL
ITEM MECH AME

NO ITEM
21Check crank case oil sump, accessory section and front
0 crank shaft seal for damages, oil and gas leaks, burning
marks,.
211 Hoses, metal lines and fittings check for damages and
correct installation and for leaks.
212 Intake and exhaust system check for any leak, over heating
or discoloration
213 Vacuum pump. Check for mountings security , pipelines
connection for damages, sign of leaks and condition
214 Vacuum relief valve filter
215 Engine controls and linkage check for condition, operate

the control, see for smooth operations and no rubbings
sound is heard
216 Starter solenoid and electrical connection. Check for
connection condition and operations.
217 Alternator and electrical connection. Check for safety and
security
218 Voltage regulator mounting and electrical leads check for
safety and security and leads for condition
219 Magnetos (externally) and electrical connection. Check for
safety of mounting condition.
220 Magneto timings. Check magnetos to engine timings.
221 Carburetor and drain plug, Check for conditions
222 Engine cowling. Check for damages, replace missing or

defective fasteners
Fuel System – 03
301 Fuel strainer, drain valve and control, check for leak and
condition
302 Fuel strainer screen and bowl: clean strainers, check bowl
for proper installation, leak and security
Fuel tank vents check for blockage, caps for safety and
303 security , placard for damages
304 Fuel tanks check for leaks or damages, sumps drain for
proper operation and leak, fuel drain line check for leak

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ITEM MECH AME

NO ITEM
307 Engine primer, check for operation.
Landing gear - 04
401 Main gear wheel and fairing, check for condition and
security of attachments
402 Nose gear wheel, torque links steering rods boots and
fairing for condition ,correctness of installation and security
403 Wheel bearing check for smoothness and condition
404 Nose gear strut and shimmy damper for proper attachment
and proper operation
405 Tires: checks for condition, weather cracking and proper
inflation.
406 Brake fluid lines and hoses, lining and disc brake assembly
and master cylinder, Check for leaks, damages and proper
operation of brakes
407 Check parking brake system for correct operation
408 Main gear springs. Check for condition, corrosion and

security
Air Frame – 05
501 Aircraft exterior check for condition, sign of corrosion
damages paint………..
502 Aircraft structure check for any damage, loose rivet,
corrosion, cleaning of all drain holes.
503 Windows, wind shield door and seals, check for security
and proper sealing
504 Seats belts and shoulder harness. Check for attachment and
condition
505 Seat stops, seat rails, upholstery, structure and mounting.
Check for condition, lubricate and operate to ensure seats
are operating smoothly.
506 Control bearings, sprocket, pulley cables, chains and turn
buckle check for condition, freedom of movement and
correctness of tension

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OJT MANUAL
ITEM MECH AME
NO ITEM
507 Control lock, control wheel mechanism check for
condition, freedom of operation and lubricate as necessary
508 Instrument and marking. Check for condition of range
markings and condition of instruments.
509 Gyros central air filter . Check for condition and clean
510 Magnetic compass compensation check and correct
511 Check instrument wiring and plumbing for condition and

damages and correct as required
512 Instrument panel for condition shock mounts for damage
and condition, ground strap check for condition , covers are
secure decal labeling damage, replace as required
513 Defrosting, heating system and ventilating system and
control, check for cleanliness , freedom of operation and
proper operation
514 Cabin upholstery; trim sun vision and ash tags. Check for
condition
515 Area beneath floor lines, hose wires, and control cable
check for wear, damage and freedom of movement, and
sign of any leak.
516 Lights switches circuit breakers fuses, and spare fuse,
check for pressure, operation and condition.
517 Exterior light check for condition and operation
518 Pilot static system, check no damage, no blockage.
519 Stall warning system. Check for condition, blockage and

operation,.
520 Radios, radio controls, avionics and flight instrument.
Check for installation and operation.
521 Antennas and cables. Check for conditions security and
cable routing and cleatings.
522 Battery for condition and charge, check capacitor, battery
box for condition, battery cable for condition and
continuity
523 Emergency locater transmitter, check battery voltage, and
date due.

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OJT MANUAL
ITE MECA AME
M ITEM
NO
Control system - 6
600 In addition to the items listed below, always check for
correct direction of movement, correct travel and correct
cable tension.
601 Cables, terminal pulleys, pulley bracket cable guards, turn
buckle and fair lead check for condition, alignment routing
security wear and tension
602 Chains terminals, sprockets and chain guards. Check for
condition correct assembly, corrosion free movement.
603 Trim control wheels indicators actuator bungee. Check for
condition, operation and proper installation
604 Travel stop check for correctness of adjustment and
condition
605 Decal cabling check for condition
606 Flap control switch, flap roller and tracks, flap indicator
check for proper operation, condition freedom of movement,
lubricate as required.
607 Flap motor, transmission limit switch structure, linkage, Bell
cranks etc. Check for operation, security of attachments.
608 Elevator and trim tab hinges, lips and control rods, check
for attachment, condition and correct operation
609 Elevator trim tab for free play inspection
610 Elevator trim and tab actuator lubrication
611 Rudder peddle assemblies and linkage for condition and
proper operation
612 Skins (external) of control surface and tab check for damage
, paint condition and corrosion
613 Internal structure of control surface , check for condition
614 Balance weight of control, surface , Check for security and
condition
615 Aileron , hinges and push pull rods, check for attachment,
safety and security and proper operation
616 Vertical fin attachment bracket. Check for condition, and
security
Date:……………….. Signature…………………
AME……………………..

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OJT MANUAL
REQUIRED TOOLS AND GROUND EQUIPMENTS

1 Common screw driver 12” – one
2 Common screw driver 6” - one
3 Pliers side cut - one
4 Wire twister - one
5 Steel rod - one
6 Inclinometer - one
7 Magnifying glass - one
8 Portable inspection mirror - one
9 Nose pliers - one
10 Mallet - one
11 Hammer plastic - one
12 Ring spanner set(9No) - one
13 Set spanner set(9 No) - one
14 Box spanner with Allen key set - one
15 Socket set - one
16 C’ spanner - one
17 Tension meter - one
18 TPG - one
19 Torque wrenches - one
Ground equipment
20 L.P compressor - one
21 Fire extinguisher - one
22 Step ladders - two
23 Drip tray - one
24 Replenishing cans - one

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OJT MANUAL
PROCEDURE SHEET NO: - RIA/PS/MECH/MER/01 Group Size: 03
MERLIN 2B: MOORING – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
4. Tie down the rope on each of the two mooring eyes

provided one on each wing and to the ground.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
MERLIN 2B: MOORING EQUIPMENT AND TOOLS
1. Two pieces of ropes
2. Six chocks

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OJT MANUAL
MERLIN 2B: JACKING – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
JACKING UP
Note:- Before jacking up of the airplane the battery switch
must be put off.
1 Select a hard and level ground. Preferably inside the
Hanger.
2 Check up the serviceability of jacks (Hydraulic type
capacity at least 4000 lbs)
3 Position 03 jacks under Neath the jacking points (Two pads
on the center section rear spar inboard of each nacelle and
one near the aft edge of the nose wheel well to the left of
the fuselage control line.
4 Position one man on each jack and a supervisor in front of
aircraft.
5 Confirm and take clearance from other tradesman working
before jacking up.
6 Observe the clearance from all side and raise all the three
jacks .
7 The jacks should be raised to level simultaneously so as to
clear the wheels from the ground and put on the mechanical
lock and ensure it is locked.
JACKING DOWN
Note:- Confirm that sufficient clearance is taken for

lowering of aircraft and remove all equipments objects
from the bottom of aircraft and from its surrounding.
1 Release the mechanical locks from all three jacks.

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OJT MANUAL
Continued……..
2 Lower all the three jacks simultaneously by opening the

release valve.
3. Allow the aircraft wheels to touch the ground all at a time.
Collapse the jacks so as to clear them from underneath the

4. aircraft.
5 Reposition the chocks on front and aft of the wheels.
6 Position back the jacks to ground equipment bay.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2 B: JACKING EQUIPMENT AND TOOLS
1. 03 hydraulic jacks with mechanical locks and having a capacity of at least

4000 Lbs.

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OJT MANUAL
OJT MANUAL
MERLIN 2B: TOWING THE AIRCRAFT – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. With the tow bar connected to the towing lugs on the lower
toque knee fitting of the nose strut.
2. The aircraft can be steered with the nose wheel when
towing manually.
3. A person who is conversant to operate brakes should be
positioned in the pilot seat to operate the brakes in the
event of any emergency.
4. Observe the turn line marked on the nose gear strut to
prevent damage to nose gear.
5. Do not push on the propeller or control surfaces.
6. Do not pull down on the horizontal stabilizer to raise the

nose wheel off the ground.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
MERLIN 2B: TOWING THE AIRCRAFT

EQUIPMENT AND TOOLS
Steering arm

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OJT MANUAL
PROCEDURE SHEET NO:- RIA/PS/MECH/MER/04 Group Size: 04
MERLIN 2B: REFUELING & DEFUELING PRECAUTIONS AND

PROCEDURE – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Be sure that only the correct grade of fuel is put into an aircraft.
Remember that aviation gasoline comes in various grades and the
wrong grade can cause severe damage to the engine. Turbine fuel in
a reciprocating engine can cause severe detonation and engine
failure, and the improper use of aviation gasoline in a turbine engine
can also be harmful.
2. Be sure that the fuel truck, or Servicer, is properly bonded to the
aircraft and the fuel nozzle is bonded to the structure before the
cover is taken from the fuel tank.
3. Wipe up spilled fuel or flood it with water. Do not sweep spilled
fuel with a dry broom.
4. Be sure that there are no open fires in the vicinity of the fueling or
defueling operations.
5. Be sure that fire extinguishers suitable for a Class B fire are
available. Either CO2 or dry-powder units are generally used.
6. Protect the aircraft structure from damage from the fuel hose and
from the nozzle.
7. Be sure that the radio or radar are not used during fueling or
defueling, and that no electrical equipment is turned on or off,
except for the equipment needed for the fueling operation.
8. When defueling, be sure that the fuel is not con-laminated if it is to
be used again.
9. Be sure that the filters in the tank truck or servicer remove all traces
of water and contamination and that the fuel pumped into an aircraft
is bright and clear.
10. If a biocidal additive is required, be sure that it is mixed with the
fuel in the proper concentration.

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OJT MANUAL
Continued……….
11. If the aircraft is being fueled in the rain, be sure that the tank
opening is covered to exclude water from the tank.
12. Be sure that dust covers and caps are placed over the end of the fuel
nozzles and any open fuel lines when they are not in use.
13. Drive the tank truck parallel to the wing of the aircraft and be sure
that the parking brake is set so the truck cannot roll into an aircraft.
14. If any fuel is spilled on to your body, wash it off with soap and
water as soon as possible. Do not wear any clothing on which fuel
has been spilled.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
MERLIN 2B: BLEEDING OF BRAKE SYSTEM – 5hrs
DATE :----------------------------- AF HOURS:----------------------
O JOB MECH AME/APPRD
PERSON
1. There are two methods to carry out the bleedings (i) Back
bleeding (ii) straight bleeding
2. The efficient method is back bleeding is pressure pot.
3. Place a container under the reservoir bent line the aft nose
wheel bay.
4. Connect the pressure pot to the wheel cylinder bleeder
valve.
5. Maintain a pressure of appx. 15 pounds on the pressure pot
& open the bleeder valve.
6. Bleed the pilots break until sponginess removed.( a free
flow on the vent line) when the pilots break functions
satisfactorily close the valve on the pressure pot and pump
the co-pilot break pedal to change the shuttle valve
position. So that fluid will be routed through the co-pilot
break system.
7. Bleed the co-pilot breaks the same manner as the pilot
breaks where bled.
8. Close the bleeder valve repeat the process for the other
wheel.
9. Fill the hydraulic reservoir to within one inch of the top.
10. Check the break operation, pedal pressure should be equal

on both breaks.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
MERLIN 2B: BLEEDING OF BRAKE SYSTEM
EQUIPMENT AND TOOLS
01. Common screw driver-8’’

03. Philips screw driver-8’’
05. Pliers s/c
06. Cutter
07. Locking wire twister
08. Snap on combination 7/16’’
12. Snap on combination ¾’’
13. Toque wrench 20-100 inch pounds
14. Locking wire
15. Muslin cloth

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OJT MANUAL
OJT MANUAL
MERLIN 2B: CHARGING THE NOSE & MAIN LANDING GEAR
SHOCK ABSORBERS – 5 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. To check the fluid level in the landing gear shock absorbs.
2. Jack up the aircraft
3. Release the air pressure entirely before removing the value
adapter.
4. Remove filler valve adapter.
5. With strut fully compressed position the fluid level should
be at the bottom of the valve stalk pipe.
6. If the level is low, add MIL –H-5606 fluid to reach the
stalk pipe.
7. Again compress the strut to expel the air to eliminate any
trapped air.
8. Then add more fluid as necessary
9. Install the valve adapter and lock it
10. Inflate the nose strut till the piston is extended 5 inch
(condition aircraft empty except for fuel and oil)
11. Inflate the main strut until the piston is extended 4 inch.
12. Lower the aircraft.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: CHARGING THE NOSE & MAIN LANDING GEAR

SHOCK ABSORBERS EQUIPMENT AND TOOLS

05. Pliers s/c
06. Cutter
14. Locking wire
15. Muslin cloth

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OJT MANUAL
OJT MANUAL
MERLIN 2B: FLAP REMOVAL AND INSTALLATION – 10 Hrs

DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Partially extend the flap.
2. Disconnect the actuator by removing the bolt and nut

attaching actuator and flap.
3. Remove attachment bolt of the flaps from the rollers,
access to the upper rollers is through the hole on either side
of the flap track slots.
4. Remove the flap from the aircraft and place it carefully.
INSTALLATION
1. While installing the flap be sure the flap roller flanges are
facing each other i.e. to the center of the flap.
2. Grease the bearing properly.
3. Engage the bolts which attach the flap to the flap track
slots.
4. Connect the flap actuator rod to the flap assembly.
5. Operate the flap and check the correct movement.
Caution: When the right inboard flap is removed, flap

control switch must be in the “OFF” position or the battery
master switch turned “OFF” and pull the flap C.B out. Do
not operate the flaps with the flap removed as the limit
switches will be inoperative and can result serious damage
to the flaps, wings and actuating system.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: FLAP REMOVAL AND INSTALLATION

EQUIPMENT AND TOOLS

03. Pliers s/c
04. Cutter
05. Spanner on combination 7/16’’
06. Spanner on combination 3/8’’
07. Spanner socket 3/8”
08. Ratchet handle one
09. Cotter pin 1/16”
10. Muslin cloth
11. Grease for general purpose

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OJT MANUAL
OJT MANUAL
MERLIN 2B: COCKPIT SEAT REMOVAL & INSTALLATION – 5 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Remove the seat stops the end of each track.
2. Release the fore and aft adjustment lock.
3. Move the seat forward until it clears the mounting track.
4. The seats will not clear the pilots compartment door in the
upright positions. To remove the seat from the
compartment, place the armrests up, turn the seat arm its
side and remove the seat.
INSTALLATION
1. Place the seat in position and align the seat guides with the
mounting tracks.
2. Release the force and aft adjustment lock and slide the seat
into the desired position. Engage the fore and aft lock
making certain it holds the seat securely in place.
3. Replace the seat stops on the end of each track.
4. Attach the seat bungee.
DATE :----------------- SIGNATURE:---------------------------
AME NO:------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: COCKPIT SEAT REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

05. Pliers s/c
06. Cutter
14. Locking wire
15. Muslin cloth

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OJT MANUAL
OJT MANUAL
MERLIN 2B: MAIN LANDING GEAR WHEEL REMOVAL &

DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Make the entry in the aircraft servicing record as outer

cover worm out.
2. Jack up the aircraft. When jacking individuals wheels a
hydraulic type jack with a capacity of at least 4000 lbs
should be used. Place chocks on nose and other main wheel
fore and aft.
3. Disconnect the brake fluid lines.
4. Remove the brake assembly.
5. Remove the dust cap after removing the circlip.
6. Extract split pin securing wheel nut.
7. By using special spanner, remove the wheel nut.
8. Remove the wheel from assembly.
INSTALLATION
1. Engage the wheel assembly along with wheel brake

pressure plate in position
2. Mount the brake assembly to the strut by engaging and
tightening the mounting bolts with proper torque.
3. Connect the hydraulic lines to the brake unit, Bleed the
brake system.

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OJT MANUAL
OJT MANUAL
Continued……
4. Tighten the wheel nut.
5. Align the cotter pin hole by applying proper torque on

wheel nut. Insert cotter pin and place the dust cap.
6. Secure the dust cap with external circlip.
7. Lower the aircraft from jack after having observed all the
lay down procedure.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CHAPTER : 01 PROCEDURE SHEET, MECHANICAL Page: 5.1.101

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OJT MANUAL
MERLIN 2B: MAIN LANDING GEAR WHEEL REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

05. Pliers s/c
06. Cutter
08. Spanner combination 7/16’’
12. Spanner combination ¾’’
13. Spanner 32mm
14. Locking wire
15. Muslin cloth

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO:- RIA/PS/MECH/MER/10 Group Size: 03
MERLIN 2B: ELEVATOR REMOVAL AND INSTALLATION – 10hrs
DATE :----------------------------- AF HOURS:------------------------
SL SIGN SIGNATURE
NO JOB ATURE AME/APPRD
MECH PERSON
REMOVAL
1. Remove the fairing between the elevator and the fuselage.
2. Remove the four bolt from the elevator torque tube caps
outside of fuselage
3. Disconnect tab push rod at the tab.
4. Remove two bolt at each of the three elevator hinge points.
5. Remove elevator
INSTALLATION
1. Position the elevator.

2. Fit the two bolts at the hinges
3. Connect the tab push rod
4. Connect elevator torque tube

5. Fit the fairing.
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: ELEVATOR REMOVAL AND INSTALLATION
EQUIPMENT AND TOOLS

05. Pliers s/c
06. Cutter
14. Locking wire
15. Muslin cloth
MERLIN 2B: AILERON REMOVAL & INSTALLATION – 10 Hrs

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OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:-----------------------
PERSON
REMOVAL
1. Disconnect the right aileron tab push rod at the rear span
access is through the hole in the skin below. .
2. Disconnect the left aileron trim tab push rod at the actuator
a head of rear span..
3. Remove the four screws securing hinge brackets at each
hinges.
4. Support and pull the aileron out.
INSTALLATION
1. Position the aileron; and connect the tab push rod..
2. Fill – all screws securing hinge brackets..
3. Operate the aileron and check free movement.
5. Close the access panels &check aileron travel and

alignment
DATE :----------------- SIGNATURE:------------------------

-
AME NO:-----------------------------
MERLIN 2B: AILERON REMOVAL AND INSTALLATION

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL

02. Common screw driver 10’’
03. Pliers s/c
04. Cutter
05 .open end spanner – 10mm- 2

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OJT MANUAL
CHAPTER : 01 PROCEDURE SHEET Page: 5.1.106
PROCEDURE SHEET NO: - RIA/PS/MECH/MER: 12 Group Size: 03
MERLIN 2B: BRAKE MASTER CYLINDER REMOVAL &

DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Disconnect and plug the brake lines at the cylinder.
2. Remove the master cylinder attaching bolt at the forward

and aft end of the master cylinder.
3. Remove the unit.
Inspection: Check externally any damage on the surfaces.

Change the seals in case found deformed or deteriorated.
Give temporary hydraulic connection. Check for any
seepage or leak of hydraulic fluid.
INSTALLATION
1. Fit the attachment bolts on both the end. Connect the brake
line.
2. Carry out brake bleeding as per PS/No.
RIA/PS/MECH/MER/05
3. Carry out the same operation on all the four BMC.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: BRAKE MASTER CYLINDER REMOVAL &


05. Pliers s/c
06. Cutter
14. Locking wire
15. Muslin cloth

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OJT MANUAL
CHAPTER : 01 PROCEDURE SHEET Page:5.1.108
PROCEDURE SHEET NO: - RIA/PS/MECH/MER: 13 Group Size - 02
MERLIN 2B: SHUTTLE VALVE OPERATION –05Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Operate the brake from pilot seat as well as copilot seat.
Ensure prompt operation. This will be correct functioning
of the shuttle valve.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: SHUTTLE VALVE OPERATION

EQUIPMENT AND TOOLS

05. Pliers s/c
06. Cutter
14. Locking wire
15. Muslin cloth
CHAPTER : 01 PROCEDURE SHEET Page:5.1.110

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OJT MANUAL
PROCEDURE SHEET NO: - RIA/PS/MECH/MER: 14 Group Size - 03
MERLIN 2B: BRAKE UNIT REMOVAL & INSTALLATION – 5 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Remove the brake hydraulic lines.
2. Remove the brake assembly attachment bolt from hub
assembly.
3. Remove the wheel assembly.
4. Check of the brake disc.
5. Inspect for its wear limit. If the brake lining worn out
beyond the allowable limit. Then replace.
INSTALLATION
1. After having inspected and cleaned properly engage the
wheel assembly.
2. Tighten the attachment bolts in the brake assembly with
hub assembly.
3. Do the wire locking on the connectors. Bleed the system as
per PS/ No. RIA/PS/MECH/MER/05
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: BRAKE UNIT REMOVAL & INSTALLATION
EQUIPMENT AND TOOLS

05. Pliers s/c
06. Cutter
14. Locking wire
15. Muslin cloth
PROCEDURE SHEET NO :- RIA/PS/MECH/MER/15 Group Size - 02
MERLIN 2B: OIL COOLER REMOVAL & INSTALLATION – 10 Hrs

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OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Drain the oil from the cooler and oil lines
2. Remove the screws securing the duel to the cooler and the
engine oil and remove the assembly
3. Remove the fire detector bracket
4. Disconnect the inlet and outlet lines from the cooler
5. Remove the remaining cooler moving screws and remove
the cooler from the aircraft.
INSTALLATION
1. Connect the oil cooler to the outlet air duet
Note: The oil cooler must be installed with the outlet port
(the port with the temperature control valve installed) to the
inboard side of the nacelle
2 Re-install the fire detector.
3 Connect the inlet and outlet lines to their proper fittings.
4 Position the inlet air duet and cowling assembly and install
the securing screws
5 Motor the engine over with the starter only (No ignition)
long enough to obtain an engine oil pressure reading.
CAUTION
Do not exceed the starter motor operating limits
(2 minutes)
6 Check the engine for oil leaks and service the oil system
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: OIL COOLER REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

05. Pliers s/c
06. Diagonal cutting plier
07. Safety wire twisting tool
08. Open end wrench 11/16’’
10. Open end wrench 1’’
12. Locking wire
13. Muslin cloth

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: - RIA/PS/MECH/MER/16 Group Size - 02
MERLIN 2B: FUEL FILTER REMOVAL & INSTALLATION – 10 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
2. Remove filter housing cap from fuel pump assembly.
3. Remove washer from fuel pump assembly.
4. Remove clip, filter cup, spring, and fuel filter from filter
housing cap.
5. Remove plug from filter housing cap.
6. Remove packings.
INSTALLATION
1. Install plug, with new packing, into filter cap. Tighten plug
to 25 to 30 inch-pounds torque and lock with wire.
2. Install washer into filter cup.
3. Install new packing onto fuel filter and insert fuel filter into
filter cup with open end downward.
4. Install spring into filter cup with small end up.
5. Install filter housing cap over filter cup and secure with
clip.
6. Apply the thin coat of lubricating compound to treads of
filter housing cap with new packing. Tighten filter housing
cap to 15 to 20 inch pounds torque and lock with wire
7. Install the engine cowling.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: FUEL FILTER REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

03. Pliers s/c
06. Open end wrench 9/16”
07. Open end wrench ¾’’
09. Locking wire
10. Muslin cloth

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL ,INSPECTIN& INSTALLATION OF STARTER GENERATOR

– 10 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Open the engine cowling
2. Remove the Electrical connections from generator
3. Unscrew the jubilee clip and remove the cooling hose from
the generator end.
3. Cut the locking wire , loosen the lock nut ,and carefully
slide the generator and take it out.
3. Open the inspection cover of starter generator
4. Turn the armature and check for any un usual noise
5. Remove the graphite brushes from its holder and measure
the brush length. If less replace the whole set.
6. Inspect the commutator assy: for any damage, clean the
generator with compressed air.
7. Re-fit the brushes and check the terminal blocks for its
condition.
8. Close the gen; inspection cover.
9. Clean the generator externally.
10. Install the generator, connect the electrical connections and
fit back the cooling hose
11. Close the engine cowling
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
ECTION : 05 APPENDIX

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL ,INSPECTIN& INSTALLATION OF STARTER GENERATOR

EQUIPMENT AND TOOLS

03. Pliers s/c
06. Socket 11 mm
07. Socket ¼”
08. Straight extension
10. Locking wire
11. Muslin cloth

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OJT MANUAL
OJT MANUAL
INTENTIONALLY KEPT BLANK

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OJT MANUAL
OJT MANUAL
MERLIN 2B: OIL FILTER AND ADAPTER REMOVAL &

DATE :----------------------------- AF HOURS:----------------------
PERSON
RemREMOVE OIL FILTER
1. (Pre SB 79-0010) Remove bushing, cap and oil filter

element. If required, inspect oil filter for contamination.
2. (Post SB 79-0010) Remove cap, retainer, washer and oil
filter element. If required, inspect oil filter for
contamination in accordance with 72-00-00,
INSPECTION/CHECK
INSTALL OIL FILTER
1. Note: Lightly coat new packing’s with clean engine oil or

lubricant (OS-124 or Santovac 5) prior to installation.
2. Install washer (80) on nipple in adapter
Caution: FAILURE TO PROPERLY INSTALL PACKING
(85) INTO GROOVE IN ADAPTER CAN RESULT IN
LOSS OF ENGINE OIL.
3. Install packing (85) into groove in adapter.
4. Ensure packing (70) is installed in filter element.
5. (Pre SB 79-0010) Install oil filter element, with packing

(70), into adapter. Install cap over oil filter element and
secure with bushing. Tighten bushing (5) hand tight and
lock wire.
6. (Post SB 79-0010) Install washer (35) in adapter.
7. (Post SB 79-0010) Secure filter, with packing (70), in cap

with retainer. Install cap with filter and retainer in to
adapter Tighten cap (20) hand tight and lock wire.

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OJT MANUAL
Continued……….
REMOVE OIL FILTER ADAPTER
1. Remove oil filter element in accordance with paragraph A.
2. (Pre SB 72-0012) Remove swivel and packing.
3. Remove nuts, washers and remove adapter or plate and

adapter
INSTALL OIL FILTER ADAPTER
1. Lightly coat new packing’s with clean engine oil or

lubricant (OS-124 or Santova 5) prior to installation.
2. Install new packing’s onto adapter and swivel.
Note: Adapter must be tightened evenly to prevent war
page and damage that may cause leakage.
3. Install adapter with new packing’s, onto accessory drive
housing and secure with washers and nuts. Tighten nuts
(115,120) to a torque value of 50 inch-pounds.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: OIL FILTER AND ADAPTER REMOVAL & INSTALLATION
EQUIPMENT AND TOOLS

05. Pliers s/c
06. Diagonal cutting pliers
07. Aluminum drift
08. Hammer
10. Locking wire
11. Muslin cloth

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OJT MANUAL
OJT MANUAL
MERLIN 2B: PROPELLER GREASING – 10 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Remove spinner screws
2. Remove spinner
3. Remove one grease nipple of out of two from each braded

root.
4. Refill the grease gun with grease
5. Clean the fixed nipple and place the charging point of the
grease gun over it and pump.
6. Continue charging grease till the fresh grease starts coming
out of the open end.
7. Wipe off and clean the propeller
8. Refit the opened nipple
9. Refit the propeller spinner
10. Tighten the screws
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
MERLIN 2B: PROPELLER GREASING

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL
1. PSD – 8” - one
2. Open end wrench ¼ “
3. Grease gun - 1
4. Aero shall grease
5. Muslin cloth

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OJT MANUAL
OJT MANUAL
MERLIN 2B: FUEL MANIFOLD AND NOZZLE ASSEMBLIES – 20 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL

2. Remove cooling jacket from combustion chamber.
3. Disconnect primary fuel manifold and nozzle assemblies

from flow divider and drain valve.
4. Remove bolt securing primary fuel manifold and nozzle
assemblies to plenum assembly. Remove mounts, if
applicable. Remove clamps, then remove fuel nozzle and
manifold assemblies. Drain any residual fuel. Remove
grommets if applicable.
5. Remove primary fuel nozzle shrouds and nozzle gaskets
using care not to damage shroud mating flange or plenum
boss.
INSTALLATION
1. Install gasket and shrouds on mount pads of plenum
assembly.
Note: Ensure indexing pins on primary nozzles align with
mating holes in shrouds when primary manifold and nozzle
assembly is installed.
2. Position primary manifold and nozzle assembly around
engine and install fuel nozzle in the shroud.
3. Install mount on to primary manifold and nozzle assembly.
4. Install bolts securing primary manifold and nozzle
assembly to engine and lock with wire.
5. Connect ends of manifold assembly to flow divider and
drain valve. Tighten tube or hose nut.

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OJT MANUAL
Continued………
6. Install the cooling jacket on combustion chamber.
7. Install the engine cowling.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: FUEL MANIFOLD AND NOZZLE ASSEMBLIES

EQUIPMENT AND TOOLS

05. Pliers s/c
10. Locking wire
11. Muslin cloth

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OJT MANUAL
OJT MANUAL
MERLIN 2B: FUEL SHUTOFF VALVE AND PLUMBING REMOVAL &

DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Remove engine cowlings
2. Disconnect electrical connector and disconnect attached
aircraft linkage.
3. Remove actuating arm (manual override).
4. Remove fuel inlet and outlet pipe connections from fuel
shutoff valve assembly.
5. Remove linkage support bracket assembly.
6. Remove fuel shutoff valve attachment bolts from bracket,
attached to accessory drive housing assembly.
7. Remove fuel shutoff valve from bracket.
INSTALLATION
1. Ensure that fuel shutoff valve is in AUTO position. Fuel
shutoff valve is in AUTO position when index mark on end
of actuating shaft is aligned with fuel shutoff valve
centerline in relation with valve cover.
2. Install washers (maximum of two) and spacer between fuel
shutoff valve and bracket.
3. Install fuel shutoff valve onto bracket. Install washers, bolts
and nut.
4. Install actuating arm (manual override) on shaft extension
of fuel shutoff valve secure with washers, bolt, and nut.
Tighten nut to a torque value of 12 inch- pound. Lock wire
bolt to actuating arm.

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OJT MANUAL
Continued--------
5. Install linkage support bracket onto accessory drive

housing assembly and secure. Tighten nut to a torque value
of 50 inch-pounds. Install bearing, washer, and screw.
6. Install tube assembly between elbow or fitting in fuel
shutoff valve and fuel flow divider.
7. Install tube assembly onto union in bottom of fuel shutoff
valve.
8. Connect electrical connector in accordance with Aircraft
Maintenance Manual.
9. Install engine cowlings.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL


03. Pliers s/c
11. Locking wire
12. Muslin cloth

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OJT MANUAL
OJT MANUAL
MERLIN 2B: ENGINE RIGGING – 20 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
AIRCRAFT CONTROLS CHECK
Note: Space next to description should be marked OK if
check is satisfactory.
1. Propeller governor stops High (Contact in Reverse)
L_____________ R____________ , Low (Contact in
Cruise) L_____________ R____________ , Under speed
governor High L_____________ R____________ , Low
L_____________ R____________
2. Reset angle 35 – 38o
L_____________ R____________
3. Release MFV linkage and check zero degree position.
L_____________ R____________
4. Pitch control rig pin drops in reverse slot and check zero
degree position. L_____________ R____________
5. Reconnect MFV linkage L______ R____________
6. Power lever full reverse in pitch servo and pointer at zero
degree position. L _____ R__________
7. Power lever maximum forward, pitch servo and MFV
maximum position. Pointer at 100 + 1o
8. Power lever smartly to flight idle stop. Pitch servo rig pins
smooth fit. Pointers at 40° position.
9. USG reset angle L________ R________ (13 - 15°)
10. Engine speed levers to feather position. Insure fuel shutoff
moves to manual off prior to actuation of feather valve. At
full lever travel, feather valve should be at maximum
travel.
DATE :----------------- SIGNATURE:---------------------------

AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
TOOLS AND EQUIPMENT REQUIREMENTS
TOOLS:
2. Pliers side cutter – one
3. Screw driver common – one
4. Screw driver Philips – one
5. Inspection Lamp

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OJT MANUAL
CHAPTER : 01 PERIODIC MAINTENANCE Page :5.1.132
PROCEDURE SHEET NO: RIA/PS/MECH/MERL: 23 Group Size - 02
MERLIN 2B: PREFLIGHT INSPECTION – 5 Hrs
DATE :----------------------------- AF HOURS:-----------------------
SIGNATURE SIGNATURE
NO PERSON
1. Check static vents for obstruction.
2. Check nose wheel tire for condition and pressure
3. Check nose wheel well and landing gear for condition.
4. Check Nose oleo-leg for extension (5” minimum)
5. Check windshield for obstruction and cleanliness.
6. Inspect the right propeller blade for any damage and free
for rotation, in the direction of rotation.
7. Remove right engine air intake blanking, check for
condition and FOD.
8. Checks the right engine oil level, if required replenish.
9. Check the right engine cowlings for loose rivet and
attachment fastener.
10. Check for any fuel and oil leak externally in right engine.
11. Check right main wheel and tire for condition and pressure
12. Remove the right engine exhaust blanking and check for
any damage.
13. Check right main landing gear, brakes and wheel well for
condition
14. Check the right MLG for extension (4” minimum)
15. Check for loose rivets, dent & damage in fuselage & wing
16. Check the control surfaces for any damage and obstruction
for free movement.
17. Drain the fuel from wing tank drain, check for water
contamination.
18. Check left main wheel and tire for condition and pressure
19. Inspect the left propeller blade for any damage and free for
rotation, in the direction of rotation.

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OJT MANUAL
Continued…………
20. Remove left engine air intake blanking, check for condition
and FOD.
21. Checks the left engine oil level, if required replenish it.
22. Remove the left engine exhaust blanking and check for any
damage.
23. Checks the hydraulic reservoir fluid level, if required
replenish.
24. Ensure the emergency exit window is properly secured.
25. Check oxygen system.
26. Check battery condition and voltage.
27. Check landing lamps for its condition.
28. Check wing icing lamps for its condition.
29. Check navigation lights for its condition.
30. Inspect external power plug and its cover.
31. Inspect the condition of switches and knobs in cockpit.
32. Check the circuit breakers.
33. Check all annunciator lamps for serviceability.
34. Ensure proper operation of dimmer knobs.
35. Check the operation of static inverter.
36. Check for proper installation and operation of flight director
37. Check for proper installation& operation of compass system
38. Check for proper installation and operation of auto pilot.
39. Check the transponder for proper installation.
40. Check the functioning of glide slope.
41. Check the weather radar for proper installation.
42. Check the functioning of audio system.
43. Check the marker Receiver for proper installation.
44. Check the radio altimeter for proper installation.
45. Check the functioning of No.2 NAV
46. Check the functioning of No.1 ADF
47. Check the functioning of No.2 VHF
48. Ensure all switches are in OFF position
49. Ensure all switches are in OFF position
DATE: ----------------- SIGNATURE: ------------------
AME NO: ------------------------

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OJT MANUAL
OJT MANUAL
TOOLS:
4. Inspection Lamp
5. Steel ruler
6. T.P.G – one
GROUND EQUIPMENTS:
1. Step ladder – one
2. Fuel sample jar – one
3. Compressed air trolley
CONSUMABLES
1. Hydraulic fluid
2. Engine oil
3. Water finding capsule

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OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/MECH/MER: 24 Group Size - 02
MERLIN 2B: OVERNIGHT INSPECTION SCHEDULE – 10 Hrs
DATE :----------------------------- AF HOURS:-----------------------
SIGNATURE SIGNATURE
NO PERSON
1. Refuel the aircraft as required
2. Check fuel tank filler cap for condition and security
3. Check nose wheel tire and wheel for condition.
4. Check nose wheel well and gear for condition.
5. Check right engine air intake for condition and FOD. Install
the engine air intake cover.
6. Check for any fuel and oil leak externally in right engine.
7. Check right engine turbine and exhaust area for condition
and obstruction. Install the exhaust cover.
8. Check right main wheel and tire for condition
9. Check right main gear, brakes and wheel well for condition
10. Check for any damage in fuselage & wing
11. Check left main wheel and tire for condition
12. Check left main gear, brakes and wheel well for condition
13. Check left engine air intake for condition and FOD. Install
the engine air intake cover.
14. Check for any fuel and oil leak externally in left engine.
15. Check left engine turbine and exhaust area for condition
and obstruction. Install the exhaust cover.
16. Ensure pilot heating switch is in OFF position
17. Ensure battery master switch and all other circuit control
switches are in OFF position
18. Install the pilot cover
19. Complete documentation
DATE: ----------------- SIGNATURE: -----------------
AME NO: -----------------------

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OJT MANUAL
OJT MANUAL
TOOLS:
4. Inspection Lamp
GROUND EQUIPMENTS:
2. Refueling apparatus

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OJT MANUAL
OJT MANUAL
MERLIN 2B - 50 HRS SERVICING – 15Hrs
DATE :----------------------------- AF HOURS:-----------------------
CHECK À’
ITEM DESCRIPTION MECH INSP
CENTER SECTION
01. Remove inspection doors inboard of engine nacelles.
02. Remove wing to fuselage fairing.
03. Check skin for corrosion, dents, cracks, loose rivets-and general
condition.
04. Check internal structure for cracks, loose or missing rivets,
distortion and cleanliness.
05. Check fuel cell access doors for fit and evidence of fuel leakage.
06. Check flap skin and structure for cracks, dents, loose or missing
rivets.
07. Check flap hinges, tracks, rollers, cables, and fairleads for
condition, wear and proper safety.
08. Check landing gear .
09. Check landing gear torque tubes and joints for condition and
security.
10. Check landing gear actuator
11. Check all fuel, oil and airlines for condition, leaks and security.
12. Check condition of de-icier lines and distributor valve.
13. Check condition and security of air condition condenser plumbing
check for Freon leakage.
14. Reinstall all access doors and wing to fuselage fairing.
POWER PLANT LH
15. Remove all cowling. Clean and inspect for general condition,
cracks, damage, or delamination.
16. Check engine oil filter. Clean and replace as per P & WA Service
instructions.
17. Check for security and safety of engine drain plugs.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK À’
18. Check fuel filter aft of firewall. Clean as required.
19. Check exhaust section stacks and vanes for condition, cracks,
visible damage and security.
20. Check air intake screens for damage, obstructions and security.
21. Check air intake duct for condition, damage or obstructions.
22. Check plumbing for general condition, security, leakage or
damage.
23. Check engine controls for proper rigging, condition, alignment,
attachment and security.
24. Check engine accessories for condition, security and leakage.
25. Check engine mounts for condition.
26. Check Propellers and accessories for condition, security and
operation.
27. Check fuel heater for condition, leakage and attachment.
28. Perform hot section inspection as recommended in p &'WA
Service Bulletin #117.
29. Remove prop spinner. Note: Check index mark on spinner and
bulkhead.
30. Check engine and prop for fuel or oil leakage, including all
plumbing, valves and accessories.
31. Wash down engine.
32. Clean fuel flow divider filter. Install new seal. (P/N - S8096-
510). Note: It is recommended that metallic filter elements be
cleaned using the sonic cleaning method. Paper filter elements
should be replaced.
33. Check 1st stage compressor guide vanes for damage.
34. Check first stage compressor blades for nicks, cracks or other
damage.
35. Check engine exhaust section and turbine buckets for any visible
cracks or other damage.
36. Check engine vibration isolators and engine mount for condition
and attachment.
37. Check all engine accessories for condition and attachment.
38. Check all hoses, lines and hose clamps for condition, such as
wear, leakage and rubbing against other lines.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK À’
39. Remove starter generator and lube drive spline with MIL-6-21164.
40. Check for seal leakage at starter generator drive.
41. Check tachometer generator, for security of mounting, common
connector and general condition.
42. Check all engine controls for travel, freedom of movement and
security of mounting, paying close attention to missing or broken
safety wire, cotter pins, loose "jam" nuts and frozen rod end
bearing.
43. Check fuel control assembly for security and evidence of leakage.
44. Check fuel solenoid valve, flow divider, fuel manifold assemblies
for security and evidence of leakage.
45. Check security of plumbing and connections. Check for leaks,
cracks, cuts or rubbing.
46. Check engine bleed air lines for security and damage.
47. Check fire seals, shields, shrouds for damage and general
condition
48. Inspect aspirator assembly.
49. Check oil cooler for foreign object damage, general condition and
oil leakage.
50. Check drains and vents for restrictions.
51. Check prop unfeather pump for security, condition and evidence of
leakage.
52. Check all connectors and general condition.
POWER PLANT RH
53. Remove all cowling. Clean and inspect for general condition,
cracks, damage, or delamination.
54. Check engine oil filter. Clean and replace as per P & WA Service
instructions.
55. Check for security and safety of engine drain plugs.
59. Check air intake duct for condition, damage or obstructions.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK À’
ITE DESCRIPTION MECH INSP
M
63. Check engine mounts for condition.
64. Check Propellers and accessories for condition, security and
operation.
66. Perform hot section inspection as recommended in p &'WA Service
Bulletin #117.
bulkhead.
68.Check engine and prop for fuel or oil leakage, including all plumbing,
valves and accessories.
69.Wash down engine.
70. Clean fuel flow divider filter. Install new seal. (P/N - S8096-510).
Note: It is recommended that metallic filter elements be cleaned
using the sonic cleaning method. Paper filter elements should be
replaced.
71. Check 1st stage compressor guide vanes for damage.
damage.
74. Check engine vibration isolators and engine mount for condition and
attachment.
76. Check all hoses, lines and hose clamps for condition, such as wear,
leakage and rubbing against other lines.
79. Check tachometer generator, for security of mounting, common

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OJT MANUAL
OJT MANUAL
CHECK À’
safety wire, cotter pins, loose "jam" nuts and frozen rod end
bearing.
85. Check fire seals, shields, shrouds for damage and general
condition
87. Check oil cooler for foreign object damage, general condition and
oil leakage.
leakage.
90. Check all connectors and general condition.
DATE: ----------------- SIGNATURE: -----------------
AME NO: -----------------------

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OJT MANUAL
OJT MANUAL
TOOLS:
EQUIPMENTS:
2. Fire extinguisher – one
4. Engine oil for replenishing – As required.
5. Refueling apparatus – As required
6. Hydraulic fluid – As required.
7. T.P.G – one

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OJT MANUAL
OJT MANUAL

MERLIN 2B - 100 HRS SERVICING – 20 Hrs

DATE :----------------------------- AF HOURS:-----------------------
CHECK `B’
COCKPIT
1. Check control cables, pulleys and associated equipment for
condition, alignment, clearance and proper operation.
2. Check control column for security of attachment, cracks--,
alignment and operation. Verify that control surface position
coincides with that of control column.
3. Check rudder pedal condition, clearance, attachment and freedom of
movement.
4. Check engine controls for security of attachment, freedom of
movement and full travel.
5. Check brake system components for condition, security of
attachment, leakage and proper operation. Check for proper pedal
travel and parking brake release.
6. Check instrument panel, subpanels, placards, shock mounts,
instrument plumbing, electrical wiring and components for
condition, security of attachment, chafing, kinks and clearance.
7. Check cockpit windows for cracks, crazing, distortion and security
of attachment.
8. Check pilots and co-pilots seats for condition, operation and security
of attachment; seat belts for condition and security of attachment.
9. Check operation and security of Emergency Static Air Source.
CABIN
10. Remove cabin seats from aircraft.
11. Remove cabin carpeting and floor boards.
12. Check skin for condition, loose or missing rivets.
13. Check structure for cracks, dents, loose or missing rivets.
14. Check control cables, pulleys and associated equipment for
condition, attachment, alignment, clearance and proper operation.
15. Check landing gear motor, gear box and associated equipment for
condition and security of attachment. Check actuator, drive
mechanism for alignment.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `B’
16. Check landing gear emergency extension lever for security of
attachment, cracked sprocket and alignment.
17. Verify a 1/16-inch clearance of the clutch teeth, when fully
disengaged, of the landing gear emergency extension clutch.
18. Check flap drives for security, condition and alignment.
19. Check heating and pressurization ducts for condition, security of
attachment, air outlets for obstructions.
20. Check evaporators for condition, security of attachment and drain
lines for obstructions.
21. Check seats and seat belts for condition, security of attachment
and operation, -
22. Check emergency escape hatch for condition, proper fit and
operation of release handles; reinstall and safety wire with 0.021
breakaway copper safety wire.
23. Check all cabin windows for condition, cracks, security of
attachment and moisture between panes.
24. Check main cabin door for condition, security of attachment,
proper operation, condition of pressure seal and operation of door
bungee.
25. Check baggage compartment doors and latches for condition and
operation.
26. Check elevator stability augmentation system for condition,
security of attachment, cracked or broken motmt brackets; and
elevator down spring for condition and attachment
27. Check static system for condition and security of attachment, vents
for security and obstructions. Drain static system.
28. Check pressurization outflow valves and plumbing for condition
and security of attachment. Clean outflow valve seats as necessary
29. Lube flap actuator as per lube chart.
30. Reinstall all removed items.
DATE: ----------------- SIGNATURE: -----------------
AME NO: -----------------------

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OJT MANUAL
OJT MANUAL
TOOLS:
EQUIPMENTS:
7. T.P.G – one

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OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:-----------------------
CHECK `C’
LEFT HAND WING
1. Check skin for corrosion, dents, cracks, loose rivets and general
condition.
2. Check internal structure for cracks, loose rivets, distortion and
cleanliness.
4. Check aileron and its fittings for condition, attachment, loose or
missing rivets, and freedom of movement and proper safety.
5. Check aileron trim tab and its fittings for condition, attachment,
loose or missing rivets, freedom of movement, and proper safety.
rivets.
7. Check flap hinges, tracks rollers, cables, and fairleads for
condition, wear and proper safety.
8. Check all control cables, pulleys and associated equipment for
condition, attachment alignment, security, clearance and safety.
9. Check fuel quantity components for damage, leakage and security
of attachment.
10. Check fuel and de-icier plumbing for security, condition and
leakage.
11. Check condition of de-icier boots.
12. Check condition and attachment for air conditioning condenser,
plumbing, and Freon leakage.
13. Check wing attach bolts for condition and security. Check for
proper torque(lower-forward bolt5,000-5,5000inch-
pounds,remaining three bolts2,000-2,300inch-pounds) on
first100hour inspection after new or after wing removal.
RIGHT HAND WING
14. Check skin for corrosion, dents, cracks, loose rivets and general
condition.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `C’
15. Check internal structure for cracks, loose rivets, distortion and
cleanliness.
17. Check aileron and its fittings for condition, attachment, loose or
missing rivets, and freedom of movement and proper safety.
18. Check aileron trim tab and its fittings for condition, attachment,
loose or missing rivets, freedom of movement, and proper safety
rivets.
20. Check flap hinges, tracks rollers, cables, and fairleads for condition,
wear and proper safety.
21. Check all control cables, pulleys and associated equipment for
condition, attachment alignment, security, clearance and safety.
22. Check fuel quantity components for damage, leakage and security of
attachment.
23. Check fuel and de-icier plumbing for security, condition and
leakage.
24. Check condition of de-icier boots.
25. Check condition and attachment for air conditioning condenser,
plumbing, and Freon leakage.
26. Check wing attach bolts for condition and security. Check for proper
torque(lower-forward bolt5,000-5,5000inch-pounds,remaining three
bolts2,000-2,300inch-pounds) on first100hour inspection after new
or after wing removal.
LANDING GEAR AND BRAKES
27. Check main wheels and tires for condition and proper inflation.
28. Check brake discs, pucks, lines and housing for condition, wear and
leaks.
29. Remove, clean, inspect and repack all wheel bearings.
30. Service brake reservoir (Use hydraulic fluid MIL-H-5605).
31. Check main landing gear struts for condition, inflation and evidence
of leakage.
32. Check main landing gear attach fittings for condition, cracks and
worn bushings.
33. Check nose wheel and tire for condition and proper inflation.
34. Check nose landing gear strut for condition, inflation and evidence
of leakage.
35. Check nose landing gear attach fittings for condition, cracks and
worn bushings.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `C’
LANDING GEAR OPERATION
36. Check nose gear steering components for condition, security and
attachment.
37. Check nose landing gear shimmy dampener for condition and
attachment. Service as necessary
38. Check nose landing gear for condition, security of attachment and
broken or lens.
39. Jack aircraft.
40. Check retraction system for proper operation of all components
through at least two complete cycles. Check for unusual noises and
evidence of binding.
41. Check all doors for proper operation, fit and fair; door linkages for
alignment and security of attachment.
42. Check nose gear retract chain for broken links, corrosion, dirt and
dust; clean as necessary.
43. Lube landing gear system as per attached lube chart.
LEFT HAND ENGINE
44. Remove engine cowling, clean and inspect.
bulkhead.
47. Remove and replace oil filter. Install new seal.(every200 hours).
Filter Element - P/N 337-524-9103, Seal - P/N S817AL05.
49. Clean fuel control filter. Install new seal. (P/N S8057AP292)
50. Clean fuel flow divider filter. Install new seal. (P/N -S8096-510).
replaced.
51. Check air intake duct and 1st stage compressor guide vanes for
damage.
damage.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `C’
and attachment.
57. Check all engine controls for travel, freedom of movement, and
security; paying close attention to missing or broken safety wire
and cotter pins.
60. Check tachometer generator' for security of mounting, common
safety wire, cotter pins, loose "Jam" nuts and frozen rod end
bearing.
66. Check fire seals, shields and shrouds for damage and general
condition.
68. Check oil cooler for foreign object damage, general condition And
oil leakage.
70. Check fuel heater for condition, security and evidence of leakage
leakage.
72. Check starter generator for condition and security.
73. Check propellers and accessories for condition, security and
operation.
75. Perform hot section inspection

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `C’
76. Check for security and safety of engine drain plugs.,
80. Check air intake duct for condition, damage or obstructions..
damage.
Check engine mounts for condition and security.
84. RIGHT HAND ENGINE
bulkhead.
replaced.
damage.
damage.
and attachment.
97. Check all electrical equipment, shielding and wiring for condition
and attachment.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `C’
and cotter pins.
bearing.
condition.
oil leakage.
113. Check prop unfeather pump for security, condition and evidence
of leakage.
115. Check starter brushes for condition and armature for wear.
operation.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `C’
118. Perform hot section inspection as recommended in P &'WA
damage.
127. Check engine mounts for condition and security.
DATE: ----------------- SIGNATURE: -----------------
AME NO: -----------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
TOOLS:
EQUIPMENTS:
7. T.P.G – one

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OJT MANUAL
OJT MANUAL
DATE :------------------------------ AF HOURS:----------------------
CHECK `D’
NOSE SECTION
1. Remove radome, nose section, inspection doors and tail cone.
4. Check radome for condition, cracks or delamination.
5. Check radome bulkhead for general condition.
6. Check oxygen bottle for security and general condition.
7. Check oxygen lines and fittings for security and general
condition.,
8. Check air condition heat exchanger and ducts for condition and
security.
9. Check air condition compressor and motor for condition and
security of attachment, check belt for proper tension, belt guard for
clearance and brushes.
10. Check mixing valve for operation and security.
11. Check mass flow control valve for condition and security.
12. Check all nose section air condition and de-icier system
components for condition and security.
13. Check and clean filter on vacuum regulator.
14. Check tension on nose landing gear chain.
15. Check condition of nose gear chain and sprockets.
16. Check radio rack structure, radio equipment and vibration mounts
for condition and security
17. Check brake reservoir for condition and security attachment.
18. Check all nose section plumbing for condition and security.
19. FUSELAGE
20. Check all windshields, windows, cabin entry doors and escape
hatch for cracks, leaks and security.
21. Check skin and structure for loose or missing rivets, cracks, dents
or corrosion.
22. Check static vents for security and obstructions. Drain static
system.
23. Check all radio antennas for condition and security.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `D’
24. Check all fuselage drain holes for accumulated water and for
obstruction.
EMPENNAGE
25. Check condition of tail cone and tail light lenses.
26. Check aft pressure bulkhead for general condition and security.
29. Check all flight control cables, actuating horns, hinges, pulleys,
brackets, and fairleads for condition, security and safety.
30. Check condition of de-icier boots and associated plumbing.
31. Check elevator for freedom of movement and displacement.
32. Check elevator tab for freedom of movement and displacement.
33. Check rudder for freedom of movement and displacement.
34. Check rudder trim tab for freedom of movement and displacement.
35. Check condition of de-icier boots and associated plumbing.
LEFT HAND ENGINE
bulkhead.
replaced.
damage.
damage.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `C’
and attachment.
and cotter pins.
bearing.
condition.
oil leakage.
leakage.
operation.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `C’
67. Perform hot section inspection
damage.
76. RIGHT HAND ENGINE
bulkhead.
replaced.
damage.
damage.
and attachment.
and attachment.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `C’
and cotter pins.
bearing.
condition.
oil leakage.
105. Check prop unfeather pump for security, condition and evidence
of leakage.
operation.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK `C’
110. Perform hot section inspection as recommended in P &'WA
damage.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
TOOLS:
EQUIPMENTS:
7. T.P.G – one

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHAPTER : 01 SPECIAL INSPECTIONS Page :5.1.161
PROCEDURE SHEET NO: RIA/PS/MECH/MERL: 29 Group Size - 04
MERLIN 2B: HARD OR OVER WEIGHT LANDING – 20 Hrs
DATE :------------------------------ AF HOURS:-----------------------
SIGNATURE SIGNATURE
NO PERSON
1. After every hard landing or over weight landing inspect the
following areas
Wing lower skin in landing rib(WS 53) area for skin
buckles, fastener failure, security of landing gear rib and
trunion fittings
2. Wing to fuselage fittings and supporting structure for
security, fastener condition, and permanent deformation.
Remove the wing to fuselage fairing and inspect the
fuselage skin panel for diagonal compression wrinkles
inspect the longer on for deformation paying particularly
close attention to the area immediately adjacent to the
lightning holes
3. Trailing edge region of wing for local deformation affecting
normal usage of flaps aile
4. Wing attachment for security fastener condition and
evidence of excessive load such as failures and /or
permanent de formation
5. Nose and main landing gear assemblies and main gear
actuator assemblies for damage of de formation. actuator
attach points and support structure for security fastener
condition and permanent de formation

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
SIGNATURE SIGNATURE
NO PERSON
6. Engine mount beam structure for security fastener
condition, fire wall web wrinkles or other permanent
deformation.
7. If excessive force was exerted on the nose gear, remove
nose gear wheel and perform dye penetrate inspection of
wheel bead seat radius in accordance with the procedures
out lined in the appropriate vendor manual
Replace nose gear tire
DATE :----------------- SIGNATURE:--------------------
AME NO:-------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: HARD OR OVER WEIGHT LANDING

05. Pliers s/c
06. Cutter
12. Spanner combination ¾’’
13. Spanner 32mm
14. Locking wire
15. Muslin cloth

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHAPTER : 02 PROCEDURE SHEET, AVIONICS Page : 5.2.01
PROCEDURE SHEET NO: -RIA/PS/AVIO/CES/01 Group Size - 03
CESSNA 150: MOORING – 03 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
4. Tie down the lope on each of the two mooring eyes
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CESSNA150: MOORING EQUIPMENT AND TOOLS
1. Two pieces of lopes
2. Six chocks

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: - RIA/PS/AVIO/CES/02 Group Size - 05
CESSNA 150: TOWING / STEERING OF AIRCRAFT – 03 Hrs
AIRCRAFT SL NO: --------------- REG NO: ----------------------
DATE: ----------------------------- AF HOURS: --------------------
SIGNATURE SIGNATURE
SL
JOB MECH AME/APPRD
NO
PERSON
Note:- Steering of aircraft has to be done only on a level
and Hard ground. Necessary clearance is to given by the
wing walkers and tail walkers.
1. Attach the towing bar to the nose strut.
2. Hold the towing bar steadily and ensure that the nose
wheel is not turned more than 30 degree.
3. Push the aircraft manually; by applying pressure on wing
struts and landing gear struts only.
DATE: ----------------- SIGNATURE: -----------------------
AME NO: ----------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 150: TOWING / STEERING OF AIRCRAFT

EQUIPMENT AND TOOLS
1. Tow Bar

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OJT MANUAL
OJT MANUAL
CHAPTER : 02 PROCEDURE SHEET, AVIONICS Page :5.2.05
PROCEDURE SHEET NO:- RIA/PS/AVIO/CES/03 Group Size - 02
CESSNA150: INSPECTION OF ELECTRICAL CABLES AND WIRING AT

COCKPIT, WINGS, FUSALAGE & TAIL AREA – 04 Hrs
AIRCRAFT SL NO: --------------- REG NO: -------------------------
DATE: ----------------------------- AF HOURS: ----------------------
PERSON
1. Inspect the general condition of electrical cables and its
routing in cockpit wings, fuselage and tail area.
2. Check the condition of cable termination and cable
connectors.
3. Check for any signs of damage or overheat.
DATE: ----------------- SIGNATURE:---------------------------
AME NO: -------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA150: INSPECTION OF ELECTRICAL CABLES AND WIRING AT

COCKPIT, WINGS, FUSALAGE & TAIL AREA EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Set spanner
5. Box spanner
6. Cloth for cleaning

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OJT MANUAL
OJT MANUAL
CESSNA150: INSPECTION OF LIGHTING SYSTEMS- 04 Hrs
DATE: ----------------------------- AF HOURS: ----------------------
PERSON
1. Inspect the condition of all lights of aircraft.
2. Clean and inspect all filters of lights for its condition and
security.
3. Inspect the electrical cable connecting to the filaments
DATE: ----------------- SIGNATURE: ---------------------------
AME NO: -------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA150: INSPECTION OF LIGHTING SYSTEMS

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Set spanner
5. Box spanner

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO:- RIA/PS/AVIO/CES/05 Group Size – 02

ENGINE BAY – 04 Hrs
DATE: ----------------------------- AF HOURS: ----------------------
PERSON
2. Visually inspect the condition of electrical components like
relays, contactors, voltage regulators etc…
3. Check the component for any mechanical damage; ensure
safety of cable routing and security of mounting.
4. Check the electrical cable terminations for its condition.
Tighten all the cable connections.
5. Inspect the electrical components and electrical cables for
the sign of overheat or damages.
DATE: ----------------- SIGNATURE: ---------------------------
AME NO: -------------------------------

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OJT MANUAL
OJT MANUAL

ENGINE BAY EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Set spanner
5. Box spanner

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OJT MANUAL
OJT MANUAL
CESSNA150: REMOVAL ,INSPECTION AND INSTALLATION OF STARTER

MOTOR AND GENERATOR – 04 Hrs
DATE: ----------------------------- AF HOURS: ----------------------
PERSON
1. Open the engine cowling and inspect the condition of
starter motor and generator
2. Check the cable connections and cable terminations to the
starter motor and generator.
3. Inspect the cables for any signs of overheat or insulation
deterioration and safety of routing.
4. Check the mountings of starter motor and generator.
5. Check the belt tension of generator.
6. Clean the starter motor and generator externally.
7. Extract the graphite brushes and inspect for uneven wear,
cracks, and chippings.
8. Close the engine cowling.
DATE: ----------------- SIGNATURE: ---------------------------
AME NO: -------------------------------

\

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OJT MANUAL
OJT MANUAL
CESSNA150: INSPECTION OF STARTER MOTOR & GENERATOR

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Set spanner
5. Box spanner

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO :- RIA/PS/AVIO/CES/07 Group Size - 02
CESSNA150: INSPECTION OF ENGINE WIRING – 04 Hrs
DATE: ----------------------------- AF HOURS: ----------------------
PERSON
2. Inspect the condition of wiring harness and its rooting.
3. Check the wiring for its safety and security of mountings.
4. Clean the electrical wiring harness around the engine.
5. Check the ignition leads for its condition, rooting and
terminations.
DATE: ----------------- SIGNATURE: ---------------------------
AME NO: -------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA150: INSPECTION OF ENGINE WIRING

EQUIPMENT AND TOOLS
0- CSD
1- Inspection lamp
2- Box spanner
3- Cloth for cleaning

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OJT MANUAL
OJT MANUAL

DATE :----------------------------- AF HOURS:------------------------
PERSON
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL
CESSNA152: PITOT AND STATIC HEAD REMOVAL, FITMENT AND

INSPECTION AND CHECKING THE HEATER CONNECTIONS – 04 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
1. Disconnect the Altimeter, Airspeed Indicator. Vertical speed
indicator from the pitot – static connection
2. Disconnect the electrical connection to the pitot heater..
3. Unscrew the mounting screws, and remove the pitot probe
and clean the drain
4. Clean the pitot static connections and electrical
connections. Check for any damage or blockage
FITMENT
1. Install the pitot head in the reverse order of the removal.
2. Switch on the pitot heater and check the serviceability of
the heater
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA150: PITOT AND STATIC HEAD REMOVAL, FITMENT AND

INSPECTION AND CHECKING THE HEATER CONNECTIONS
EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
CHAPTER : 02 PROCEDURE SHEET, AVIONICS Page: 5.2.19
PROCEDURE SHEET NO: - RIA/PS/AVIO/CESS/10 Group Size - 04
CESSNA 150: LEAK TEST OF PITOT STATIC SYSTEM – 04 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
PITOT SYSTEM LEAK TEST
1. Connect a low pressure air source, equipped with an ON-
OFF Valve, to the Pitot head.
2. Apply Pressure slowly until the air speed Indicator registers
80 knots and then turn the valve to the OFF position.
3. If the system retains the pressure required to maintain this
reading of 80 knots for a period of 01mnts, there should be
no leaks in the pitot line.
STATIC SYSTEM LEAK TEST
OFF Valve, to the static connection.
2. Apply static pressure until the altimeter registers 1500 feet
then turn OFF the valve in the pitot static leak tester.
3 If the system retains the static pressure required to maintain
this reading of 1500 feet for a period of 01mnts, there
should be no leaks in the static line.
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
MERLIN 2B: LEAK TEST OF PITOT STATIC SYSTEM

EQUIPMENT AND TOOLS

1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers

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OJT MANUAL
OJT MANUAL
CESSNA150: AIR SPEED INDICATOR REMOVAL & INSTALLATION – 03 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
screws.
Instruments.
instrument
and instrument.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CESSNA150: AIR SPEED INDICATOR REMOVAL & INSTALLATION

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OJT MANUAL
OJT MANUAL
EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers
CESSNA150: VERTICAL SPEED INDICATOR REMOVAL &

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OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
screws.
Instruments.
instrument
and instrument.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CESSNA150: VERTICAL SPEED INDICATOR REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers

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OJT MANUAL
OJT MANUAL
CESSNA150: ALTIMETER REMOVAL & INSTALLATION – 03 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
screws.
Instruments.
instrument
and instrument.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA150: ALTIMETER REMOVAL & INSTALLATION
EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers

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OJT MANUAL
OJT MANUAL
CESSNA150: RPM INDICATOR REMOVAL & INSTALLATION – 03 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
screws.
Instruments.
instrument
and instrument.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA150: RPM INDICATOR REMOVAL & INSTALLATION
EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers

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OJT MANUAL
OJT MANUAL
CESSNA150: DIRECT READING COMPASS REMOVAL &
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
1. Unscrew the mounting screws with non magnetic screw
diver
2. Remove the compass from the mounting slot. Inspect the
liquid for any discoloration
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------
CESSNA150: DIRECT READING COMPASS REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

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OJT MANUAL
OJT MANUAL
1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL
CESSNA150: TURN AND BANK INDICATOR REMOVAL &

DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
1. Unscrew the four mounting screw from the face of the
Instrument.
Remove the electrical connection from the Instrument.
2. Visually inspect the inclinometer fluid dis-coloration and
the easy movement of the float.
Check the function of ON-OFF flag
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA150: TURN AND BANK INDICATOR REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL

DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
1. Remove the mounting screws from the bracket
Remove the instrument
FITMENT
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL
CESSNA150: SUCTION GUAGES REMOVAL & INSTALLATION – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Unscrew the mounting screws from the Instruments panel.
2. Remove the Electrical connection.
3. Remove the pressure line.
4. Remove the Instrument from the panel.
5. Blank the connections.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA150: SUCTION GUAGES REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL
CESSNA 150: REMOVAL, TESTING & INSTALLATION OF VHF/VOR – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
NO MECH AME/APPRD
JOB
PERSON
1. Remove VHF/VOR equipment from the instrument panel.
2. Check the plugs at the back of the equipment and at the
instrument panel.
3. Clean the plugs.
4. Check the insulation of the aerial cables.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

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OJT MANUAL
OJT MANUAL
CESSNA 150: REMOVAL, TESTING & INSTALLATION OF VHF/VOR

EQUIPMENT AND TOOLS
1. Watt meter
2. Megger
3. Multimeter
5. Cutting Pliers
6. Cleaning Brush

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OJT MANUAL
OJT MANUAL
CESSNA 150: REMOVAL, TESTING & INSTALLATION OF

DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Remove the transponder from the instrument panel.
2. Check the plugs for any possible damages.
3. Clean the plugs.
4. Check the insulation test of the aerial cables.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 150: REMOVAL, TESTING & INSTALLATION OF TRANSPONDER

EQUIPMENT AND TOOLS
1. Megger
2. Multimeter
3. Screwdriver
4. Cutting pliers
5. Cleaning brush

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OJT MANUAL
OJT MANUAL
CESSNA 152: FLAP MOTOR AND GEAR BOX REMOVAL &

AIRCRAFT SL NO :--------------- REG NO: ---------------------------
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
2. Disconnect battery ground cable and insulate terminal
3. Remove access plates as required on stbd. wing
4. Note:-Flap motor, gear assembly, hinge assembly and

actuating tube are removed as a single unit. Remove bolt
securing actuating tube to drive pulley
5. Screw in actuating tube toward transmission as far as
possible by hand
6. Remove bolt securing flap motor hinge to wing
7. Disconnect motor electrical leads at quick disconnects ,

wiring at limit switch
8. Carefully take out the assembly from wing through the
access opening
9. Retain all spares for use on reinstallation. After inspection,
repair if any ,lubrication etc. ,If hinge assembly was
removed from transmission ensure that short end of
hinge is re installed towards top

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OJT MANUAL
OJT MANUAL
INSTALLATION
1. Position back the assembly connect flap motor hinge to
wing
2. Connect motor electrical leads to quick connection
3. Connect wiring at limit switches
4. Connect actuating tube to drive pulley with bolt and nut
5. Ensure security , safety , locking and proper torque

correct operation
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 152: FLAP MOTOR AND GEAR BOX REMOVAL & INSTALLATION
EQUIPMENT AND TOOLS
1. Control column locking tool

2. Cable tensiometer
3. Torque wrench
4. 7/16 Spanner D/E
5. 7/16 socket
6. 5/16 Spanner D/E
7. 5 /16socket
8. Ratchet drive
9. T handle
10. Extension rod
11. Pliers
12. Philips screw driver
13. Oilcan
14. Oil gen.purpose
15. Grease gen.purpose
16. Cleaning material MEK

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/AVIO/CES/22 Group size – 02
CESSNA 152: STARTER REMOVAL & INSTALLATION – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
2. Disconnect starter cable. Do not permit starter terminal bolt

to rotate, which may eventually cause starter motor
inoperative.
3. Disconnect starter power cable at starter. Insulate terminal
on power cable to prevent accidental shorting.
4. Remove the three nuts and washers and one bolt securing
starter to crankcase and remove starter.
INSTALLATION
1. Install starter by positioning starter on mounting pad, align
dowel pins in starter mounting pad with holes in mounting
pad on engine.
2. Secure starter with washers, lock washers and nut in three
place and install bolt and washes.
3. Tighten nuts and bolt evenly to a torque value of 150 lb in
4. Connect electrical cable to starter terminal and install

engine cowling.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 152: STAETER REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
3. SPANNER ¼ - ONE

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/AVIO/CES/23 Group size – 02
CESSNA 152: SPARK PLUG REMOVAL & INSTALLATION – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Remove the engine cowling.
1.1 Engine battery connection removed, masters and ignition

switch ‘OFF’.
2. Remove spark plug lead.
3. Remove spark plug and tag the cylinder No. and its
location.
4. Blank the spark plug openings using dummy spark plugs.
4.1. Protect the spark plug lead by proper covering.
INSTALLATION
1. Clean, Re-gap and test spark plugs prior to installation. If it

is satisfactory install.
2. Place the washers in its place, then install the spark plug.
3. Tighten the spark plugs to the required torque.
4. Connect spark plug leads.
5. Fit back the engine cowling.
DATE :----------------- SIGNATURE:---------------------------
AME NO:------------------------------

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OJT MANUAL
OJT MANUAL
CESSNA 152: SPARK PLUG REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
3. SPANNER ¼ - ONE

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/AVIO/CESS: 24 Group size – 02
CESSNA 152: PREFLIGHT INSPECTION - 05
DATE :----------------------------- AF HOURS:----------------------
ITEM MECH AME

NO ITEM
CABIN
1. Pilot's Operating Handbook – AVAILABLE IN'THE
AIRPLANE.
2. Parking: Brake - SET.
3. Control Wheel Lock - REMOVE.
4. Ignition Switch -- OFF.
5. Master Switch - ON.
WARNING
When turning on the master switch, using an external power
source or pulling the propeller through by hand, treat the
propeller as if the ignition switch were on. Do not stand, nor
allow anyone else to stand, within the arc of the propeller, since a
loose or broken wire, or a component malfunction, could cause
the propeller to rotate.
6. Fuel Quantity indicators - CHECK QUANTITY.
7. Avionics Cooling- Fan -- CHECK AUDIBLY FOR
OPERATION.
8. Low-Vacuum Warning Light -- CHECK ON.
9. Master Switch -- OFF.
10. Fuel Shutoff Valve - ON.
11. Door Release Pins — CHECK prior to aerobatic flight.
12. Seat Belts and Shoulder Harnesses -- CHECK condition and
security.
13. Seat Cushions -- STOW prior to aerobatic flight as required
EMPENNAGE
1. Rudder Gust Lock -- REMOVE.
2. Tail Tie-Down -- DISCONNECT.
3. Control Surfaces -- CHECK freedom of movement and security.
R1GHT WING Trailing Edge

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OJT MANUAL
Continued………
RIGHT WING
1. Wing Tie-Down -- DISCONNECT.
2. Main Wheel Tyre -- CHECK for proper inflation.
3. Fuel Line quick- Drain Valve (on bottom of fuselage near cabin
door) -- DRAIN at least a cupful of fuel (using sampler cup) to
check for water, sediment, and proper fuel grade before first fight
of day and after each refueling. If water is observed, take further;
samples until clear and then gently rock wings and lower tail to
the ground to move any additional contaminants to the sampling
points. Take repeated samples from all drain points until all con-
tamination has been removed.
4. Fuel Tank Sump Quick-Drain Valve – DRAIN at least a cupful
refueling. If water is observed, take further sampler until clear
any additional. contaminants to the sampling points. Take
repeated samples from, all drain points until all contamination
has been removed.
6. Fuel Filler Cap - SECURE.
NOSE
1. Engine Oil Dipstick / Filler Cap -- CHECK oil level,
then check dipstick/filler cap SECURE- Do not operate with
less than four quarts. Fill to six quarts for extended flight.
2. Fuel Strainer Drain Knob -- PULL OUT for at least four seconds
to clear strainer of possible water and sediment before first flight
of day and after each refueling. Return drain knob full in and
check strainer drain CLOSED. If water is observed,
perform further draining at all drain points until clear and then
gently rock wings and lower tail to the ground to move any
additional contaminants to the sampling points. Take
repeated samples from all drain points until all
contamination has been, removed.
3. Propeller and Spinner -- CHECK for nicks and security.
4. Engine Cooling Air Inlets and Oil Cooler - CLEAR of
obstructions.
5. Carburetor Air Filter -- CHECK for restrictions by dust or other
foreign matter.
6. Nose Wheel Strut and Tyre -- CHECK for proper inflation.
7. Nose Tie-Down - DISCONNECT.
8 Static source opening (left side or fuselage) - CHECK for
stoppage.

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OJT MANUAL
OJT MANUAL
Continued………
LEFT WING
2. Fuel Filler Cap -- SECURE.
3. Fuel Tank Sump Quick-Drain Valve -- DRAIN at least a cupful

refueling. If water is observed, take further samples until clear
any additional contaminants to the sampling points. Take
repeated samples from all drain points until all contamination
has been removed.
4 Main Wheel Tyre - CHECK for proper inflation.
LEFT WING Leading Edge
1. Pitot Tube Cover -- REMOVE and check opening for stoppage.
2. Stall Warning Opening -- CHECK for stoppage. To check the

system , place a clean handkerchief over the vent opening and
apply suction; a sound from the warning horn will confirm
system operation.
3. Fuel Tank Vent Opening - CHECK for stoppage.
4. Wing Tie Down - DISCONNECT.
5. Landing light(s) - CHECK for condition and cleanliness of lens.
LEFT WING Trailing Edge
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
TOOLS
1. C.S.D
2. Pliers
3. T.P.G
4. Smooth cloth
EQUIPMENTS REQUIRED
4. Fuel drain bowl



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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/AVIO/CESS: 25 Group Size - 02

CESSNA 150 OVERNIGHT INSPECTION – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
ITEM MECH AME

NO ITEM SIGN SIGN
GENERAL
001 Visually check air plane for general condition during walk
around.
002 Do refueling operation as per procedure and requirements
003 Check operation of all lights and ensure flash light is
available
CABINE -01
0101 Pilot operation hand book available in the airplane
0102 Parking brake –set
0103 Control wheel lock – engage
0104 Ignition switch – 0FF
0105 Master switch –ON
0106 Fuel quantity indicator , check quantity
0107 Avionic cooling fan-check for audibly operation
0108 Vacuum warming light check on
0109 Master switch OFF
0110 Fuel shut off valve –OFF
0111 Door release pin – insert
0112 Seat belts and shoulder harness- check condition and
security
0113 Seat cushion – check condition
EMPENNAGE.02
0201 Rudder gust lock- engaged
0202 Tail tie –Down – Connect
0203 Control surface ,check freedom of movement and security

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OJT MANUAL
OJT MANUAL
ITEMNO ITEM MECH AME
SIGN SIGN
03RIGHT WING TRAILING EDGE
0301 Aileron –check externally
04-RIGHT WING
0401 Wing tie down- Connect
0402 Main wheel Tyre- check for condition
0403 Fuel line quick drain valve drain fuel to check for water
sediment and proper fuel grade before first of day and
after each refueling return drain knob full in and check
strainer drain closed
0404 Fuel quantity check visually for desired level
ENGINE
0501 Engine oil dipstick/filler cap check oil level, then check
dipstick filler cap secure. Do not operate with less than
four quarts
0502 Fuel strainer drain knob ,pull out for about four seconds
to clear strainer of possible water and sediment before first
flight of day and after each refueling return drain knob full
in and check strainer drain closed .If water is observed the
fuel system may contain additional water , and further
draining of the system at the strainer fuel tank sump , and
fuel line drain valve must be accomplished
0503 Propeller and spinner. check for nicks and security
0504 Engine cooling air/ inlets and oil cooler –clear of

obstruction
0505 Landing lights check for condition and cleanliness
0506 Carburetor Air filter –check for registration by dust or

other from forgien matter.

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OJT MANUAL
OJT MANUAL
ITEM MECH AME

NO ITEM SIGN SIGN
0507 Nose wheel strut and Tyre –check for condition
0508 Nose Tie down – Connect
0509 Static source opening (left side of fuselage –check for

blockage)
0601 LEFT WING 06
Fuel quantity –check visually for desired level
0604 Main wheel Tyre- check for condition
07. LEFT WING LEADING EDGE

0701 Pitot tube cover – Remove and check opening for blockage
0702 Stall warning opening –check for stoppage to check
stoppage, to check system, place a clean hand kerchief over
the vent opening and apply suction a sound from warning
horn will confirm system operation.
0703 Fuel tank vent opening check for blockage
0704 Wing Tie down – di connect
08- LEFT WING Trailing

0801 Aileron – Freedom of movement and security
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
TOOLS
1. C.S.D
2. Pliers
3. T.P.G
4. Smooth cloth
EQUIPMENTS REQUIRED
1. Fuel drain bowl



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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/AVIO/CESS: 26 Group Size - 05
CESSNA 152: 50 /100 Hrs SERVICING – 10 Hrs
DATE :----------------------------- AF HOURS:----------------------
ITEM MECH AME

NO ITEM
GENERAL
001 Collect required tools, ground equipment and cleaning
material
002 Remove the access doors as required
101 Propeller – I
Spinner check for external damages
102 Check the propeller blades for nicks, dents and other
mechanical damages and erosion
Engine – 02
201 Engine compartment check for evidence of fuel and oil
leaks, clean the entire engine compartments, if needed
202 Engine oil check for correct grade , and level, replenish if
required
203 Filler cap [check for safety and security]
204 Dipstick check for damages and security
205 Drain plugs check for safety and obstructions
206 External filler elements check for cleanliness and security
207 Oil cooler, check for external damage, oil leaks matrix for
any blockage damage
208 Induction air filler check for cleanliness and damages
209 Induction air box, air valves doors and controls check for
nay external damages air valves, door and controls for
proper operation.
210 Cold and hot air hoses, check for condition and any leak
ensure there no kink on the hose length
211 Engine baffles check for any damages and inflation

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OJT MANUAL
ITEM MECH AME

NO ITEM SIGN SIGN
212 Crank case oil sump, accessory section and front crank
shaft seal , check for damages , oil and gas leaks, burning
marks,. Check for oil leak from crank shaft seal and radio
as required
213 Hoses, metal lines and fittings check for damages and
correct installation and for leaks.
214 Intake and exhaust system check for nay leak over healing
discoloration
218 Vacuum pump. Check for mountings security , pipelines
connection for damages, sign of leaks and condition
219 Vacuum relief valve filter
220 Engine controls and linkage check for condition, operate
the control see for smooth operations and no rubbings
sound is heard
221 Starter solenoid and electrical connection. Check for
connection condition and operations.
222 Alternator electrical connection. Check for safety and
security
223 Voltage regulator mounting and electrical leads check for
safety and security and leads for condition
224 Magnetos (externally) electrical connection. Check for
safety of mounting condition.
225 Magneto timings. Check magnetos to engine timings. Refer
service manual section 11
226 Carburetor and drain plug. Check for condition
227 Engine cowling. Check for damages replace missing or
defective fasteners
228 Tapped clearance. As per the Avco Lycoming overhaul
manual
Fuel System - 03
301 Fuel strainer, drain valve and control, check for leak and
condition
302 Fuel strainer screen and bowl, clean strainers, check bowl
for proper installation leak and security

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OJT MANUAL
OJT MANUAL
ITEM MECH AME

NO ITEM SIGN SIGN
303 Fuel tank vents, check for blockage, caps for safety and
security , placard for damages
304 Fuel tanks check for leaks or damages, sumps drain for
proper operation and leak, fuel drain line check for leak
307 Engine primer check for operation.
Landing gear - 04
401 Main gear wheel and fairing check for condition and
security of attachments
402 Nose gear wheel, torque links steering rods boots and
fairing for condition correctness of installation and security
403 Wheel bearing check for smoothness and condition
404 Nose gear strut and shimmy damper for proper attachment
and proper operation
405 Tyres: checks for condition weather cracking and proper
inflation.
406 Brake fluid, lines and hoses lining and disc, brake assembly
and master cylinder check for leaks, damages and proper
operation of brakes
407 Parking brake system for correct operation
408 Main gear springs. Check for condition, corrosion and
security
Air Frame - 05
501 Aircraft exterior check for condition, sign of corrosion
damages and erosion of paint
502 Aircraft structure check for any damage, loose rivet,
corrosion, cleanliness of all drain holes.
503 Windows, wind shield door and seals. Window check for
security and proper sealing
504 Seats belts and shoulder harness. Check for attachment
and condition
505 Seat stops, seat rails up holster, structure and mounting.
Check for condition, lubricate and operate. Ensure that
seats are operating smoothly.
506 Control bearings, sprocket, pulley cables, chains and turn
buckle check for condition, freedom of movement and
correctness of tension

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OJT MANUAL
OJT MANUAL
ITEM MECH AME

NO ITEM SIGN SIGN
507 Control lock, control wheel, control mechanism check for
condition, freedom of operation and lubricate as necessary
508 Instrument and marking. Check for condition of range
markings and condition of instruments.
509 Gyros central air filter, check for condition and cleanliness
510 Magnetic compass compensation check and correct
511 Check instrument wiring and plumbing for condition and
damages and correct as required
512 Instrument, panel for condition shock mounts for damage
and condition, ground strap check for condition , covers are
secure decal labeling damage, replace as required
513 Defrosting, heating system and ventilating system and
control. check for cleanliness , freedom , of operation and
proper operation
514 Cabin upholstery; trim sun vision and ash tags. Check for
condition
515 Area beneath floor lines, hose wires, and control cable
check for wear, damage and freedom of movement, and
sign of any leak.
516 Lights switches circuit breakers fuses, and spare fuse,
check for pressure, operation and condition.
517 Exterior light check for condition and operation
518 Pitot static system, check no, damage, no blockage
519 Stall warning system. Check for condition, blockage and
operation,.
520 Check Radios, radio controls, for installation and operation.
521 Check avionics and flight instrument for installation and

operation.
522 Antennas and cables. Check for conditions security and
cable routing and cleatings.
523 Battery for condition and charge, check capacitor, battery
box for condition, battery cable for condition and
continuity
524 Emergency locater transmitter check battery voltage, and
date due

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OJT MANUAL
OJT MANUAL
ITE MECH AME
M ITEM SIGN SIGN
NO
Control system - 6
In addition to the items listed below, always check for
correct direction of movement, correct travel and correct
cable tension.
601 Cables, terminal pulleys, pulley bracket cable guards turn
buckle and fair lead check for condition, alignment routing
security wear and tension
602 Chains terminals, sprockets and chain guards. Check for
condition correct assembly, corrosion free movement.
603 Trim control wheels indicators actuator bungee. Check for
condition, operation and proper installation
604 Travel stop check for correctness of adjustment and
condition
605 Decal cabling check for condition
606 Flap control switch flap roller and tracks flap indicator
check for proper operation, condition freedom of movement,
lubricate as required.
607 Flap motor, transmission limit switch structure, linkage, Bell
cranks etc. Check for operation, security of attachments.
608 Elevator and trim tab hinges, lips and control rods, check
for attachment, condition and correct operation
609 Elevator trim tab for free play inspection
610 Elevator trim and tab actuator lubrication
611 Rudder peddle assemblies and linkage for condition and
proper operation
612 Skins (external) of control surface and tab check for damage
, paint condition and corrosion
613 Internal structure of control surface , check for condition
614 Balance weight of control, surface , Check for security and
condition
615 Aileron , hinges and push pull rods, check for attachment,
safety and security and proper operation
616 Vertical fin attachment bracket. Check for condition, and
security
DATE :----------------------
SIGNATURE -----------------------------
AME NO ------------------------------
AME NO:-------------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
REQUIRED TOOLS AND GROUND EQUIPMENTS

3 Pliers side cut - one
4 Wire twister - one
5 Steel rule - one
6 Inclinometer - one
7 Magnifying glass - one
8 Portable inspection mirror - one
9 Nose pliers - one
10 Mallet - one
11 Hammer plastic - one
12 Ring spanner set(8*9) - one
13 Set spanner set(8*9) - one
14 Box spanner with Allan key set - one
15 Socket set - one
16 'c’ spanner - one
17 Tensiono meter - one
18 TPG - one
19 Torque wrenches - one
Ground equipment
20 L.P compressor - one
21 Fire extinguisher - one
22 Step ladders - two
23 Drip tray - one
24 Replenishing cans - one

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: - RIA/PS/AVIO/MER/01 Group Size - 03
MERLIN 2B: MOORING – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
4. Tie down the rope on each of the two mooring eyes
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: MOORING EQUIPMENT AND TOOLS
1. Two pieces of ropes
2. Six chocks

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO :- RIA/PS/AVIO/MER/02 Group Size - 05
MERLIN 2B: TOWING THE AIRCRAFT – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
a. Connect the tow bar to the towing lugs on the lower toque
knee fitting of the nose strut.
b. The aircraft can be steered with the nose wheel when
towing manually.
c. A person who is conversant to operate brakes should be
positioned in the pilot seat to operate the brakes in the
event of any emergency.
d. Observe the turn line marked on the nose gear strut to
prevent damage to nose gear.
e. Do not push on the propeller or control surfaces.
f. Do not pull down on the horizontal stabilizer to raise the
nose wheel off the ground.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: TOWING THE AIRCRAFT

EQUIPMENT AND TOOLS
1. Steering arm

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OJT MANUAL
OJT MANUAL
ECTION : 05 APPENDIX
MERLIN 2B: INSPECTION OF IGNITION SYSTEM – 10 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Ensure CB of ignition system is open.
2. Ignition S/w must be in off position.
3. Remove engine cowlings.
4. Remove the input connecter from ignition unit and if dirty
clean it with gasoline
5. Remove the output leads from the ignition unit and inspect
the mating points.
6. Inspect the ignition harness for its condition.
7. Disconnect the lead from the igniter plug and inspect the
condition of the cable ends.
8. Fit back the ignition harness and wire lock it.
9. Fit back the input connector and wire lock it.
10. Remove the haunt blanking.
11. Close the ignition CB and test the ignition box for its
function.
12. After testing refit the exhaust blanking.
13. Fit back the engine cowlings.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF IGNITION SYSTEM

EQUIPMENT AND TOOLS
2. Allen Key
3. CSD
4. Inspection lamp
5. Set spanners
6. Adjustable pliers

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF FUEL BOOSTER PUMPS – 10 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Ensure CB of fuel booster pumps are off at LH & RH
panels.
2. Ensure booster pump selector s/w are in off position.
3. Open the access panels in the wings.
4. Check the condition of electrical cables and connectors.
5. Ensure that connections to the fuel booster pumps are firm.
6. Inspect the cable & terminal sign of overheat.
7. Take corrective actions as necessary.
8. Close the access panels.
9. Close the CB's and carry out functional test of booster
pumps.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF FUEL BOOSTER PUMP

EQUIPMENT AND TOOLS
1. Allen Key
2. CSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF COCKPIT ILLUMINATION AND

ANNUNCIATES – 10 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Inspect the condition of the dimmer knobs on LH & RH
forward consoles in the cockpit.
2. Check the tightness of grab screws on the dimmer knobs
3. Check the movement of the dimmer knobs.
4. Energies the bus bar and operate the dimmer s/w for its
proper operation.
5. Check the filament on the instruments. Replace the
filaments if faulty.
6. Press the light test knob on the center panel and ensure that
all filaments are serviceable.
7. De energies the bus bars.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF COCKPIT ILLUMINATION AND

ANNUNCIATES EQUIPMENT AND TOOLS
1. Allen Key
2. CSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF START SYSTEM CONTACTORS – 10 Hrs
AIRCRAFT SL NO: --------------- REG NO :-------------------------
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Ensure that internal & external power is removed from
aircraft. Battery master S/W in OFF position.
2. Inspect battery master relay ,start control relays and series
parallel relay for its condition.
3. Check the general condition of electrical cables.
4. Check the tightness of nuts at cable termination
5. Check the electrical cable for any signs of discoloration due
to heating.
6. Check the general condition of routing of cables and cable
ends.
7. Connect internal battery
8. S/W ON the battery master S/W and then essential, non
essential bus bars ensure that supply is available on these
bus bars.
9. S/W OFF the bus bars and battery master S/W
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF START SYSTEM CONTACTORS

EQUIPMENT AND TOOLS
1. Set Spanners
2. Box spanners
3. Inspection lamps

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF STATIC INVERTERS – 10 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. S/W OFF the CB on LH & RH consoles in the cockpit
2. Open the Access panel of nose compartment.
3. Visually inspect the condition of static invertors.
4. Check the electrical wiring and general condition of
electrical cables.
5. Open the AN connector and inspect the contact pins for any
signs of pitting / deterioration.
6. Clean the connectors with unleaded gasoline after drying fit
the connectors back and wire lock it.
7. Externally clean the static invertors.
8. Close the CB and carry out a functional check.
9. Close the access panel.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF STATIC INVERTERS

EQUIPMENT AND TOOLS
1. PSD
2. Wire cutter
4. Inspection lamps.

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OJT MANUAL
OJT MANUAL

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF FUEL SHUT OFF VALVES – 10 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Open the access panels behind fire wall inboard side.
2. Visually inspect the condition of shut off values
3. Check the general condition of electrical and routing.
4. Energies the essential bus bars.
5. Open the guarded s/w and operate the valves.
6. Ensure that valve operation is smooth
7. Close the guarded s/w and de-energies the essential bus
bars.
8. Close the access panels behind fire wall.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF FUEL SHUT OFF VALVES

EQUIPMENT AND TOOLS
1. PSD

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF CB, SWITCHES AND WIRING AT

COCKPIT – 10 Hrs
DATE: ----------------------------- AF HOURS: ------------------------
SL SIGNATURE
NO JOB MEC AME/APPRD
SIGN PERSON
1. Ensure that internal & external power is removed from
aircraft. Battery master S/W in OFF position.
2. Remove the CB panel assy: and inspect the condition of
cable looms.
3. Check the general condition of electrical cables.
4. Check the tightness of cable termination at switches and
CB.
5. Check the electrical cable for any signs of discoloration due
to heating.
6. Operate the switches and CB and ensure proper operation.
7. Mount back the CB panel assembly:
DATE: ----------------- SIGNATURE: ---------------------------
AME NO: -------------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF CB, SWITCHES AND WIRING AT COCKPIT

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Allen key
CHAPTER : 02 PROCEDURE SHEET, AVIONICS Page: 5.2. 80

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OJT MANUAL
OJT MANUAL
MERLIN 2B: STANDARD ELECTRICAL WIRING & CABLE WORK

PRACTICES – 15 Hrs
DATE: ----------------------------- AF HOURS: ------------------------
PERSON
1. Introduction to types of wiring diagrams.
2. Symbols and notations used in a wiring diagram.
3. Logical approach to electrical wiring diagrams.
4. Cable connections soldering and crimping.
5. Cable looming and routing.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: STANDARD ELECTRICAL WIRING & CABLE WORK

PRACTICES EQUIPMENT AND TOOLS
1. Electrical wiring diagram

2. Soldering Iron
3. Crimping tool

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF HOSES & CONNECTIONS TO AND FROM

DATE :----------------------------- AF HOURS:------------------------
PERSON
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: INSPECTION OF HOSES & CONNECTIONS TO AND FROM

1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL
MERLIN 2B: PITOT AND STATIC HEAD REMOVAL, FITMENT AND

INSPECTION AND CHECKING THE HEATER CONNECTIONS – 10Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
1. Disconnect the Altimeter, Airspeed Indicator. Vertical speed
indicator from the pitot – static connection
2. Disconnect the electrical connection to the pitot heater..
3. Unscrew the mounting screws, and remove the pitot probe
and clean the drain drapes
4. Clean the pitot static connections and electrical
connections. Check for any damage or blockage
FITMENT
5. Install the pitot head in the reverse order of the removal.
6. Switch on the pitot heater and check the serviceability of
the heater
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: PITOT AND STATIC HEAD REMOVAL, FITMENT AND

INSPECTION AND CHECKING THE HEATER CONNECTIONS
EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL
MERLIN 2B: LEAK TEST OF PITOT STATIC SYSTEM – 10 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
PITOT SYSTEM LEAK TEST
OFF Valve, to the Pitot head.
2. Apply Pressure slowly until the air speed Indicator registers
180 knots and then turn the valve to the OFF position.
3. If the system retains the pressure required to maintain this
reading of 180 knots for a period of 01mnts, there should
be no leaks in the pitot line.
STATIC SYSTEM LEAK TEST
OFF Valve, to the static connection.
2. Apply static pressure until the altimeter registers 2500 feet
then turn OFF the valve in the pitot static leak tester.
If the system retains the static pressure required to maintain
this reading of 2500 feet for a period of 01mnts, there
should be no leaks in the static line.
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: LEAK TEST OF PITOT STATIC SYSTEM

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers

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OJT MANUAL
OJT MANUAL

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO:- RIA/PS/AVIO/MER/14 Group Size - 02
MERLIN 2B: AIR SPEED INDICATOR REMOVAL & INSTALLATION – 05Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
screws.
Instruments.
instrument
and instrument.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: AIR SPEED INDICATOR REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers

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OJT MANUAL
OJT MANUAL
MERLIN 2B: VERTICAL SPEED INDICATOR REMOVAL &

DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
screws.
Instruments.
instrument
and instrument.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: VERTICAL SPEED INDICATOR REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers

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OJT MANUAL
OJT MANUAL
MERLIN 2B: ALTIMETER REMOVAL & INSTALLATION – 05 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
screws.
Instruments.
instrument
4. Blank the pilot / static pipe lines on the aircraft installation
and instrument.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: ALTIMETER REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp
4. Socket 11/32
5. Ratchet
6. Cutter/Pliers

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OJT MANUAL
OJT MANUAL
MERLIN 2B: DIRECT READING COMPASS REMOVAL &

DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
1. Unscrew the mounting screws with non magnetic screw
diver
2. Remove the compass from the mounting slot. Inspect the
liquid for any discoloration
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: DIRECT READING COMPASS REMOVAL &

1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL
MERLIN 2B: TURN AND BANK INDICATOR REMOVAL &

INSTALLATION –05 Hrs
DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
1. Unscrew the four mounting screws from the face of the
Instrument. Remove the electrical connection from the
Instrument.
2. Visually inspect the inclinometer fluid de-coloration and
the easy movement of the float. Check the function of ON-
OFF flag
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: TURN AND BANK INDICATOR REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS
1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL
MERLIN 2B: AIRCRAFT CLOCK, CHECKING, REMOVAL &

DATE :----------------------------- AF HOURS:------------------------
PERSON
REMOVAL
1. Remove the mounting screws from the bracket Remove the
instrument
FITMENT
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: AIRCRAFT CLOCK, CHECKING, REMOVAL &

1. CSD
2. PSD
3. Inspection lamp

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST & INSTALLATION OF VHF

TRANSRECIEVER – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Remove the antenna cables from the TxRx.
2. Release the securing fasteners from the mounting.
3. Pullout the TxRx from the mounting.
4. Visually inspect the connector at the back of TxRx for any
damage and possible pin damage
5. Visually inspect the mating connector on the mounting.
6. Clean all the connectors
7. Check the insulation of aerial cable with a 250V megger.
8. Fit back the VHF TxRx and secure the mounting fasteners.
9. Fit back the aerial cable.
10. Carryout functional check of the TxRx .
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST & INSTALLATION OF VHF TRANSRECIEVER

EQUIPMENT AND TOOLS
1. Wattmeter
2. Megger
3. Multimeter
4. Screwdriver
5. Cutting pliers
6. Cleaning brush

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OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO:- RIA/PS/AVIO/MER/21 Group Size – 04
MERLIN 2B: REMOVAL, TEST & INSTALLATION OF VOR/ILS

EQUIPMENT – 05Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Release the securing fasteners from the mounting and
remove the equipment.
2. Check the connectors for any damage.
3. Clean the connectors.
4. Check the insulation of antenna cable with a 250V megger.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST & INSTALLATION OF VOR/ILS EQUIPMENT

EQUIPMENT AND TOOLS
1. Megger
2. Multimeter
3. Screwdriver
4. Cutting pliers
5. Cleaning brush

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OJT MANUAL
OJT MANUAL
CHAPTER : 02 PROCEDURE SHEET, AVIONICS Page:5.2.104
MERLIN 2B: REMOVAL, TEST & INSTALLATION OF MARKER

RECEIVER – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Remove the marker receiver from the mounting and check
the connectors for damage.
3. Check the insulation of antenna cable.
INSTALLATION
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST & INSTALLATION OF MARKER RECEIVER

EQUIPMENT AND TOOLS
1. Megger
2. Multimeter
3. Screwdriver
4. Cutting pliers
5. Cleaning brush

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST & INSTALLATION OF

DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Release the securing fasteners on the mounting of both the
transponders.
2. Remove the transponders from the mountings.
3. Inspect the connectors at the back of the equipment and on
the mounting for any damage.
5. Check for proper insulation of the antenna cables.
INSTALLATION
1. Fit back the equipments and secure them.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST & INSTALLATION OF TRANSPONDERS

EQUIPMENT AND TOOLS
1. Megger
2. Multimeter
3. Screwdriver
4. Cutting pliers
5. Cleaning brush

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST & INSTALLATION OF RADIO

ALTMETER – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Remove the altimeter and check the connectors for any
damage.
2. Carry out insulation check of the antenna cable.
3. Fit back the radio altimeter.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST & INSTALLATION OF RADIO ALTMETER

EQUIPMENT AND TOOLS
1. Multimeter
2. Screwdriver
3. Cutting pliers
4. Cleaning brush

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST AND INSTALLATION OF

WEATHER RADAR – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
Remove the nose dome by releasing all the screws.
Check antenna for any damage.

Check the movement of the antenna for proper sweeping.
Carry out functional check.
Fit back the nose dome and tighten all the securing screws.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST AND INSTALLATION OF WEATHER RADAR

EQUIPMENT AND TOOLS
1. Multimeter
2. Screwdriver
3. Cutting pliers
4. Cleaning brush

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST AND INSTALLATION OF ADF – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Remove aerial connectors from the receiver.
2. Release the fasteners on the mounting and the reservoir

from the rack.
3. Visually inspect all the connectors for any image and clean
them.
4. Check the antenna and cables for any damage and make
sure they are secured properly.
5. Install the receiver back and carry out functional check.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST AND INSTALLATION OF ADF

EQUIPMENT AND TOOLS
1. Megger
2. Multimeter
3. Screwdriver
4. Cutting pliers
5. Cleaning brush

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST AND INSTALLATION OF AIS – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Remove the audio selection panels from the instrument
panel.
2. Check the connectors on the back for any damage and clean
them.
3. Remove the connectors from the AIS amplifiers and check
for any damage and clean them.
4. Fit back the audio selection panels.
5. Fit back the connectors to the AIS amplifiers.
6. Carry out functional checks.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST AND INSTALLATION OF AIS

EQUIPMENT AND TOOLS
1. Multimeter
2. Screwdriver
3. Cutting pliers
4. Cleaning brush

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST AND INSTALLATION OF GPS – 05 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
1. Remove the display unit from the instrument panel and
inspect the connectors at the back for any damage.
2. Check the antenna for proper fitment.
3. Check the insulation of antenna cables.
4. Fit back the display unit.
DATE :----------------- SIGNATURE:--------------------------
AME NO:-------------------------------

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OJT MANUAL
OJT MANUAL
MERLIN 2B: REMOVAL, TEST AND INSTALLATION OF GPS

EQUIPMENT AND TOOLS
1. Multimeter
2. Screwdriver
3. Cutting pliers
4. Cleaning brush

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: - RIA/PS/AVIO/MER/29 Group Size – 02
MERLIN 2B: COCKPIT SEAT REMOVAL & INSTALLATION –5 Hrs
DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Remove the seat stops the end of each track.
2. Release the fore and aft adjustment lock.
3. Move the seat forward until it clears the mounting track.
4. The seats will not clear the pilots compartment door in the
up right positions. To remove the seat from the
compartment, place the armrests up, turn the seat arm its
side and remove the seat.
INSTALLATION
1. Place the seat in position and align the seat guides with the
mounting tracks.
2. Release the fore and aft adjustment lock and slide the seat
into the desired position. Engage the fore and aft lock
making certain it holds the seat securely in place.
3. Replace the seat stops on the end of each track.
4. Attach the seat bungee.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: COCKPIT SEAT REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

05. Pliers s/c
06. Cutter
14. Locking wire
15. Muslin cloth

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: STARTER GENERATOR INSPECTION REMOVAL & INSTALLATION –

10Hrs
DATE :----------------------------- AF HOURS:----------------------
SL SIGNATU SIGNATURE
NO JOB RE MECH AME/APPRD
PERSON
REMOVAL
1. Open the engine cowling and remove lower engine nacelle
2. Loosen clamp and remove starter generator cooling duct from
starter generator.
3. Remove terminal cover bolt and terminal cover from starter
generator. Disconnect electrical wiring.
4 Cut the locking wire , loosen the lock nut sufficiently to allow
the removal of starter generator.
5. Carefully slide the generator and take it out
6. Open the inspection cover of starter generator
7. Turn the armature and check for any un usual noise.
8. Remove the graphite brushes from its holder and measure the
brush length. If less replace the whole set.
9. Inspect the commutator assy: for any damage, clean the
generator with compressed air.
10. Re-fit the brushes and check the terminal blocks for its
condition.
11. Close the gen; inspection cover.
12. Clean the generator externally.
INSTALLATION
13. Apply grease to male spline of starter generator.
14. Assure the starter generator adapter plate and QAD clamp are
free of any foreign material.
15. Install starter generator to engine. Check to assure that edge of
clamp and the adjacent edge of the groove in the generator
housing are parallel and that the space between these edges is
approximately 1/16 inch.
16. As a clamp is tightened move the generator slightly to assure
that no binding occurs.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
Continued……
17. Torque clamp to 60 inch pounds and safety wire. Check that
space between ends of clamp is between 1/32 and 9/32 inch.
18. Connect wiring to starter generator terminals.
19. Install starter generator cooling duct and secure the clamp.
20 Close the engine cowling and install lower nacelle
21 Access the starter generator performance during ground run
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
MERLIN 2B: STARTER GENERATOR REMOVAL & INSTALLATION

EQUIPMENT AND TOOLS

05. Pliers s/c
06. Cutter
14. Locking wire
15. Muslin cloth

Thiruvananthapuram
OJT MANUAL
OJT MANUAL

DATE :----------------------------- AF HOURS:----------------------
PERSON
REMOVAL
1. Disconnect electrical connector and disconnect attached
aircraft linkage.
2. Remove tube assemblies, attaching parts, unions, fittings,
and gaskets from fuel shutoff valve, fuel flow divider, and
fuel control unit.
3. Remove linkage support bracket assembly.
4. Remove fuel shutoff valve and bracket from accessory
drive housing assembly.
5. Remove fuel shutoff valve from bracket.
6. Remove actuating arm (manual override).
INSTALLATION
1. Ensure that fuel shutoff valve is in AUTO position. Fuel
shutoff valve is in AUTO position when index mark on end
of actuating shaft is aligned with fuel shutoff valve
centerline in relation with valve cover.
2. Install actuating arm (manual override) on shaft extension
of fuel shutoff valve secure with washers, bolt, and nut.
Tighten nut to a torque value of 12 inch- pound. Lock wire
bolt to actuating arm.
3. Install washers (maximum of two) and spacer between fuel
shutoff valve and bracket.
4. Install fuel shutoff valve onto bracket. Install washers, bolts
and nut. Tighten bolts to a torque value of 70 inch-pounds.
Tighten nut to a torque value of 50 inch-pounds.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
Continued--------
5. Install fuel shutoff valve and bracket onto accessory drive

housing assembly and secure. Tighten nuts to a torque
value of 50 inch-pounds.
6. Apply compound (Loctite 222) to threads of bolt and install
spacer and bolt into accessory drive housing assembly.
Tighten bolt to a torque value of 40 inch-pounds.
7. Install linkage support bracket onto accessory drive
housing assembly and secure. Tighten nut to a torque value
of 50 inch-pounds. Install bearing, washer, and screw.
8. Apply compound (Loctite 222) to bolt and install spacer
and bolt. Tighten bolt to a torque value of 40 Inch-pounds.
9. Install sleeve bearing, washer, and screw.
10. Install plug and bleeder with new packing into fuel shutoff
valve. Tighten plug and bleeder to a torque value of 65 to
70 inch-pounds and lock wire.
11. Install elbow and nut, with new gasket and packing, into aft
side of fuel shutoff valve. Tighten nut to a torque value of
50 to 55 inch-pounds.
12. Install fitting and nut, with new gasket and packing, into
fuel shutoff valve. Tighten nut to a torque value of 50 to 55
inch-pounds.
13. Install cap onto fitting. Tighten cap and lock wire.
14. Install tube assembly between elbow or fitting in fuel
shutoff valve and fuel flow divider.
15. Install union with new packing into bottom of fuel shutoff
valve. Tighten union to a torque value of 60 to 65 inch-
pounds.
16. Install tube assembly onto union in bottom of fuel shutoff
valve.
17. Install tee into tube assembly.
18. Install tube assembly between tee and fuel flow divider.
Install clamps, bolt, and nut. Tighten nut to a torque value
of 20 inch-pounds.
19. Install cap onto tee. Tighten cap and lock wire.
20. Install union, with new packing, into fuel control unit.
Tighten union to a torque value of 60 to 65 inch-pounds.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
Continued--------
21. Assemble and install tube assemblies between tee below

fuel shutoff valve and fuel control unit.
spacer, clamp, and bolt into accessory drive housing
assembly. Tighten bolt to a torque value of 40 inch-pounds.
spacer, bracket, washer, and bolt into accessory drive
housing assembly. Tighten bolt to a torque value of 40
inch-pounds.
24. Install clamp, bolt, and nut onto bracket. Tighten nut to a
torque value of 20 inch-pounds.
25. Apply compound (Loctite 222) to bolt and install spacer,
clamp, and bolt into accessory drive housing assembly.
Tighten bolt to a torque value of 40 inch-pounds.
26. Install clamp onto pressure switch housing support and tube
assembly. Install bolt and nut. Tighten nut to a torque value
of 20 inch-pounds.
27. Install clamp onto pressure switch housing support and
onto tube assembly. Install bolt and nut. Tighten nut to a
spacer, bracket, washer and bolt into accessory drive
housing. Tighten bolt to a torque value of 40 inch-pounds.
29. Install clamp, bolt, and nut into bracket. Tighten nut to a
30. Connect electrical connector in accordance with Aircraft
Maintenance Manual.
31. Connect linkage to fuel shutoff valve in accordance with
Aircraft Maintenance Manual.
DATE :----------------- SIGNATURE:---------------------------
AME NO:-------------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL


03. Pliers s/c
11. Locking wire
12. Muslin cloth

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/AVIO/MERL: 32 Group Size - 02
MERLIN 2B: PREFLIGHT INSPECTION – 05Hrs
DATE :----------------------------- AF HOURS:-----------------------
SIGNATURE SIGNATURE
NO PERSON
9. Operate the C/B and ensure proper operation.
11. Check the condition of annunciator mounting.
13. Check serviceability of cabin lamps.
14. Check proper functioning of entrance lights.
16. Check for proper installation and operation of flight
director.
17. Check for proper installation and operation of compass
system.
19. Check the functioning of transponder.
20. Check the functioning of glide slope
21. Check the functioning of radar
23. Check the functioning of marker receiver
24. . Check the functioning of radio Altimeter

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
25. Check the functioning of No.2 NAV VOR

26. Check the functioning of No.1 ADF
DATE: ----------------- SIGNATURE: ------------------
AME NO: ------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
TOOLS:
EQUIPMENTS:
7. T.P.G – one

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/AVIO/MERL: 33 Group Size - 02
MERLIN 2B: OVERNIGHT INSPECTION SCHEDULE – 10 Hrs
DATE :----------------------------- AF HOURS:-----------------------
SIGNATURE SIGNATURE
NO PERSON
9. Operate the C/B and ensure proper operation.
11. Check the condition of annunciator mounting.
13. Check serviceability of cabin lamps.
14. Check proper functioning of entrance lights.
16. Check for proper installation and operation of flight
director.
17. Check for proper installation and operation of compass
system.
19. Check the functioning of VHF
20. Check for proper attachment of transponder.
21. Check the functioning of glide slope.
22. Check the functioning of radar.
24. Check for proper attachment of marker receiver.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
25. Check for proper attachment of radio Altimeter

26. Check the functioning of No.2 NAV
27. Check the functioning of ADF
DATE: ----------------- SIGNATURE: ------------------
AME NO: ------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
TOOLS:
EQUIPMENTS:
7. T.P.G – one

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/ AVIO /MERL: 34 Group Size - 04
DATE :----------------------------- AF HOURS:-----------------------
CHECK À’
CENTER SECTION
01. Check flap actuator switches wiring for condition and freedom of
movement.
02. Check all electrical wiring for security and safety.
03. Check landing gear control motor and relay for condition and
security.
04. Check landing gear limit switches for condition and security.
POWER PLANT LH
05. Check electrical wiring, equipment and. associated accessories for
condition and security.
07. Inspect and clean igniter plugs.
and attachment.
09. Remove generator cover and inspect brushes for wear and
condition of armature. Check wiring and connections for security.
10. Check thermocouple and harness assembly for security and
damage. Check for continuity. Check harness for continuity.
POWER PLANT RH
11. Check electrical wiring, equipment and associated accessories for
12. Inspect and clean igniter plugs.
and attachment.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
CHECK À’
DATE: ----------------- SIGNATURE: ------------------
AME NO: ------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
TOOLS:
EQUIPMENTS:
7. T.P.G – one

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:-----------------------
CHECK `B’
COCKPIT
1. Check switches, knobs and circuit breakers for looseness and
operation.
2. Check all instruments for security of attachment, proper markings,
broken lenses, missing screws and placards.
3. Check instrument air filters and clean as necessary.
Check voltage regulators for condition, security of attachment,
arcing or burned contacts and wiring.
CABIN
4. Check flap drive motor for security, condition and alignment.
5. Check all electrical wirings for condition and proper operation.
6. Check all lights and switches for condition and proper operation
7. Check elevator actuator for condition and attachment.
DATE: ----------------- SIGNATURE: ------------------
AME NO: ------------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
TOOLS:
EQUIPMENTS:
7. T.P.G – one

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
DATE :----------------------------- AF HOURS:-----------------------
CHECK `C’
LEFT HAND WING
1. Check all electrical wiring for security and condition.
2. Check all navigation, ice detection, and landing lights for loose or
broken lenses.
3. Check pitot tube for condition and security of attachment. Drain
pitot system
RIGHT HAND WING
4. Check all electrical wiring for security and condition.
5. Check all navigation, ice detection, and landing lights for loose or
broken lenses.
6. Check pilot tube for condition and security of attachment. Drain
pilot system.
LANDING GEAR AND BRAKES
7. Check electrical wiring and components in all three wheel wells for
8. Check nose landing gear shimmy dampener for condition and
attachment. Service as necessary.
9. Check nose landing gear for condition, security of attachment and
broken or lens.
LANDING GEAR OPERATION
10. Check position indicators for security and adjustment of switches;
condition of wiring and proper operation of warning horn.
11. Check down-lock mechanism for proper engagement with the
landing gear in the down position; check down-lock switches for
proper adjustment.
12. Check landing gear safety switch for security of attachment and
proper operation and adjustment.
13. Check all electrical wires, "J" boxes and units for security, chaffing
and general condition.

Thiruvananthapuram
OJT MANUAL
OJT MANUAL

LEFT HAND ENGINE
14. Inspect and clean igniter plugs. Install new gasket every 200hours.
(Gasket- P/N 362-509-9001).
and attachment.
18 Check electrical wiring, equipment and associated accessories for
20. Remove, clean, insect and check operation of ignition glow plugs.
RIGHT HAND ENGINE
21. Inspect and clean igniter plugs. Install new gasket every 200hours.
(Gasket- P/N 362-509-9001).
24. Check all electrical wires, "J" boxes and units for security,
chaffing and general condition.
25. Check electrical wiring, equipment and associated accessories for
26. Remove, clean, insect and check operation of ignition glow plugs.
27. Refuel the aircraft as required.
28. Replenish the oil system as required.
DATE: ----------------- SIGNATURE: ------------------
AME NO: -----------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
TOOLS:
EQUIPMENTS:
7. T.P.G – one
CHAPTER : 02 SCHEDULED MAINTENANCE Page :5.2.141

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
PROCEDURE SHEET NO: RIA/PS/ AVIO /MER: 37 Group Size – 04
DATE :----------------------------- AF HOURS:-----------------------
CHECK `D’
NOSE SECTION
1. Check all nose section wiring for condition and security.
2. Check A.C. inverters for condition and security.
FUSELAGE
3. Check all navigation lights for security of attachment and loose or
broken lenses.
EMPENNAGE
4. Check all electrical wiring for condition and security.
5. Check navigation lights and rotating beacon for security of
attachment and loose or broken lenses.
AVIONICS.
6. Check VHF No. 2 For proper functioning
7. Check VOR For proper functioning
8. Check ADF For proper functioning
9. Check Transponder For proper functioning
10. Check ILS For proper functioning
11. Check Radar For proper functioning
12. Check Flight Director For proper functioning
13. Check Compass System For proper functioning
14. Check Autopilot For proper functioning
15. Check AIS For proper functioning
16. Marker receiver For proper functioning
17. Radio Altimeter For proper functioning
DATE: ----------------- SIGNATURE: ------------------
AME NO: -----------------------

Thiruvananthapuram
OJT MANUAL
OJT MANUAL
TOOLS:
EQUIPMENTS:
7. T.P.G – one

Thiruvananthapuram
OJT MANUAL
OJT MANUAL


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REGIONAL INSTITUTE OF

Controlled Copy No. …………………

REVISION AFFECTED INCORPORATED

Issue No. : 01 Revision No. : 01

REVISION AFFECTED INCORPORATED

01. Feb2013 05 5.1.137

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Section Chapter Page Issue Date Revisio Date

Issue No. : 01 Revision No. : 01

SECTION CHAPTER CONTENTS PAGE NO.

Issue No. : 01 Revision No. : 01

Regional Institute Of Aviation, Thiruvananthapuram is approved by DGCA to conduct

Regional Institute Of Aviation, Thiruvananthapuram have one Merlin 2B, pressurized

Issue No. : 01 Revision No. : 01

On job training facility of Regional Institute of Aviation will be utilized only to

Issue No. : 01 Revision No. : 01

TRAINING AT OTHER APPROVED ORGANISATIONS

Issue No. : 01 Revision No. : 01

This manual will be revised or amended under the following circumstances:-

1. On change of Training policy/ procedure in the institute

Issue No. : 01 Revision No. : 01

CONTROLLED COPY NO: 1 :OJT IN- CHARGE

CONTROLLED COPY NO: 2 :DGCA, NEW DELHI

CONTROLLED COPY NO: 3 :DY.DGCA (SR),

CONTROLLED COPY NO: 4 : ASST.DIRECTOR 0F AIRWORTHINES, KOCHI

CONTROLLED COPY NO: 5 :ACCOUNTABLE MANAGER

CONTROLLED COPY NO: 6 :AME INSTRUCTOR’S LIBRARY

Issue No. : 01 Revision No. : 01

Issue No. : 01 Revision No. : 01

Jet Engine, Piston

Heavy Aircraft, Light

Issue No. : 01 Revision No. : 01

Heavy Aircraft, Light

Issue No. : 01 Revision No. : 01

Literature for Merlin 2B

Literature for Cessna 152

Issue No. : 01 Revision No. : 01

The support equipment’s include the following.

SL.No MERLIN 2B CESSNA