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Aviation Mechanic Practical Test Guide
Aviation Mechanic Practical Test Guide
CTICAL
AVIATION MECHANIC
PRACTICAL TEST GUIDE
ACME PUBLICATIONS
FORT WORTH, TEXAS
Copyright 19a9
FOREWORD
Thank you for purchasing this ACME publication. We have sought to make it the finest
test preparation material available. The Mechanic Practical Test is one of the many Acme
Blue Books published specifically to help persons obtain FAA certificates and ratings.
These books cover the entire range of pilot and mechanic certificates. Of special interest
to mechanics is ACME's Mechanic Test Guide series, which are prepared for the General,
Airframe, and Powerplant written test. Other ACME books can be found on the special
order sheet inserted in the back of this book. New books are being added regularly, so
if you don't find what you want, please call for updated information.
MECHANIC RATING
There are two Individual mechanic ratings. These are the Airframe mechanic rating and the Powerpiant
mechanic rating. The Airframe mechanic rating authorizes the mechanic to maintain, repair, and overhaul
everything on the aircraft except the engine, the propeller, the aircraft Instruments, and radio or electronic
units,
The Powerplant mechanic rating authorizes the mechanic to maintain, repair, and overhaul aircraft engines.
This Includes both reciprocating and turbine engines, A Powerplant mechanic may also do minor alterations
and minor repairs to propellers,
Do not confuse the mechanic rating with another rating called the "Repairman" rating, The Repairman
certificate Is Issued to persons employed for a specific Job requiring special qualifications by a certificated
repair station, or by a certificated commercial operator or certificated air carrier, This work may consist of
welding, repairing aircraft Instruments, overhauling constant'speed propellers, or other specified Jobs, A
repairman loses the privileges of the certificate if the place of employment changes,
You do not need to be a citizen of the United States to obtain an FAA mechanic rating, However, you must
be at least 18 years of age.
REQUIRED EXPERIENCE
Federal regulations require a mechanic applicant to have practical experience appropriate to the rating being
sought before the FAA written mechanic examinations may be taken.
The FAA requires documentary evidence of at least 18 months of practical experience with procedures,
practices, materials, tools, and equipment generally used In constnucting, maintaining, or altering of airframes
or powerplants (as appropriate to the rating being sought).
If you wish to acquire both mechanic ratings simultaneously, then you must present proof of at least 30
months of practical experience concurrently performing the duties appropriate to both the Airframe and
Powerplant mechanic ratings.
PROOF OF EXPERIENCE
When you apply to the FAA District Office to take the written exam, the FAA will expect reasonable
documentary proof of your mechanic experience. Such proof may consist of military service records or
letters from present or former employers, The FAA prefers that the letters of proof be signed by a
certificated airframe and powerplant mechanic. If this cannot be done, the signature of the shop foreman,
shop superintendent, or a maintenance officer Is normally acceptable,
For experience purposes, the FAA will accept a graduation certificate or a certificate of completion from an
FAA-certificated aviation maintenance techniCian school. The school curriculum must consist of 1,150 hours
for each rating, or 1,900 hours for both the airframe and powerplant rating.
After the FAA maintenance Inspector has approved your record, you will be given FAA Form 8610-2 to fill
out In dupllcate. This form authorizes you to take the written exam at any FAA testing faCility.
If you are not a citizen of the United States, you must have either a signed written statement from your
country's airworthiness authority or from an advisor of the ICAO (International Civil Aviation Organization)
certifying your experience.
WRITTEN EXAMS
Three written exams must be passed to obtain an FAA Mechanic Certificate with both the Airframe and
Powerplant ratings, These are the General Mechanic, Airframe Mechanic, and Powerplant Mechanic written
exams.
To obtain an FAA Mechanic Certificate with only one rating (either the Airframe or Powerplant), only two
written exams must be passed. These are the General Mechanic and either the Airframe or Powerplant
written exams. Once you have passed the General Mechanic exam and received one rating, you do not
have to retake the General exam when testing for the other mechanic rating.
The General Mechanic written exam has one section consisting of 50 multiple choice-type questions. The
Airframe and Powerplant written exams each have two sections as follows: Airframe Structures (25
questions) and Airframe Systems and Components (75 question); Powerplant Theory and Maintenance (25
questions) and Powerplant Systems and Components (75 question). If you fail any section of the exams,
you must retake only the section you failed. 70% Is the passing grade for each section.
The FAA has designated certain persons to administer written exams. Your answer sheet must be mailed
to the FAA In Oklahoma City, Oklahoma for grading and recording, You can normally expect to receive the
test results in one to two weeks.
DESIGNATED EXAMINERS
The practical examination for a mechanic certificate may be obtained from either the FAA maintenance
Inspector at an FAA District Office, or from an Airframe and Powerplant Mechanic who has been designated
by the FAA as a mechanic examiner. Also, this designated examiner probably holds an Inspection Authorization (IA). The great majority of mechanic applicants take their practical examination with a designated
examiner.
When you have your written examination grade slips shOWing a passing grade for each section, make an
appointment with a designated Mechanic Examiner to take the practical examinations. YOll do not have to
supply any tools, just your written examination grade slips, the appropriate fee, and the FAA Form 8610-2.
The projects and questions that you will be given on the practical exams will depend on the examiner, what
equipment he has, and what he believes to be Important. The various test subjects are grouped as in the
following. Each group consists of both practical job projects and oral questions. Genera!!y, the practical
will consist of projects from about 10% to 50% of the subjects listed. Six hours Is the official time for the
oral and practical exams.
Basic electricity
2.
Aircraft drawings
8.
Mathematics
10. Physics
Wood structures
5.
Welding
2.
Aircraft covering
6.
3.
Aircraft finishes
7.
Airframe inspection
4.
1.
6. Fuel systems
2.
7. Electrical systems
3.
8.
4. Instrument systems
2,
3,
Engine inspection
2,
a.
Induction systems
9,
4.
Lubricating systems
5,
Ignition systems
11, Propellers
6.
If you already have either an Airframe or Powerplant mechanic certificate you will not be tested on the
General oral or practical test subjects.
The mechanic examiner will grade you as "satisfactory" or "unsatisfactory" on each test subject given. If you
receive an unsatisfactory on any subject, you fall the pracllcaltest and must be retested later on that specific
subject. At the time of retesting, you must present documentary evidence to the examiner that you have
received at least five hours of additional training or Instruction on the failed subject before you can be
retested,
Upon successful completion of the practical test, the mechanic examiner will complete the application form,
assign a grade of satisfactory, and Issue you a temporary mechanic certificate, He will then mall the
application to the FAA, Airman Certification Branch, Oklahoma City, Oklahoma Your permanent mechanic
certificate will be sent to you by the FAA within 120 days,
= E + A)
7. What Is inductance?
A voltage that is induced in a call In an AC circuit. This voltage is opposite in direction to the
applied voltage, and opposes any change in the alternating current.
8. What is impedance?
14. What should be the specific gravity of'the electroly1e in a fully charged lead-acid battery?
It should be between 1.275 and 1.300.
15. What Instrument Is used to determine the specific gravity of electroly1e in a lead-acid battery?
A hydrometer.
16. Why can't a hydrometer be used to determine the charge of a nickel-cadmium battery?
The specific gravity of the electroiy1e In a nickel-cadmium battery does not change appreciably
during charge or discharge of the battery.
17. When USing a hydrometer to check the charge of a lead-acid battery, at what temperatures must a
correction factor be applied to the reading?
Adjustments must be made if temperature of the electroly1e Is above gOF or below 70'F.
1B. What Is electromagnetic induction?
It Is the transfer of electrical energy by means of a magnetic field. This Is the prinCiple of transformer
operation.
19. How are battery compartments protected against corrosion?
They are coated with special corrosion resistant paints such as bituminous paint.
'1
20. What should be the correct electroly1e level In a properly serviced batter'(
It should be approximately 3/8 Inches above the plates. If the battery has baffle plates above the
cell plates, the electroly1e level should be up to the hole in the baffle plate in each cell.
1.
What type of lines are used on aircraft drawings to Indicate hidden views, alternate positions, and
center lines?
A hidden view line Is a medium width line made up of short dashes. It represents an edge that
cannot be seen when looking at the part from a specific position.
Alternate position lines are medium width lines composed of one long and two short evenly spaced
dashes. They are used to show the alternate position of a part or the relative position of a missing
dart.
Center lines are composed of alternate long and short dashes, and are used to Indicate the center
of an object or part of an object.
2.
3.
4.
5.
Why are dimensions used, and how are they shown on an aircraft drawing?
Dimensions are solid narrow lines, broken at midpoint for the Insertion of measurements. They
are used to Indicate the size of an object.
6.
7.
8.
10
9.
2.
Interpret any dimension appearing on a drawing, Including the correct application of limits or
tolerances to the dimension.
3.
Make a sketch of a repair or an alteration, Including the correct position of the views, the dimension,
and the material specifications.
4.
Use an electrical cable and determine the correct cable size for carrying a specified amount of
current for a certain distance.
5.
Identify lines and symbols on a typical aircraft detail and assembly drawing.
6.
Name all the major components and their location in an Installation diagram.
7.
8.
11
The prime concem Is the longitudinal balance, or the fore and aft locallon of the CG along the longitudinal
axis. The CG location with reference to the lateral axis (wing tip to wing tip) is also Important. However,
as far as weight Is concerned, the design of the aircraft assumes lateral symmetry. That is, for an item of
weight left of the fuselage centerline, there is an equal weight at a corresponding location on the right.
DATUM - Is an imaginary vertical plane or line from which all fore and aft measurements are taken. It Is
established by the manufacturer and can be at the nose, firewall, wing leading edge, a point In space in
front of the nose, etc.
ARM (also moment arm) - is the horizontal distance in inches from the datum to the center of gravity of
an Installed item. It Is also the distance from the datum to the CG of the aircraft. When an item is Installed
forward of the datum, the arm will be minus (-). An Item installed aft of the datum will have a positive or plus
valve and the algebraic sign (+) Is normally omitted. An arm may also be a "station" or abbreviated to "F.S."
meaning "fuselage station." Station 70 would be an arm of 70 Inches.
MOMENT - Is the product of the weight of an item mUltiplied by its arm. Moments are expressed In poundInches. Total moment Is aircraft weight multiplied by the distance between the datum and aircraft 00. The
CG of an aircraft can, therefore, always be found by dividing total moment by total weight.
INDEX -Is a moment divided Qya constant such as 100,1,000,10,000, etc. The purpose of an Index (or
"reduction factor") is to simplil'y weight and balance computations where heavy items and long arms result
In large, unmanageable numbers. An index may be referred to as a 'moment Index" and Is normally written
as "MOM/100," "MOM/1000,' etc.
STANDARD WEIGHTS - have been established for numerous Items Involved In weight and balance
computations. Aviation gasoline weighs 6 pounds per U.S. gallon, engine oli weighs 7.5 pounds per U.S.
gallon. and water weighs 8.35 pounds per gallon. Unless the actual weight is furnished, each occupant
may be assumed to weigh 170 pounds.
The first step In any weight and balance problem Is to list all items of weight beginning with the empty
weight of the aircraft. The next step is to list the arm of each item (preceded by a minus sign when the
item Is located forward of the datum). The moment for each Item may now be found by multiplying the
weight of that Item by Its arm. Now, add or subtract as necessary (using separate columns for plus and
minus H you prefer) to find a total weight and total moment. DO NOT total the arms. The location of the
new CG (arm) Is now found by dividing total moment by tolal weight.
1. What Is the datum and its purpose when making weight and balance computations?
It Is an Imaginary vertical line or plane used In weight and balance calculations from which
measurements are taken both forward and aft to determine the relative location of Items In the
aircraft. The distance from the datum. In Inches, to the weight center of an lIem Is called the "arm:
2.
3.
When computing weight and balance, what Is the "moment" and how Is It obtained?
A moment Is a force which tends to rotate the aircraft about Its center of gravity. It Is obtained by
multiplying the weight of an Item (pounds) by the distance of the Item from the datum (inches). It
Is, therefore, expressed In "pound-Inches."
12
4.
5.
What Is "tare" weight, and how Is it handled when making weight and balance calculations?
'Tare' Is the weight of the extra equipment used for weighing the aircraft such as chocks, blocks,
jacks, and chains. Tare weight must be subtracted from the scale readings in order-to obtain the
actual weight of the aircraft.
6.
What Is meant
by "minimum fuel" and how Is It calculated for weight and balance purposes?
Minimum fuel Is the amount of fuel that should be used in weight and balance computations when
the aircraft Is loaded for an extreme condition check. For a reciprocating engine airplane cert~icated
under FAR Part 23, this Is the fuel necessary to operate the englne(s) for one-half hour at maximum
continuous power.
7.
B.
How would you determine the empty weight and empty weight CG of an aircraft which has tricycle
landing gear if all weight and balance records are missing?
Use three scales and record the weight under each wheel. Then, measure the distance in inches
from the nosewheel to the main gear and multiply this figure by the combined weight of each main
wheel. Into this number, divide the total weight of the aircraft. The answer will be the number of
inches. the CG Is located aft of the nosewheel. NOTE: This can be proved by using the figures in
Problem 2 on page 13. You should find a CG 46.75 inches aft of the nosewheel. The nosewheel
is B Inches forward of datum.
9.
What is "ballast"?
Ballast is lead bars, metal plates, shot bags, sand bags, or other items of weight which are placed
in an aircraft to attain a desired CG location.
10. What Is the difference between flxedwing aircraft and helicopter CG ranges?
The CG location in a helicopter Is much more critical than in fixed-wing aircraft. The CG range In
some helicopters is less than three inches.
11. When weighing an aircraft to determine the empty weight CG, what must you do with regard to the
equipment Which is normally carried In the aircraft?
All operating eqUipment whether It is required, optional, or special equipment must be included In
the aircraft's empty weight.
12. Why do some manufacturers specify an empty weight CG even though the aircraft Is not operated at
this empty weight?
When the empty weight CG falls within the empty weight CG range, it is unnecessary to perform
a forward or aft weight and balance check If standard loading and seating arrangements are used?
13
13. Why must the aircraft category be considered when computing weight and balance?
Some airplanes are certificated In both normal and utIlity categories. This means a different
maximum allowable gross weight depending on which category the aircraft will be operated In.
The following problems are typical of the different types of weight and balance calculations which
may be required during the Mechanic Practical Test.
PROBLEM 1
You have a 5-pound welghllocated 24 Inches aft of a fulcrum (datum) and a 10-pound weight located 48
inches aft of the fulcrum. How far forward of the fulcrum must you place a 20-pound weight In order to
establish a balance?
The first step Is 10 find the tolal moment acting aft of Ihe fulcrum. Using the basic weight and balance
formula of WEIGHT times ARM equals MOMENT, find the total moment acllng aft of the fulcrum to be 600
pound-Inches.
WEIGHT
ARM
MOMENT
5lbs.
x
24"
120
101bs.
x
48"
480
151bs.
600
You have now determined that a 600 pound-Inch moment Is acting downward aft of the fulcrum. To be In
balance, the 20-pound weight must be placed forward of the fulcrum at a distance which will create an
equal 600 pound-Inch moment. since WEIGHT x ARM ~ MOMENT, MOMENT + WEIGHT ~ ARM.
Therefore, 600 pound-Inches divided by 20 pounds equals 30 Inches.
The 20-pound weight placed 30 Inches forward of the fulcrum will exactly balance the 5 and la-pound
weights at 24 and 48 Inches respectively aft of the fulcrum.
PROBLEM 2
When an empty airplane was weighed, the scale readings were as follows: Nosewheel - 500 pounds; left
main wheel - 570 pounds; and right main wheel - 530 pounds. The nosewheel arm Is 8 Inches forward of
datum and the main gear Is located at 60 Inches aft of datum. Find the empty weight CG.
WEIGHT lib)
Nosewheel
500
Right main Wheel 530
Left main wheel
570
16001bs.
ARM (In)
- 8
60
60
MOMENT (Ib-in)
- 4000
31800
34200
62000 Ib-In.
The CG Is now obtained by dividing total moment by total weight. Therefore, 62,000 divided 1,600 ~ 38. 75
inches aft of datum.
14
PROBLEM 3
Find the location of the new loaded CG for an airplane which was modified Into a cropduster.
The original empty weight was 1,BOO pounds with the CG located at 40 Inches aft of datum. Removed a
300-pound engine at - 15 Inches and replaced It with a 40o-pound engine at an arm of -25 inches. Removed
a 20-pound propeller at -40 Inches and replaced It with a 40-pound propeller at -50 Inches. The fuel tank
remains at 50 inches aft of datum (+50) and has capacity of 20 gallons usable fuel. The pilot seat Is at 60
Inches aft of datum and the pilot weighs 170 pounds. Removed a 2O-pound passenger seat at an arm of
30 inches (+30) and installed a 50-pound hopper at the same point Total capacity of the hopper is 440
pounds.
WEIGHTS
Plus Minus
ITEM
Emptyairplane 1,BOO.
40.
Remove engine
-300.
Add engine
400.
Remove propeller
-20.
Add propeller
40.
Fuel (5 Ib/gal)
120.
Pilot
170.
Remove seat
-20.
500.
Add hopper
3,030. -340.
-340.
2,690.lbs.
ARM
72,000,
-15.
-25.
-40.
-50.
50.
60.
30.
30.
MOMENTS
Positive
Negative
4,500.
-10,000.
800.
-2,000.
6,000.
10,200.
-BOO.
15,OOg.
108,600.
-12,600.
- 12,{lgg.
95,900. Ib-In.
The loaded airplane CG may now be found by dividing the new total moment by the new total weight.
Therefore, 95,900 divided by 2,690 = 35.66 Inches aft of datum.
1.
2.
3.
Alter making an equipment change, establish new weight and balance data, then determine if the
change has caused either the maximum weight or the CG limits to be exceeded.
4.
Determine the amount of fuel needed as minimum fuel for weight and balance computations.
5.
6.
7.
Compute weight and balance for a helicopter and determine If it Is within the CG range.
S.
Using a weight and balance report, list the forward and aft CG limits and determine the total distance
between them.
9.
Using the weight and balance information for two aircraft, locate the datum line lor each aircraft
without error.
10. During the weighing of an aircraft, list all the tare items.
15
1.
2.
3.
What precautions should be taken when routing fluid lines adjacent to electrical wiring?
Route the fluid lines below the electrical wiring and maintain a clearance of at least six Inches
whenever possible. In no case should fluid lines and electrical wiring be closer than one-hall inch.
Ensure that both the wiring and the fluid lines are fastened to the aircraft structure by clamps or
other methods that will maintain the separation.
4.
What is the purpose of the Identification stripe running along the length of a flexible hose?
The stripe is used to determine H the hose has twisted during Installation. The stripe should not
spiral around the hose after installation is completed.
5.
6.
7.
8.
9.
What are the three parts of a Military Standard (MS) flareless-tube fitting?
The body, the sleeve, and a nut.
16
12. What is tlie advantage of flexible tellon hose over rubber hose?
It can be used in the same manner as rubber hose and it has a better operating strength.
13. What precaution should be taken when deburring the cut end of a tube?
Care should be taken that the tubing is not cracked or that the wall thickness Is not reduced by
the deburrlng process.
1.
Make up and Install a complete replacement rigid fluid line that requires cutting, bending, and the
installation of fittings.
2.
3.
4.
5.
6.
Point out defects in metal tubing that are cause for relection.
7.
Install support clamps on a metal fluid line using the proper spacing.
S.
POint oULand identify several different fluid and air lines that are Installed in an aircraft.
What is a suitable nondestructive method for detecting surface cracks in aluminum castings and
forgings?
The dye penetrant inspection method detects surface cracks with equal success on aluminum,
magnesium, brass, copper, and titanium. It can also be used on ceramics, plastics, and glass.
2.
Briefly describe the steps to be taken when performing a dye penetrant Inspection.
Thoroughly clean the metal surface, dry completely, and apply the penetrant. Remove the penetrant
from the surface, dry the part, and apply the developer. Inspect and interpret the results.
3.
4.
17
5.
6.
7.
What is the smallest cable that can be used in primary control systems?
Federal regulations state that no cable smaller than one-eighth Inch In diameter may be used for
this purpose.
8.
9.
What should be the width of the weld bead and depth of penetration when making a butt weld?
The bead width should be 3 to 5 times the thickness of the base metal and there should be 100
percent penetration.
What Is done to prevent certain aluminum alloy rivets from becoming hard after heat treating and
quenching?
The rivets are stored in a refrigerator at a temperature lower than 32'F. The rivets will remain soft
for several days.
What tool is used to measure the outside dimenSions of shafts, thickness of sheet metal stock,
diameter of drills, and for many other similar applications?
Outside micrometer calipers.
16.
18
2.
3.
4.
5.
Identify aircraft hardware such as bolts and rivets by the manufacturer's markings.
6.
7.
8.
Check the alignment of a crankshaft using a dial Indicator and determine If it is within limits.
9.
Perform a chemical etching test on aluminum alloy and determine if the material Is weldable.
10. Make a visual Inspection of several sample welds and point out any undesirable characteristics.
What Is the procedure for extinguishing an Induction system fire that occurs during starting of a
reciprocating aircraft engine?
A IIreguard who is familiar with the aircraft's Induction system should be standing by with a C02
fire elctlngulsher during the engine start. If an engine fire develops, continue cranking to start the
engine and blowout the fire. If the engine does not start and the fire continues to burn, discontinue
starting; The flreguard should extinguish the fire using available equipment
2.
What Is the purpose of pulling a propeller through by hand for two or three revolutions prior to
starting some reCiprocating engines?
The purpose Is to detect a hydraulic lock If one Is present. Any liquid present In the cylinder will
be Indicated by an abnormal effort required to rotate the propeller, or by the propeller stopping
abruptly during rotation.
3.
What damage is most likely to occur If force Is exerted on the crankshaft when there Is a liquid lock?
The force can bend or break a connecting rod.
4.
What information must be located on or near fuel filler openings? Oil filler openings?
For normal category aircraft, the word "fuel" and the minimum fuel grade or designation for the
engine. For transport category aircraft, the same Information listed for normal category. 011 filler
openings require the word "011" to be marked at or near the filler cover.
19
5.
6.
What would be the result of operating an aircraft reciprocating engine using a lower grade of
gasoline than that specified for the engine?
There would be a loss of engine power, efficiency, and possible detonation.
7.
Why should an aviation mechanic know the meaning of the standard light signals which are used by
control tower operators?
If radio communication Is not possible, the light signals may be used for taxi control when
an aircraft must be taxied to another part of the airport.
S.
Which publication lists the standard FAA hand signals a taxi signalman should use?
The FAA Airman's Information Manual (AIM).
9.
What will be the result of mixing aviation gasoline with Jet fue! In a turbine engine?
When aviation gasoline is m!xed with jet fuel, the tetraethyllead In the gasoline will form deposits
on the turbine blades and vanes. Continued use of mixed fuels may cause a loss In engine
efficiency. However, there will be no detrimental effect on the engine if such usage Is on a
limited basis.
10. What may result if gasoline that is contaminated with Jet fuel is used in a reciprocating engine?
Gasoline which Is contaminated with Jet fuel is unsafe for use In a reciprocating engine and can
result In complete engine failure.
11. When towing an aircraft with a tow tractor, what brakes should be used to slOP the aircraft?
The tow tractor brakes and the aircraft brakes should both be used. Use of the brakes should be
coordinated by the man In the cockpit.
1.
Start, runup and shutdown an aircraft reciprocating engine which has a floattype carburetor.
2.
3.
Check an aircraft fuel system for water contamination by draining all sumps and strainers.
4.
5.
Demonstrate the procedures to check for and to clear a hydraulic lock In a reCiprocating engine.
20
6.
Tledown and secure an aircraft that Is to be stored outside. Assume storage will be under normal
weather conditions.
7.
8.
9.
1.
2.
3.
What are the factors which affect the type (form) of corrosion?
Theform of corrosion varies with atmospheric conditions, size and shape of the metal, the type of
metal, and the corrosion-producing agents present.
4.
What methods are used for removing rust from aircraft materials?
Except on highly stressed steel surfaces, the use of abrasive papers and compounds, small power
buffers and buffing compounds. hand wire brushing and steel wool are all acceptable methods of
removing rust.
5.
6.
7.
B.
21
9.
2.
3.
Use paints and other organic coatings for corrosion protection purposes.
4.
5.
Select correct cleaning materials for aluminum, steel, and magnesium parts.
6.
7.
e.
MATHEMATICS ORAL
1.
A = LW
2.
What is PI (.) ?
PI Is a constant (3.1416) and Is the ratio of the circumference to the diameter of any circle.
3.
4.
22
5.
6.
7.
B.
9.
What 15 the sum of a large negative number and a small positive number?
Subtract the smaller number from the larger number and use the sign of the larger number In the
answer.
MATHEMATICS PROJECTS
1.
2.
Select the correct formula from a list of formulas and compute the volume of a cylinder.
3.
4.
5.
6.
7.
Select the correct fonnula and compute the volume of a baggage compartment.
8.
9.
Using reference material, locate the Instructions for determining square root.
23
What are the record requirements for returning an aircraft to service after a 100 hour Inspection?
There must be an entry made In the maintenance records Indicaling the type and date of the
inspection, aircraft time In service, a statement to the effect that the aircraft has been inspected In
accordance with 100 hour Inspection requirements and was determined to be In airworthy
condltlon,and the signature and certificate number of the person approving the aircraft for return to
service.
3.
What are the record requirements after compliance with an Airworthiness Directive (AD)?
No specific format for the record entry is required. However, the record entries must show the
specific number assigned to the AD, the date of compliance, the method of compliance, aircraft
lime In service, as well as the signature and certificate number of the person who compiled with
the AD. In addition, the records must show the current status of all applicable Airworthiness
Directives, and must Include the method of compliance.
4.
5.
6.
Who is required to make the entry in the aircraft records after a 100 hour inspection has been
pertormed?
.
7.
How long must the record of a 100 hour inspection be retained by the owner or operator?
Until the work is repeated or superseded by other work or for one year after the 100 hour Inspection
was pertormed.
8.
Where can a mechanic find an example of a 100 hour Inspection maintenance record entry?
FAR 43.11.
9.
When an aircraft is sold, what is done wllh the aircraft records containing the current status of
Airworthiness Directives?
FAR's require the records to be transferred to the purchaser at the lime of the sale.
10. What type of maintenance record entry is required when an inspection under FAR 91.169 Is made to
a large airplane or a turbine engine-powered multienglne airplane and defects are found?
The entry must name the kind of inspection (continuous airworthiness inspection program, approved
inspection program, etc.). A signed and dated list of defects found must be given to the owner.
24
11. What are the required entries In a new maintenance record for an engine that has been rebuilt and
granted zero time by the manufacturer or by an agency approved by the manulacturer?
The manufacturer or agency that grants zero lime to a rebuilt engine must enter Into the records
a signed statement of the date the engine was rebuilt, each change made as required by
Airworthiness Directives, and each change made In compliance with the manufacturer's service
bulletins if an entry is specifically requested In a bulletin.
1.
Prepare an FAA Form 337, Major Repair and Alteration form, describing either a major repair or
major alteration. Know the disposition of this form and all copies.
2.
From samples of completed FAA Form 337, select the ones that have been filled in correctly with
all the required Information.
3.
Make a maintenance record entry for returning an aircraft to service after a 100 hour inspection.
4.
5.
Enter the required information In the permanent maintenance records when routine maintenance has
been pelformed.
6.
Make a maintenance record entry for the altimeter system test and inspection which is required by
FAR Part 91.
1.
What is matter?
Anything that occupies space and has weight.
2.
3.
4.
What Is the name of the atmospheric phenomenon where cool air Is trapped near the earth by warm
air?
A temperature inversion.
5.
What is the speed of souna through the air under standard sea level conditions?
It is 662 knots and 76i mph.
6.
25
7.
10. What Is the formUla for computing force, pressure, and area?
Force equals pressure times area or F = P x A.
11. What Is absolute zero?
It Is the temperature al which all motion of the molecules will cease entirely In a given sample of
gas. It Is considered to be -273C.
12. What are the two factors Involved In work?
Force and movement through a measurable distance.
13. How is pressure expressed In hydraulics and pneumatics?
1.
From a drawing of ten levers, select two each of the three classes of levers.
2.
From a standard temperature and altitude chart, select the standard temperature at sea level, and at
5,000 foot Increments up to 30 thousand feet.
3.
Label the area of lowest pressure and highest velocity on a drawing of a venturI.
4.
Correctly compute force, pressure, and area problems using the formula, F = P x A.
5.
6.
1.
1
L =
1=
R=
E=
7.
R
E
Using a single pulley, draw a pulley system that will 11ft a 200 pound load with a 100 pound force.
26
2.
3.
4.
Where can you find a list of approved engines for use In a specific model aircraft?
On the Type Certificate Data Sheet for the Aircraft.
5.
Where can you find Airworthiness Standards for normal, utility, and acrobatic category airplanes?
FAR Part 23.
6.
Where can you find Airworth:ness Standards for transport category airplanes?
FAR Part 25
7.
What federal regulation defines the requirements for the Issue of Type Certificates?
FAR Part 21.
8.
Where would you look to find out if a specific airplane can be certified in more than one category?
On the Aircraft Specifications or Type Certificate Data Sheet.
9.
What publication is issued by airirame, engine, and component manufacturers to notify aircraft
owners of design defects.
Service bulletins.
10. What publication contains complete instructions for maintenance of all systems and components
installed In an aircraft?
The manufacturer's Aircraft Maintenance Manual.
11. What are FAA Advisory Circulars?
They are publications containing non-regulatory material of Interest to the aviation public.
Use the Aircraft Specifications or Type Certificate Data Sheets and flnel the CG range of an aircraft.
2.
Find and list all the AilWorthiness Directives that apply to a specific airplane.
3.
27
4.
Use Technical Standard Orders to find the standards lor a specific part manufactured under the TSO
system.
5.
Read, Interpret, and write a short descrlpllon of the work to be accomplished as set forth In an
Airworthiness Directive or a Supplementaf Type Certificate.
6.
Using a manufacturer's Illustrated Parts Catalog. locate and list the correct part number for a
replacement part
3.
4.
When a mechanic has a permanent change of address, what must be done within 30 days after the
change?
He must notify in writing the Administrator of the FAA.
7.
B.
9.
10. What are the privileges of a certificated mechanic in regard to performing a 100 hour inspection and
returning an aircraft to service? An annual Inspection?
A certificated A& P mechanic may perform a 100 hour inspection and return an aircraft to service
by making the proper entries In the maintenance records. An A&P mechanic with an Inspection
Authorization may perform an annual inspection and return an aircraft to service.
28
11. Who has final responsibility for maintaining aircraft maintenance records?
The owner or operator of the aircraft.
12. Mayan airframe mechanic perform maintenance on engines?
Yes, under the supervision of a powerplant mechanic.
1.
Using FAR Part 43, Part 65, and Part 91, list the type of Inspections a certificated mechanic may
perform and the FAR reference for each one.
2.
Review a list of 10 maintenance functions and determine which an airframe mechanic may perform.
3.
Review a list of 10 maintenance functions and determine which functions a powerplant mechaniC
may perform.
4.
Using FAR Part 43, classify a list of 10 repairs as either major or minor repairs.
5.
Using FAR Part 43, classify a list of 10 alterations as either major or minor alterations,
6.
Using FAR Part 65, list the procedures required for a permanent change of address.
29
30
AIRFRAME STRUCTURES
WOOD STRUCTURES ORAL
1.
What species of wood Is used as a standard for strength properties of other species of wood used In
aircraft structures?
Spruce Is used as a standard.
2.
What type of wood quality must be used In the repair of aircraft structures?
The wood must be aircraft quality.
3.
4.
What are the two types of glue used for aircraft wood structure repair?
They are casein and synthetic resin glue. The resin glues that are recommended for wood
aircraft applications are the resorcinol formaldehyde type glues.
5.
6.
What are the results of using InSUfficient gluing pressure when making a wood joint?
The results will normally be thick glue lines, which Indicate a weak Joint.
7.
How long should a wood glue Joint be kept under pressure before removing the clamps?
The pressing time will vary depending on the temperature of the curing room. The curing
temperatures are from 70T and up. Higher temperatures will cause the glue to set faster. To
be certain that a glue joint is satlslactory, it is recommended that It remain under pressure at
about 65'F. for a period of at least seven hours. Full joint strength will develop only after
conditioning for at least two days.
8.
What are some of the various methods used to apply pressure to JOints In aircraft gluing operations?
Brads, nails, screws, clamps, and hydraulic and electric power presses.
9.
Why does the strength of a scarf joint depend upon the accuracy of the two beveled surfaces?
Because an Inaccurate bevel will reduce the amount of effective glue area.
10. What type of patch is preferred for repair of stressed plywood skin and why?
A properly prepared and Inserted scarf patch Is the best repair for plywood, and Is preferred for
most skin repairs. It dillers from a splayed patch In that the edges are scarfed to a 12 to 1 slope
instead of a 5 to 1 slope, and it uses reinforcements under the patch where the glue joints occur.
11. Are mineral streaks acceptable In aircraft wood?
Yes, providing careful Inspection fails to reveal any decay,
31
15.
What is compression wood and why is it not acceptable for aircraft structures?
Compression wood Is wood that is characterized by high specific gravity and has the
appearance of excessive growth of summer wood. This defect Is difficult to recognize and is
very detrimental to strength. Reject all material containing compression wood.
1.
From reference material, locate the repair procedures for elongated bolt holes in a spar.
2.
3.
4.
5.
Determine the moisture content of wood by weighing, heating, reweighing, and making the proper
calculations.
6.
7.
8,
From reference material, locate the requirements for making scarf splice joints.
9.
32
1.
What determines the required quality and strength of fabric that Is to be used for covering aircraft?
The required strength and quality of aircraft fabric Is determined by the pounds per square foot
of wing loading, and the never-exceed airspeed of the aircraft.
2.
When are anti-tear strips recommended, and where are they used?
Anti-tear strips are used on aircraft with never-exceed speeds In excess of 250 mph, and they are
Installed over the ribs under the reinforcing tape. They are recommended for the complete upper
surface of the wings. and on the bottom surface of that part of the Wing that Is In the
slipstream.
3.
What is the maximum permissible deterioration of aircraft fabric before It Is considered unworthy?
Fabric covering is considered unworthy when it deteriorates more than 30 percent from Its originally
required tensile strength.
4.
What should be the strength of the fabric used for re-covering an aircraft?
All fabrlc, surface tape, reinforcing tape, thread and lacing cord used to re-cover or repair aircraft
cover should be of high grade aircraft textile material. The materials must be at least as good a
quality and of equivalent strength as those' originally used by the aircraft manufacturer.
5.
What is the purpose, location, and the methOd of Installing drain grommets In aircraft fabric?
Drain grommets are located on the underside of airfoils at the trailing edge as close to the rib as
practical, and at the lowest point along the center of the underside of each fuselage bay. They
allow the condensed moisture to leave the aircraft as well as furnish ventilation. Brass grommets
should be mounted on fabric patches and then doped to the covering. Plastic grommets are doped
directly to the covering. Both types are installed with the second coat of dope, and the drain holes
opened by cutting out the fabric with a small knife.
6.
7.
8.
9.
10. What should be done with structure that will come in contact with doped fabric?
Treat all parts of the structure that will come In contact with doped fabric with a protective coating
such as aluminum foil, dope-proof paint, or cellulose tape.
33
11. If the original rib stitch spacing cannot be determined when re-covering and aircraft, what rib stitch
spacing should be used?
Use the rib stitch spacing chart In Advisory Circular 43.13-1A.
12. What Is the standard tie-off knot used during rib stitching?
A modified seine knot is used to tie off all stitches except the startlng stitch.
13. What do you call the edge of cloth, tape, or webbing that has been woven to prevent raveling?
Selvage edge.
14. The types of fabric used for covering aircraft are organic and synthetic. Name two organic and two
synthetic fibers.
The organic fibers are cotton and linen. The synthetic fibers Include fiber glass and heat shrinkable
synthetic fibers such as nylon, orion, and dacron.
15. When covering aircraft, where is surface tape used?
Sewed seams, lapped edges, and rib stitching or screws must be covered w~h pinked-edge surface
tape.
2.
3.
Make a strength test on doped aircraft fabric using a punch tester and determine if it Is within
minimum strength requirements or needs furtlher testing.
4.
Demonstrate how to tie both a splice knot and a modified seine knot.
5.
6.
Hand sew a fabric tear using a baseball stitch and correct stitch spacing.
7.
8.
9.
34
2.
S.
What causes blushing when applying dope or lacquer, and how can it be prevented?
When doping Is accomplished under humid conditions blushing Is common. Rapid evaporation
of thinners and solvents lower the temperature of the surface of the wet cope causing condensation
of moisture from the air. The moisture causes a milky white appearance known as blush. The
condition may be eliminated by heating the room to decrease humidity, or by using a blushretarding
thinner to increase the drying time. Blushing is also caused by moisture in the air supply, drafts,
or changes in temperature.
4.
What Is the purpose of using fungicidal dope when finishing aircraft fabric?
To prevent mlcroblologlcal deterioration (rotting) of the fabric.
5.
What are the Identification marking requirements for United Stales registered fixed wing aircraft?
The Roman capital letter "N" followed by the registration number must be displayed on both sides
of the fuselage, or on both sides of the vertical tall sUrfaces. The height of the characters must be
equal In sIze and be at least 12 inches, and the characters must be 2/3 as wide as they are high.
The exceptions to the width rule are the number "1", which must be 1/6 as wide as it Is high, and
the letters "M" and "W', which may be as wide as they are high. Characters must be formed by solid
lines 1/6 as thick as they ate high, and the spacing between each character may not be less than
1/4 of the character width.
6.
7.
8.
What is applied to metallic surfaces as a corrosion resistant covering before the application of
enamel or lacquer?
Zinc chromate primer is normally used for this purpose.
9.
10. What type of paint may be used over any paint system that is In good condition?
Epoxy topcoats will adhere to all the paint systems that are in good condition and may be used
general touchup, including touchup of defects in baked enamel coatings.
11. What is normally the cause of runs and sags in a spray paint finish?
HoldIng the gun too long In one place causing too much paint to be applied.
12, What causes an "orange peel" or "pebble" finish?
The spray gun setting, Incorrect air pressure, incorrect paint viscosity, and holding the gun too
far from the work.
35
.L
FAR Pari 45
15. What type of materials should be thoroughly protected when using paint remover?
Synthetic rubber surfaces, aircraft tires, fabric, and acrylics must be protected against possible
contact with paint remover.
2.
3.
Determine the type dope that was used on a fabric covered surface by suitable testing methods.
4.
Prepare a metal surface for painting, and apply the primer coat.
5.
6.
7.
Inspect a doped fabric covered structure and identify any defects such as pinholes, blushing,
blisters, etc.
B.
Correctly match a list of finishing materials with the appropriate thinner for each.
9.
10. On a three view drawing of an aircraft, determine where the registration numbers should be located.
11. Using reference material, locate the requirements for aircraft registration numbers.
2.
Where are special rivets, such as Huck or Cherry lock rivets, used?
They are used in places where access to both sides of the riveted structure Is Impossible, or where
limited space will not permit the use of a bucking bar. These rivets require special tools, Installation.
and removal procedures. They are commonly called blind rivets.
36
3.
4.
5.
6.
What procedures should be used to prevent damage to the hole when drilling through plexiglas?
The plexiglas should be backed with wood and the feed slowed as the drill point breaks through
the underside of the sheet. A drill that Is to be used for this purpose should be modified to a 60'
tip angle, the cutting edge to a zero rake angle, and the back lip clearance angle Increased to 12
-15 degrees.
7.
8.
9.
= Radius + Thickness.
What Is a joggle?
A joggle is an offset formed on an angle strip to allow clearance for a sheet or extrusion.
37
13. Briefly describe the anodizing process and what purpose it serves.
Aluminum alloys are placed In an electrolytic bath which causes a thin film of hydroxide to form
on the surface of the aluminum. This anodized coating not only provides excellent resistance to
corrosion, but It Is also an excellent bond for paint.
14. What are the acceptable repair methods for bonded honeycomb structure that has been damaged?
There are two acceptable methods of repair currently being used on damaged skin and care
materials of bonded honeycomb structures. One Is the paned compound repair method. The
other Is the laminated glass fabric cloth overlay method, which Is applied to honeycomb damage
which exceeds the repair limitations of the potted compound method.
15. What size drill should be used lor the common shank rivet diameters of 3/32 inch, 1/8 inch, and
5/32 Inch?
For a 3/32 rivet, a number 41. For a l/B rivet, a number 30. For a 5/32 rivet, a number 22.
16. What Is used for hole filling in a bonded honeycomb repair?
Potting compound.
1.
Repair a hole In the sheet metal skin of an aircraft by the riveted flush patch method.
2.
3.
4.
Bend a piece 01 metal to the minimum bend radius lor the type and thickness of the material.
5.
6.
7.
8.
Select and use twist drills for drilling aluminum and steel.
9.
38
WELDING ORAL
1.
2.
df l'L\-i;<. .
Why must all nux be removed from the metal after welding magnesium?
Any nux left on the metal will result In severe corrosion.
3.
4.
5.
6.
7.
What determines the amount of heat that will be applied to the work when welding by the oxyacetylene method?
8.
What will be the result of using a torch tip that Is too large or too small?
If the torch tip is too large the heat will be too great and holes may be burned In the metal. If the
torch tip Is too small the heat provided may be insufficient to produce penetration to the proper
depth causing a low strength weld.
9.
How do you determine the correct size filler rod to be used in welding?
Welding rods are made in standard 36 Inch lengths, and in diameters from 1/16 inch to 3/8 Inch.
The diameter of the rod to be used Is governed by the thickness of the metals being Joined. If the
rod is too small, it will not conduct heat away from the puddle rapidly enough, and a burned weld
will result. A filler rod that Is too large will chill the puddle. As In selecting the proper size torch tip,
experience enables the welder 10 select the proper diameter welding rod.
39
12. Why is it especially desirable to use a soft flame when welding aluminum?
To avoid blowing holes In the metal when the puddle Is formed.
13. What Is the purpose of using flux when welding aluminum?
Aluminum and Its alloys combine with air and form oxides very rapidly, and oxides form doubly
fast if the metal Is hoI. Aluminum welding flux Is designed to remove the aluminum oxide by
chemically combining with II. Aluminum fluxes dissolve below the surface of the puddle and float
the oxides to the surface where they can be removed.
14. What is the maximum safe pressure for acetylene gas when welding?
When acetylene gas is compressed In a container to a pressure greater that 15 psi It becomes
dangerously unstable. At 29.4 psi acetylene Is self-explosive and only a slight shock can cause It
to explode.
15. How can dents at a steel tube cluster jOint be repaired?
Weld a specially formed steel patch plate over the dented area and surrounding tubes.
16. What type of flame should be used when sliver soldering?
The lIame should be neutral.
17. What are the procedures for preparing a metal fuel tank for welding?
The interior of the tank should be washed thoroughly with hot water and a detergent, and then
steamed for a minimum of thirty minutes. This procedure will vaporize and remove any residual
fuel in the tank. Then fill the tank with C02 gas from a fire extinguisher and seal the tank except
for a small vent hole.
16. When splicing tubing by the Inner sleeve method, what method can be used to insert a tight fitting
inner sleeve into the replacement tube?
The sleeve can be chilled with dry Ice or In cold water.
WELDING PROJECTS
1.
Inspect different samples of steel welds and point out acceptable and non-acceptable welds.
2.
3.
Select the proper torch tip for several metal samples to be welded.
4.
Select the proper size welding rod and alloy for several metal samples to be welded.
5.
Adjust an oxyacetylene torch to a neutral flame, and oxidizing flame, and a reducing flame.
6.
7.
8.
Using ferrous metal, make an oxyacetylene butt weld, a lap Joint weld, or a tee weld.
9.
Correctly use electric arc welding equipment to run a bead across a metal sample.
40
11. From pictures of tubular structures with damage, select the correct repair procedure from Advisory
Circular 43.13-1A.
12. Demonstrate both forehand and backhand welding procedures.
1.
2.
What Is used in large metal aircraft to keep control cable tension within acceptable limits?
Because there Is a considerable difference In temperature expansion between the aluminum aircraft
structure and the steel control cables, some large aircraft incorporate cable tension regulators In the
control cable systems. These regulators are designed to maintain a given cable tension. The unit
consists of a compression spring and a locking mechanism which allows the spring to make
corrections in the system only when the cable system Is in neutral.
3.
What Is a falrlead?
It Is a cable guide used to guide cables in a straight line through or between structural members
of the aircraft. Falrleads shOUld never deflect the alignment of a cable more than 3' from a straight
line.
4.
5.
6.
7.
B.
How do wing flaps affect landing speed and approach angle of an aircraft?
The use of flaps Increase the camber of a wing and therefore the lift of the wing making it possible
for the speed of the aircraft to be decreased without stalling. This permits a sleeper gliding angle
to be obtained for the landing approach.
9.
41
It Is an auxiliary control attached to the trailing edge of a control suriace that is positioned by
movement of a cockpit control to balance the forces acting on the control suriace.
11, What is the purpose of the collective pitch control in a helicopter?
It is used to change the lift (pitch) of the main rotor blades.
12, What unit on a helicopter Is used to compensate for torque created by the main rotor?
1.
2.
3.
Check for correct position of flight control surfaces when the cockpit controls are In various
positions.
4.
5.
6.
42
7,
B,
9.
What needs to be done to prepare an aircraft for an annual or 100 hour Inspection?
Before starting either Inspection the aircraft ~nd the aircraft engine should be thoroughly cleaned.
Then you must remove or open all necessary inspection plates, access doors, fairings and cowling,
2.
3.
Who has the authority to sign off and return to service a 100 hour inspection?
A certified Airframe and Powerplant mechanic may return an aircraft to service after a 100 hour
Inspection,
4,
What are the operating conditions which make the 100 hour inspection mandatory?
The 100 hour inspection is required for aircraft that carry persons for hire or Is used to give flight
instruction for hire.
5,
Where can you find a checklist for the 100 hour inspection?
In FAR Part 43, Appendix D,
6,
Where would you find the recommended statement for recording the approval or disapproval for
return to service of an aircraft after a 100 Inspection?
In FAR Part 43,
7.
Who can approve an aircraft for return to service after an annual inspection?
An A & P mechanic who holds an Inspection Authorization (IA},
8.
Who can approve an aircraft for return to service after a progressive inspection has been performed?
A certified mechanic holding an Inspection Authorization, the aircraft manufacturer, or'a
certificated repair station,
43
9.
Does an aircraft being operated under a progressive inspection program require a 100 hour
inspection if It Is used to give flight Instruction for hire?
No.
10. What are the privileges of a certificated mechanic with regards to propellers?
A certiffcated powerplant mechanic may make minor repairs and alterations to a propeller. He Is
not authorized to make malor repairs or major alterations to propellers.
j j
WhAt Is the maximum time that a 100 hour Inspection may be extended?
2.
Make all the required entries In the permanent maintenance records for a 100 hour Inspection.
3.
Inspect an aircraft and the maintenance records to determine if all applicable Airworthiness
Directives have been complied with.
4.
Determine from the aircraft maintenance records when the next 100 hour inspection is due.
5.
Determine from the aircraft maintenance records when the next annual Inspection is due.
6.
Inspect an aircraft after maintenance and determine if the aircraft Is ready for return to service.
7.
Determine from the aircraft maintenance records if any repetitive Inspections are required by
Airworthiness Directives and when they are due.
What are two sources of power used to extend and retract landing gear?
They are electrical and hyd raullc.
2.
3.
44
4.
5.
6.
7.
8.
What Is the purpose of the rubber packing mounted on the mating surface of the outer wheel half of
a split type wheel?
To prevent air leakage from the tubeless tire used with this wheel.
9.
45
T
i
ir
1.
2.
3.
4.
Service a landing gear oleo shock strut and check for leaks.
5.
6.
Remove and replace brake linings in a hydraulically operated single disk brake system.
7.
8.
Service a nose wheel shimmy damper with hydraulic fluid and air.
9.
i,
1.
What are the three types of hydraulic fluid currently being used in civil aircraft?
They are vegetable base, minerai base, and phosphate ester base fluids.
2.
3.
How do you determine Which type of hydraulic fluid to use In a specific system?
The type lIuid is specified In the aircraft maintenance manual, or on the instruction plate attached
to the reservoir or unit being serviced.
4.
What will happen to the seals In a vegetable base hydraulic system if It Is serviced with mineral base
or phosphate ester base fluids?
The seals will swell. break down. and black the system.
5.
When hydraulic lines have been disconnected. what precautions should be taken to prevent
contamination of the system?
All hydraulic lines and fittings should be capped or plugged immediately after disconnecting.
46
6.
What happens to the hydraulic fluid flow iF the Filter element becomes clogged with foreign matter?
There Is a bypass valve which routes the hydraulic fluid directly form the Inlet port to the outlet
port.
7.
8.
9_
47
-i
-1
1
j
1.
Install an actuating cylinder in the landing gear or flap system, and make all necessary adjustments
for proper operation.
2.
Demonstrate in what order you would adjust various pressure relief devices In a hydraulic system.
3.
4.
Check a hydraulic system for the proper type and amount of fluid, and service as necessary.
5.
Purge a pneumatic system to remove contamination, moisture, or 011 from the components or lines.
6.
7.
8.
9.
Service air bottles In a pneumatic brake system with nitrogen or air to the proper pressure.
10. Identify the correct seals to be used in three different hydraulic systems, one using vegetable base
fluid, one using mineral base fluid, and one using phosphate ester base fluid.
11. Remove, clean, and reinstall a hydraulic system filter.
12. Remove, reinstall, and check the operation of a hydraulic system pressure regulator.
13. Purge the air from a hydraulic system after a component replacement.
14. Determine the cause of fluctuating pressure in a hydraulic system.
15. Check a pneumatic brake system and determine if it should be returned to service.
16. Adjust a pneumatic system pressure relief valve to open and close at the correct pressures.
17. Locate a hydraulic power system lIuid leak and determine the corrective action.
2.
What is the purpose of the negative pressure relief valve In the pressurization system?
The negative pressure relief valve prevents aCcidentally obtaining a cabin altitude which Is higher
than the altitude of the aircraft.
3.
48
4.
5.
6.
7.
What are three methods of supplying heat to the conditioned air When the "heat of compression" Is
not SUfficient for this purpose?
Gasoline combustion heaters, electric heaters, and exhaust gas air-to-air heat exchangers.
8.
9.
5. What must be done if an oxygen system has been depleted and not recharged within two hours?
It must be purged with dry nitrogen or dry air and oxygen.
49
16. How are high and low pressure oxygen cylinders Identified?
High pressure (1800-1850 psi) oxygen cylinders are green In color and have the words "AVIATORS
BREATHING OXYGEN" stenciled lengthwise In while, one Inch letters. All low pressure (400-425
psi) oxygen cylinders are painted lighl yellow.
From reference material, locate Ihe method of protecting a freon system from contamination.
2.
3.
From reference material, locate the procedure for servicing a vapor-cycle air conditioning system.
4.
5.
From reference malerial, locate the operating Instructions for a freon system.
6.
7.
8.
9.
Using reference material, locate the method of checking a gasoline combustion heater fuel system
for leaks.
10. Using reference material, locate the Inspection requirements for cabin healer syslems thai use an
exhausl heal exchanger as a source of heat.
11. Using reference male rial, locale Ihe procedures for inspecting an oulHow valve In a pressurization
system.
12. Using reference material, find the location of the negative pressure relief valve in a pressurization
system.
What Instrument indications will result if the static pressure line becomes disconnected inside the
cabin of a pressurized aircraft?
The altimeter and airspeed Indications will both be lower than normal, and the vertical speed
indicator will Indicate a momentary descent and then return to zero.
3.
50
4_
5.
What causes an electric driven gyro rotor to tilt when the aircraft is turned?
Gyroscopic precesslon_
6.
7_
8.
What other type mark is required when range markings are applied to the glass Instrument cover?
An Index mark, which Is a white line extending from the glass cover onto the Instrument case to
Indicate slippage of the glass. Glass slippage would cause the range markings to be in error_
9.
10. What type fuel quantity system is an electronic fuel measuring device that accurately determines the
weight of the fuel In the tanks of an aircraft?
The capacitor-type fuel quantity system.
11. What is meant by "swinging a compass"?
It is the adjustment of the NORTH-SOUTH and EAST-WEST magnets In order to reduce deviation,
which is the magnetic influences of the aircraft structure and electrical systems.
12. When inspecting a magnetic compass, the bowl should be filled with liquid and should not contain
any bubbles or discolorations. What is the purpose of the liquid in the bowl?
It Is to dampen the oscillations of the float.
13. Which Instrument is used to Indicate the speed of the crankshaft of a reciprocating engine and the
speed of the main rotor assembly in a turbine engine?
A tachometer.
14. What type indicating system Is used to indicate turbine engine exhaust gas temperature (EGT}?
A thermocouple system.
15. What does the manifold pressure gage indicate when the engine is not operating?
It indicates atmospheric pressure.
51
lB. What Is used to check a manifold pressure gage for correct Indication when the engine Is no!
operating?
Either a barometer. or an altimeter after it has been set to zero.
Determine the correct range marks for an aircraft Instrument and point the marks on the glass cover,
2,
3.
Compare static manifold pressure against Held barometric pressure using an altimeter. and
determine If Ihe manifold pressure gage Is return to service quality.
4.
Perform a Pllol-slatlc system leak test and determine if the system meets the required standards,
5.
B.
7.
Paint a slippage mark on the glass cover of an instrument after determining thai the range marks are
in the correct position.
B.
9.
2.
3.
52
l
j
ti
4.
What Is a transceiver?
It Is a self contained transmlUer and receiver which share the same power supply, antenna, and
tuning.
5.
7.
8.
9.
53
ii
t1
r,
2.
3.
4.
5.
6.
Inspect the ELT batteries and determine the battery replacement date on an aircraft.
7.
8.
Inspect radio equipment for security of attachment, condition of wiring, bonding, shock mounts,
radio racks, and supporting structure.
9.
Make an operational check of the VHF communication equipment. FCC rules must be followed.
10. Check electronic equipment shock mount bonding jumpers for resistance.
11. Inspect static discharge wicks for security and resistance.
12. Inspect a radio installation and determine if ventilation, moisture control, and location near
combustible fluids is within guidelines.
13. Inspect the mounting base on a piece of electronic equipment and determine return to service
quality.
14. Check an ADF receiver by tuning to a station and determine If the ADF needle Is pointing to the
station.
15. Inspect an ADF sensing antenna for security of mountings and wires.
54
2.
Other than reducing weight, what other function can be accomplished with a fuel jettisoning system?
Fuel can be dumped from the heavy wing In order to maintain lateral stability. A fuel dump
system is required for all transport airplanes it the maximum takeoff weight is more than 105% of
the maximum landing weight. The airplane must be free of fire hazards during dumping, and fuel
must dump free and clear of the airplane.
3.
4.
5.
6.
7.
8.
9.
10. What are the four general types of fuel quantity gages?
The four types are sight glass, mechanical, electrical, and electronic.
11. Which type fuel quantity gage is considered to be more accurate than the other types?
The electronic-capacitance type, because it measures by weight instead of gallons.
12. What is a drip gage?
An under-wing bayonet type fuel gage that consists of a hollow drip tube that is drawn out from
the lower wing surface. Fuel enters the top of the tube when it reaches the level of the fuel.
55
j
1
An interconnected fuel system designed so that fuel can be fed from various tanks to any
engine.
14. What Is the purpose of the baffles In a fuel tank?
To prevent the fuel from surging as a result of changes in the attitude of the aircraft.
L
l
1
i
15. How can a fuel tank be checked for leaks after a repair?
By a pressure check using air pressure not over onehalf psi and liquid soap or bubble solution
to identify the leak.
1.
2.
Drain fuel from the fuel sumps and determine If there Is water in the fuel.
3.
4.
5.
6.
7.
8.
9.
Check manually operated fuel valves and determine If they are functioning properly.
56
,
l
1.
2.
3.
What are the colors of aircraft position lights and where are they mounted?
A green light Is mounted on the right wingtip, a red light on the left wingtip, and a white light is
mounted In a position where It Is visible from the rear of the aircraft.
4.
What are the factors to be considered when selecting wire size for electrical power'?
One factor is the allowable power loss In the line. A second factor is the permissible Voltage
drop In the line, and a third factor Is the current-carrying ability of the conductor.
5.
6.
What are the three most common faults that occur in an electrical circuit?
They are open circuits, In which leads or wires are broken; shorted circuits, in Which ground
leads cause current to be returned by shortcuts to the source of power; and low power in
circuits causing lights to burn dimly and relays to chatter.
7.
What size electrical conduit should be used for a specific cable bundle?
To allow for ease of maintenance and possible future circuit expansion, the conduit should have
an inside diameter that Is 25% larger than the maximum diameter of the conductor bundle.
S.
When should electrical switches be derated from their nominal current rating?
For high rush-in circuits such as circuits containing Incandescent lamps, for inductive circuits
that have magnetic energy stored in solenoid colis or relays, and for DC motor circuits, Which
draw several times their rated current during starting.
9.
57
I
13. What should be checked before any aircraft electrical load Is Increased?
The associated wires, cables, and circuit protection devices should be checked to determine that
the new load will not exceed the rated limits of these units.
14. What Is the main advantage of using AC for aircraft electric power systems?
The principle advantage is that the voltage of AC power systems Is easily changed by the use of
transformers. Therefore, you can transmit power at a high voltage and a low current, thus
reducing the size and weight of the wiring In the circuit
!
,
r
I
I
3.
4.
5.
6.
Using reference material, secure a wire bundle with cord and clamps.
7.
8.
9.
58
1,
2.
3.
What Iype of warning devices are usually provided for retractable landing gear?
A red light or an aural device.
4.
When does the aural device operate In a landing gear warning system?
When the throttle Is retarded and the landing gear Is In any position other than down and locked.
5.
What type of position indicators are normally used to Indicate thaI the landing gear Is down and
lOCked?
Normally there Is a green light for each gear.
6.
7.
When should you check landing gear switches, lights, warning horn, or bUzzer for proper operation?
During a landing gear retraction check.
8.
How does a takeoff warning horn differ from a landing gear warning horn?
The takeoff horn Is intermittent, whereas the landing gear warntng Is continuous.
9.
What Items may cause a takeoff warning horn 10 operate In a typical transport Jet aircraft?
If the throttles are advanced and any of the following conditions exist the takeoff warning horn
will sound,
1. Speed brakes not down,
2. Flaps not In the takeo range.
3. Auxiliary power exhaust door open.
4, Stabilizer not in the takeoff setting,
1.
2.
3.
4.
5.
Using reference material, locate the procedures for checking an antiskld system.
6.
Using reference material, locate the troubleshooting procedures for an anti-skid system.
7.
Using reference material, locate troubleshooting procedures for a takeoff warning system.
a. -Using reference material, locate troubleshooting procedures for a "mach" airspeed warning system.
9.
Using a pilot report and reference material, determine the possible cause of a malfunction in a
landing gear position system.
J
1.
2.
3.
What methods are sued to attach deicer boots to the leading edges of wing and tall surfaces?
They are attached by bonding to the surface with cement, with fairing strips and screws, or a
combination of both methods.
4.
5.
6.
What must be done before you can make a cold patch repair to a deicer boot?
The deicer boot must be rellevedJorm its Installed tension before applying the patch.
7.
What component of a pneumatic deicer system normally allows suction to be supplied to the boots
for holddown in flight?
The solenoid distributor valve.
a.
60
9.
What methods are used to supply heated air for thermal anti-Icing systems?
Bleed air from the turbine engine compressor, engine exhaust heat exchangers and ram air
heated by a combustion heater.
10. How Is overlleatlng prevented in a thermal anti-Icing system using bleed air?
A thermal switch will cause a shut-off valve to close and stop the flow of bleed air when the
temperature of the leading edge reaches approximately 185'F. When the temperature drops, the
valve opens, and hot bleed air enters the wing once again.
11. In a thermal anti-ICing system, what happens to the air after It has heated the leading edge of the
wing?
The air Is then exhausted to the atmosphere at the wingtip or at pOints where Ice formation
could be critical.
12. What problems are associated with electrically heated Windshields?
Delamination, arcing, scratches, and discoloration.
13. What Is windshield delamination?
Delamination Is the separation of the plies.
14. What does arcing usually indicate In an electrically heated windshield?
Arcing usually Indicates that there Is a breakdown In the conductive coating.
15. What type of power Is used to operate Windshield wiper systems?
Electrical or hydraulic power.
16. What are common problems encountered with windshield wipers?
One problem Is the tendency of the slipstream aerodynamic forces to reduce the wiper blade
loading pressure on the windshield, causing Ineffective wiping or streaking. Another problem Is
in achieving fast enough wiper oscillation.
17. How does a pneumatic rain removal system work?
This method uses high pressure, high temperature engine compressor bleed air which Is blown
across the windshields. The air blast forms a barrier that prevents raindrops from striking lhe
Windshield surface.
1.
Using reference material as a guide, check a pneumatic deicer boot system and determine sequence
and timing of the system.
2.
3.
4.
5.
61
1
1
6.
IJ
7.
8.
9.
l
J
1.
2.
What color does a CO detector change to when carbon monoxide fumes are present?
A reliable CO detector is an indicator tube which contains yellow silica get Impregnated with a
sillco-molybdate compound. When air containing carbon monoxide Is drawn through the tube
the silica gel turns to a shade of green. Other types change from a tan color to gray or black.
3.
4.
5.
How are the thermal switches wired in a thermal switch fire detection system?
The switches are wired in parallel with each other, but in series with the indicator lights.
6.
7.
S.
How does a thermocouple fire detection system differ Irom the thermal switch system?
A thermocouple depends upon the rate of temperature rise and will not give a warning when an
engine overheats slowly or a short circuit develops.
9.
62
11. What type extinguishing agent Is usually associated with a conventional type extinguishing system?
This system usually contains C02, but may use any other adequate agent.
12, What Is the purpose of the yellow disk In a C02 lire extinguishing system?
It Is the system discharge Indicator disk, and it indicates which bank of bottles has been
emptied,
13, In a turbine engine freon fire extinguishing system, how are the bottle discharged?
Byan explosive discharge cartridge which Is detonated electrically,
14. How Is a freon fire extinguishing system protected from temperature rises In excess of set limits?
A high temperature valve will sense the overheat condition and rupture a safety disk,
15. How can you determine the service life of a fire extinguisher discharge cartridge?
The service life of the cartridge is usually recommended in terms of hours below a
predetermined temperature calculated from the manufacturer's date stamp, which usually placed
on the face of the cartridge.
16. What type hand-held fire extinguishers are available for extinguishing interior aircraft fires?
The three most common type hand fire extinguishers use water, carbon dioxide (C02), and dry
chemical extinguishing agents,
1.
2.
Using reference material. locate inspection procedures for a smoke detection system.
3.
Using reference material, locate inspection procedures for a thermal switch fire detection system.
4.
Inspect a thermal switch fire detection system by locating all components In the system and
determine return to service quality.
5.
Using test equipment, check the operation of each thermal switch and Indicator light.
6.
Inspect a thermocouple fire detection system by locating all components in the system and
determining return to service quality.
7.
Inspect a conventional C02 lire protection system and determine return to service quality.
8.
Check C02 cylinders for the date the cylinders were last weighed.
9.
Inspect a freon fire protection system for proper bottle pressure by use of a pressure and
temperature chart
10, Inspect freon bottle discharge cartridges for manufacturer's date stamp and determine return to
service quality.
63
64
65
2.
3.
.,4:
5.
,- 6.
7.
8. What is the purpose of using more than one spring for valve closing?
If only one spring is used to close the valve. it will vibrate or surge at certain speeds. To
eliminate this difficulty. two or more springs, one inside the other are installed on each valve.
Each spring will vibrate al a different engine speed, and the spring surge vibrations will be
dampened. Two or more springs also ~educe the danger of weakness aDd possiblfl failure by
breakage due to heat and metal fatigue.
9.
66
;;-,~
10. Describe the inspecllon you would give the valve springs during engine overhaul.
They should be cleaned thoroughly, and then visually Inspected for evidence of overheating,
cra.cks, broken ends, and for compression strength.
4,
J/
11. What Is the purpose of using valves with sodium filled stems?
Some intake and exhaust valve stems are hollow and partially filled with metallic sodium.
Sodium is used because it Is an excellent heal conductor. The sodium melts at about208'F.,
and the movement of the valves cirCUlates the liquid sodium which enables it to carry th~e~heat
from the valve head to the stem, where it is dissipated through the vaive guide to the c)'ilnder
head and cooling fins.
".
-~.- ....- -.-.-~
-;
f.
'(C~lWhat type Inspection must be made after SUdden stoppage of an engine due to striking and object?
\\22';:.d;/Y
The propeller drive shaft must be checked for misalignment, and the propeller checked for track.
14. What is the purpose of crankshaft dynamic dampers used In aircraft engines?
which'c-a-u-s-e-d"'e-;:'fI~cti;;
~~
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t~~al
.....,..;....
7.
During valve clearance adjustment on an R-2800 engine, why must you depress certain valves other
than the ones being adjusted?
The valves must be depressed (unloaded) In order to remove the spong tension from the side
positions on the cam and thus permit the cam to slide away from the valves to be adjusted until
it contacts the cam bearing. This prevents cam shift from Introducing errors in the clearance
settings.
18. What can be learned "bout the condition of an engine by studying the results of a compression
check?
t. ( ~.
"~11" :C-7
From the cylinder compression check you can determine If the valves, piston rings, and pistons
are adequately sealing the combustion chamber.
67
(Sf;
19. How can a cold cylinder be located on a double row radial engine?
A cold cylinder check can be made with a cold cyllnder Indicator, sometimes called a "mallic
wand", to locate any cylinder that has a temperature lower than the normal operating
temperature of the other cylinders.
20, What Instrument can be used to check a cylinder bore for out of roundness?
A cylinder bore can be checked with dial Indicator, a telescopic gage and micrometer, or an
inside micrometer.
1,
2.
3,
4,
5.
6,
7.
Operate an engine throughout the normal operating range and check for proper operation in
accordance with the operating Instructions.
8.
Use a cold cylinder indicator and locate a cold cylinder alter an engine run up.
9.
68
2.
What are the two prlnclpai types of compressors used in turbojet aircraft?
The two most common compressors In use today are the centrifugal flow and the axial flow
types.
3.
4.
What Is the purpose of the interconnector tubes between can type combustion chambers?
To spread the flame to the combustion chambers that are not equipped with igniter plugs during
engine starting.
What
~llUV.!lfs are provided alo'ng the axial length of the liners to direct a cooling layer of air along the
'
6,
7,
What Is the location and function of the diffuser section In a turbine engine?
('./
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The diffuser Is the divergent section of the engine located between the compressor section and
the burner cans, Its function Is to change the high velocity compressor discharge air to static
pressure,
8.
Where are stress rupture cracks most likely to occur on turbine blades?
They usually appear as small hairline cracks on or across the leading or trailing edge of the
blades. The cracks appear a1 nght angles to the edge length,
~
9.
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First, the turbine nozzle must prepare the mass airflow for driving the turbine rotor, The
stationary vanes are shaped and set at such an angle that they form a number of small nozzles :
that discharge the gases at extremely high speed. That is, they convert a portion of the heat
and pressure energy to velocity energy to drive the turbine. The second purpose of the turbinel
nozzle is to deflect the gases to a specific angle in the direction of turbine rOTt'2n,.<..<-/
69
11. What Is the major difference between a turboprop and a turbojet engine?
e.
A turboprop engine usually has more turbine stages than the turbojet engine. In addition to
operating the compressor and accessories. the turboprop turbine must also drive a propellE1r.
What Is a turbofan engine?
A turbofan engine Is. In principle. the same as a turboprop. except that the propeller Is replaced
by a ductenclosed axial How fan._
13. What Is the effect of air de~y on the thrHst of a turbine engine?
<..-.rJ~"'*' ~ et-c,"-U ~-'.\ii ',ensity determines the mas~ of air that Is used by a jet engine. The factors that affet
density are the temperature and ressure 01 the a,lr. If density increases. thrust Increases. and
Vice vers. n ncrease n air temperature en erlng an engine will cause a decrease in density
and thrust. An Increase In air pressure entering the engine will cause an Increase In density and
thrust. With a given throttle setting, engine thrust will vary If the temperature or pressure 01 the
air entering the engine changes.
'
14. What are the two most common types of thrust reversers?
The mechanical blockage type and the aerodynamic blockage type.
15. What is a split compressor system in a turbine engine?
The split compressor system requires two concentric shafts Joining the turbine stages to their
respective compressors.
16. What Is one method of relieving thermal stress on a turbine dlsk.?
One means Is to bleed cooling air back onto the face of the disk.
17. What may be the indications if a turbojet engine is out of trim?
The engine has high ex. haust ~s temperature (EGT) at target engine ,E'!'essure ratio (EPR) for
takeoff.
l\~u~
Gl' I
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Check the axial and radial clearance of turbine blades and determine if clearance Is within limits.
70
10. Inspect inlet guide vanes and compressor blades for damage and determine if engine Is return to
service quality.
11. Identify and list different types of damage on turbine blades.
12. Remove and reinstall compressor or turbine blades.
13. Identify damage to nozzle guide vanes.
14. Adjust turbine idle rpm to within limits required by reference material.
15. Using reference material, perform a hot start Inspection.
16. Using reference material, perform an overspeed inspection.
17. Match a list of turbine indication mallunctions with the possible cause of each malfunction.
18. Label the direction of airflow on a drawing of a turbine engine, and Indicate the changes in air
pressure between engine sections.
1.
What steps must be taken In order to prepare an aircraft for a 100 hour or annual inspection?
Remove or open all necessary Inspection plates, access doors, fairing and cowling. Then
-thoroughly clean the aircraft anC! the engine. -
2.
What may be used as a guide for a 100 hour Inspection on an aircraft engine?
FAR Part 43, AppendiX D.
~l" What additional Inspection must ~, performe<;l If t~e c.yllnder compressio_n is weak?
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You must make an Internal cyllnd';;r inspection for improper inlernal tolerances.
Where are the engine operating limitations found?
In the Aircraft Specifications or Type Certificate Data Sheet.
5.
6.
What type of FAA approval is required when a change to an engine type design is not enough to
require a new Type Certificate?
A Supplemental Type Certificate Is required.
8.
What type of FAA approval is required when a change is made to the engine principle of operat~n?
A new Type Certificate must be obtained.
71
Inspect an engine and determine conformity with the Engine Specifications or Engine Type
Certificate Data Sheet.
2.
Make a check list for a 100 hour inspection that includes the scope and detail of the requirements
set for the in FAR Part 43, Appendix D,
3.
4.
Inspect an aircraft engine and determine if it is in compliance with a specific Airworthiness Directive,
5.
6.
7.
Review aircraft maintenance records and determine compliance with the required Airworthiness
Directives by inspection of the engine.
S.
Find and list all the information from an engine data plate.
9.
Check an engine for fluid leaks after engine operation and determine return to seNlce quality.
~'.
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It is mounted in the fuel line between the engine driven pump and the carburetor.
3.
The indicator is calibrated to record the fuel flow in pounds of fuel per hour. \', (
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In addition to fuel consumption, the operator can determine from the fuel Row indication whether
the engine Is operating at the correct fuel-air mlXiure for a given power setting.
5.
6.
72
7.
9.
Wh at IS tur 0 et
;//."
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\ _,.
It is a ratio between .!Q!al turbine discharge pressure to total inlet pressu~e, and is an indication
of thrust being developed by the eng.ne. --"-/10. What is the electric source for a Cylinder head temperature gage?
lY
I
The gage Is connected to a thermocouple attached to the cylinder which tests show to be the
hottest on the engine.
r
-----
-------
1.
2.
3.
4.
5.
6.
7.
S.
Replace a cylinder head temperature themnocouple assembly and check for proper operation.
9.
Inspect an rpm gage for proper markings by reviewing the engine operating limitations.
73
A.~. // .
What types of fire detectors are used for engine fire protection systems?
They are overheat detectors, rate-of-temperature-rise detectors, and Ilame detectors.
2.
When using a thermocouple type fire detector system, what happens if the engine overheats slowly?
A thermocouple depends on the rate of temperature rise and will not give a warning If the engine
slowly overheats or a short circuit develops.
3.
4.1/
>;
Where does a thermocouple lira detector system get its electrical power to operate?
The thermocouple produces power to close a relay, and power from the aircraft electrical system
flows through the relay to the warning light.
5.
6.
7.
What is the most common cause of a false fire warning In a continuous loop detector system?
\'c'
The most common cause of false warnings Is dents, kinks, or crushed sensing element causing
an internal wire to short to th'l-Qround wir: orouter tubing.
- 8.
9.
10. What method is used to determine proper fire extinguisher container pressure?
9heck the container gage 10 determine If the pressure Is between the prescribed ~
-mEl*lmililiJliuJts.
' . .. . .. -~
~.
74
11. What method other than the pressure gage is used to indicate low agent pressure in a container?
Some
alrcra~
12. What Is the purpose of the yellow and the red discharge plugs In a turbine engine fire extinguishing
system?
The yellow plug indicates normai discharge, and the red plug indicates thermal discharge.
li3'
Many systems us,: perforated tubing or discharge no~z~ to distribute the agent.
1 4, How does the fire extinguishing agent put out the fire?
--
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age~distributed
-.
1,
2.
Inspect a continuous loop fire detection system and point out any damaged areas.
3,
Make a continuity check of a fire detection system, locate a fault, and repair the system.
4.
Inspect a fire extinguishing system blowout plugs and determine if the pressure is within the
allowable limits.
5.
Check the pressure In a lire extinguisher container and determine if the pressure Is within the
allowable limits,
6,
Inspect a fire extinguisher container discharge cartridge for service life and determine return to
service quality.
7.
Check a fire extinguisher cartridge discharge circuit for continuity with a voltmeter by removing the
electrical connection to the cartridge.
8.
9.
Check a manually operated fire extinguishing agent discharge handle for proper operation without
discharging the agent.
10. Use a fire detector test unit and verify the proper operation of a fire detector.
75
How would you seat newly Installed generator brushes to the commutator?
When new brushes are Installed in a generator the face of the brushes must be shaped to
provide an area of l!I8xlmum contact with the commutator. To seat the brushes use numb~r 000
sandpaper placed around the commutator with the sanding surface faCing outward.-orn t e armature In the normal direction of rotation until the race of the brushes Isproperty contoured.
Remove the sandpaper and blowout any residue with compressed air.
2.
/L.f4)
vOltage~g{~~'~h alternator?
The frequency depends upon Ihe ~eed of rolallon of the rolor and the ~ber of pole~
5.
6.
7.
1i1
(If) ~F r\ ~
10. What is the American Wire Gage (AWG) system of designating electrical wire size?
A gage number Is assigned the wire according to Its cross-sectional area. The smaller the gage
number, the larger the wire.
11. What is open wiring?
Open wiring Is any wire, wire group, or wire bundle not enclosed in conduit.
12. What method Is used to control the voltage of DC aircraft generators?
The only practical means of regulating generator voltage is to .control the strength of the
!}1agnetic field. Field strength is determined by the amount of current ftowln Ifttough the field
~, and tiiB current is controlled by placing some form of variable or intermittent resistance in
the external fleid circuit of the generator.
76
(::,
Arcing can be caused by a commutator that Is dlrtS' rough, or out of round, A more common
cause of arcing Is worn or BTnding bru~111e rush spring tension too low.
When installing single
wlr:~':r ~Ire bundles, how much slack Is normally allowed between supports?
==
15. What precaution shOUld be taken when running wires close to heating ducts or exhaust stacks?
The wires should be Insulated with a high temperature material.
Use the engine electrical system service manual and locate required reference material to repair five
different electrical components.
2,
Use an electrical system parts catalog and locate the part number for five different components that
are to be replaced.
3.
Remove and reinstall an engine driven generator in accordance with reference material,
4.
Check an engine driven generator by running the engine and determining whether generator
operation Is within limits.
5.
Remove old brushes from a DC generator and install and seat new brushes.
6.
Locate and replace the reverse current cutout relay In the generator electrical system.
7.
Using reference material, parallel a dual generator system to the limits prescribed in given reference
material.
8.
9.
10. Fabricate an alternator electric cable by selecting the proper cable size and installing the proper size
lug for the alternating rating.
16. Using reference material, determine if a starter-generator Is authorized for Installation on a specific
engine.
17. Using reference material, select the proper size wire for several electrical system components.
1S, Use a voltmeter to locate an open In a generator field circuit.
77
( 1
'-
(9
Wha;;s
th~~ost important property that aircraft reciprocating engine 011 must possess?
L/;
Viscosity.
3.
What factors must be considered In determining the proper grade of oil to use in a specific engine?
The operating load, rotational speeds, and operating temperatures are the most important
.factors to be considered.
4.
5.
(:i,)
;If
-"-
They are gasoline, moisture, acids, dirt, carbon, and metallic particles.
6.
.
-----.
~
,
From what location on a reciprocating engine Is the oil temperature usually taken?
In a dry sump lubrication system the oil temperature bulb is located anywhere In the oil Inlet line
between the 011 tank and the engloe. Wet sump systems have the temperature bulb locafeaWhere it senses the temperature after the oil passes through the 011 cooler. I n either system the
bulb is located where it measures 011 temperature before it enters the hot sections of the engine.
7.
tt\.
(>~-.
Foaming can be caused by ~IILite~~, .Q11!l'\minated oil. or the 011 leveLtoo h!9h.
~~
011 flash point is that temperature at which the 011 will begin to give off ignitable vapors. The fire
point Is that temperature at which there are sufficient vapors to support a flame.
78
1.
Operate the aircraft engine and check the all cooler for proper operation.
2.
3.
4.
5.
6.
7.
8.
g.
Using reference material, lisl possible causes of low and high all temperature malfunctions.
79
What is a magneto?
A magneto Is a special type of .englne driven AC generator that uses a permanent magnet as a
source of energy. The magneto develops a high vOltage which is used to nre the spark plugs.
<---
2.
What is the purpose of the condenser In a high tension magneto electrical system?
To prevent arcing at the points and to hasten the collapse of the magnetic field around the
primary call.
3.
4.
What are the three major circuits of a high tension magneto system?
The magnetic circuit, the primary electrical circuit, and the secondary electrical circuit.
~;V What are the components of a high tension magnetic circuit? (.J)
---
The magnetic circuit consists of a permanent multipole rotating magnet, a soft Iron cQ[!, and
pole s h o e s . '
~ ..- -
6.' What happens when the primary breaker points open in a magneto?
Opanlng the breaker points stops the flow of current in the primary circuit, and allows the
magnetic rotor to qulckly,reverse the field through the coil core. This sudden flux reversal
produces a high rate of flux change In the coro, which cuts across the secondary Goiklf the
fl1,ag1J.!llQ, Inducing the pulse of high ':9!!age.current In the secondary needed..to flr~_the sQl![K ___ .
pugs.
.,....---~-~.
7.
8.
9.
-----~
What Is the difference between a low tension and a high tension Ignition system?
In the high tension system high voltage is generated in the magneto and flows to the plugs
through high tension leads. In the low tension system, low voltage Is generated In the magneto
and flows through low tension leads to the primary winding of a transformer coil located near
each spark plug. There the voltage is increased to high voltage by transformer action and is
conducted to the plugs by very short high tension leads.
10. When the Ignition switch Is in the OFF pOSition, what is the condition of the primary circuit?
It is completed through the Ignition switch to ground.
80
11. What three conditions are required to fire the plugs in a cylinder when the piston is In the prescribed
position?
( 4
\
')/,
The magneto rotor must be in the E-gap position, the breaker points must open, and the
distributors must be aligned with that cylinder.
12. In a dual magneto Ignition system, what part of the system is g?~unded when the ignition switch Is
placed In the RIGHT position?
The left magneto circuit will be grounded.
13. What Is internal timing of a magneto?
It is adjusting the breaker points to open when the rotating magnet is at the E-gap position.
14. What is the purpose of an Impulse coupling used with a magneto?
The purpose of an impulse coupling Is to spin the magneto rapidly to produce a hot spark for
starting the engine, and at the same time retard the timing of the spark.
(
J,)lJ
15. What is staggered ignition timing?
It is the firing of one sparkplug before the other one Instead of firing them simultaneously.
, \"
The proper spark plug reach is when the electrode end of the plug inside the cylinder i.~in ttl!;!
best position to achieve Ignition.
~--~- ..-.-...-..... -.-~ .. --.~""- .. """.-.-,,~,,."""-"" . ~
..
I.. ./~ .-
The funcllon of the Igniter plug Is to provide a discharge gap for the current whictU''Ls!oredJn
t~or. The discharge results in a high Intensity spark which Ignites the fuel-air mixture.
19. When are turbine engine Ignition systems normally In use?
The ignition system is normally required only for starting or restarting an engine.
1.
2.
3.
4.
5.
Test a set of spark plugs for one engine and determine return to seNice quality.
6.
7.
81
"
I
;'<0 '-2
8.
9.
10. Disassemble a magneto, identify all the major parts. and reassemble the magneto.
11. Install a magneto on an engine. time the magneto to the engine. and determine return to service
quality by engine operation.
12. Time a distributor to the engine.
13. Check the strength of a rotating magnet installed In a magneto and determine return to service
quality.
14. Install turbine engine igniter plugs and check for proper operation.
15. Using reference material. inspect a turbine engine ignition system.
1.
2.
Name two heat sources for the operation of fuel heaters used In turbine engines.
Turbine engine fuel heaters operate as heat exchangers. Fuel lines are routed through the fuel
heater. which uses as a heat source either bleed air or engine IUbricatin 011. If bleed air Is used
as a heat source It is called an alr-to'liquld heat exchanger. and when 0 rr Is used it is called a
IIquid-to-liquid heat exchanger.
('6)
The fuel control senses power lever osition. en ine r m, either com ress Inlet ressure or
.temperature. burner pressure or compressor discharge presslJre. and either EGT or
4.
What are the two most commonly used carburetors in small reciprocating engines?
They are the float-type carburetor and the pressure-type carburetor.
5.
Both hydromechanical and electron1c fuel control units are in use today. However. the most
Commonly used fuel control' unit Is the completely hydromechanlcal type.
6.
7.
82
8.
'"
(3
1/
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/
The venturi performs three functions. It proportions the fu~lair ml~ure, lowers the pressure at
the discharge nozzle, and limits the airflow at full throttle.
~-~.--
The main metering jet Is placed In the fuel passage between the float chamber and the discharge
nozzle. Its purpose Is to Jlm!t the fuel flow when the throttle valve is wide oRen.
10: What is the fuel metering force in a floattype carburetor?
It Is the differential pressure between the pressure In the float chamber and that at the nozzle.
11. What will be the result of using excessively rich idle mixtures?
Excessively rich idle mixtures will cause spark plug fouling.
12. What is the purpose of the economizer system in a fioat carburetor?
The economizer Is essentially a valve which Is closed at throttle settings below 60% to 70% of
rated power, but provide additional fuel for cooling the engine to prevent detonation at higher
throttle settings.
U)Where does a pressure injection carburetor obtain fuel pressure?
It obtains fuel pressure from the._boost pump for starting and from the engine driven fuef pump
for normal operation of the engine.
14. What operates an automatic mixture control (AMC) on a pressure carburetor?
The AMC contains a seaied bellows that expands or contracts with changes In atmospheric
pressure. The movement of the bellow operates a tapered needle that controls the Impact air
presSllre igtn the "A" chamber of the carburetor.
15. In what position do you place the mixture control of a pressure Injection carburetor to stop the
engine?
In the Idle cutoff pOSition.
16. What rpm Indication should result when the mfxture controi is placed in the idle cutoff position when
the Idle mixture Is set correctly?
There should be a slight increase in rpm, followed by a rapid drop of rpm to zero.
17. What Is the purpose of filling a pressure Injection carburetor full of fuei and allowing it to soak for a
period of about eight hours prior to Installation?
This is done is order to softenJ!Je diaphragms and make them as pliabte as they were when the
'
carburetor was orlginalfy calibrated.
1.
Inspect a turbine engine fuel control unit for fuel leaks, security, and missing safety wire.
2.
3.
Check and adjust the float level of a floattype carburetor to within prescribed limits.
83
4.
5.
6.
7.
Using reference material, remove and reinstall a float carburetor without error.
8.
Using reference material, remove and reinstall a needle-type mixture conlrol valve In a float-type
carburetor.
9.
Inspect a float needle and seat In a float carburetor by removing the needle, examining the needle
and seat, determining their serviceability, and reinstalling the needle.
(U-')
1--
They provide a means of shutting of! fuel flow, for tank and engine selection, lor crollSJiled, and
for ~ transfer.
-.-
, 3.
5.
84
6.
What happens to the excess fuel not required by the engine In a constant displacement pump?
The pressure relief valve opens and the fuel Is routed back to the Inlet side of the pump.
7.
8.
What is the purpose of the bypass valve in the engine driven fue.\:ump?
p'~mp
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Electric boost pumps are used to supply fuel to a pre~sure carburetor during e.ngh1e starti~ and
In case of engine Qrtven !Jump failure. However, a main function of a boost pump Is to keep the
pressure on the suction Side of the engine driven pump from becpmlng low enough to permit
the fuel to boil when operating at high altitudes. ___
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They are low fuel pressure. high fuel temperatures. and excessiVe fuel turbulence.
'-
Turbine engine fuel pumps may be divided Into what two distinct system categories?
Constant displacement and variable displacement.
What category Is a turbine engine driven gear-type pump?
Constant displacement.
13/ What type fuel pump can be made to vary the fuel flow at any speed?
A variable displacement pump.
14. What part of a gas turbine engine fuel system is very susceptlble.lo the formation of ice?
The fuel filter.
15. How is the engine fuel system protected from ice formation?
By the use of fuel heaters.
16. Why Is a micron fuel filter provided with a bypass valve as a necessary safety factor?
Because the small openings In this type filter make it very susceptible to clogging.
1.
Using reference material. adjust the output pressure on an engine driven fuel pump to within limits.
2.
Using reference material. remove, clean, and replace an engine fuel strainer.
3.
Inspect a main fuel filter assembly by pressurizing the fuel system and observing for fuel leaks in the
filter area.
4.
Remove and reinstall an engine driven fuel pump using reference material as a guide.
85
5.
6.
7.
8.
Correctly adjust fuel pump pressure to the limits prescribed In reference material.
9.
10. Determine If a fuel pressure warning light operates within prescribed limits.
11. Check a fuel selector valve for proper operation.
12. Locate a turbine engine fuel heater and identify all the connections.
What are the three major parts of a reciprocaling engine Inl!J.lcllon system?
-r
rf
The alrscoop and ducllng. the !~rburetor. and the Intal{e manifold.
/1
2.
",/
3.
it reciprocating
engine?
The most common method of preventing or removing Ice formation In the Induction system Is by
the use of heated air.
1.1. How is Ice cleared in some aircraft induction systems if the carburetor heat Is tgo low to clear the
Ice?
5.
6.
What Is the danger of using carburetor heat when operating at high power settings?
The higher air temperatures could cause detonation and possible engine failure.
7.
Carburetor throttle ice is most likely to form when the throttle Is In which position?
DUring part throttle operation when the throttle is near the closed position.
S.
What are the two general classifications of superchargers used In reciprocating engine induction
systems?
They are classified as Internally driven or externally driven (turbocharger) supercharger systems.
~J
86
I.
A high speed imealler Is driven through a gear train from the crankshaft at a gear ratio that
vanes from 6:1 to1:f:1.
---
1.
On a drawing of a reciprocating engine Induction system. point out the areas where icing Is most
likely to form.
2.
On a drawing of a turbine engine air Intake system. point out the two areas that are provided with Ice
protection.
3.
Inspect a carburetor air heating system and determine If It is return to service quality.
4.
Check the operation of a carburetor air heat system for proper operation.
5.
6.
7.
6.
Inspect an air Intake manifold and list any area found to be leaking.
9.
87
What Is the most common means of regulating the cooling air How through a radial engine?
By the use of cowl flaps.
2.
3.
What other engine characteristics are designed to aid In engine cooling besides cooling fins?
. j.'
.i'
The engine cowling and baffles are designed to force air over the cylinder cooling fins.
4.
Why is the "open and close" adjustment during Installation of cowl flaps important?
For each engine installation the cowl flaps are set for tolerances that will permit them to open
and close the correct amount 0 keep the cylinder head temperature within allowable limits.
5. What should be done to cylinders when too much of the coofing fin area is broken off?
---
The cylinder should be replaced because It cannot cool properly and a hotspot will de\C\lI.QP~
6.
-.~
7.
8.
(J;')
,~. What is the purpose of blast tubes that are built into the baffles on a reciprocating engine?
To direct jets of cooling air onto the rear spark plug elbows of each cylinder to prevent
o.:,tg!heating of the ignition leads.~
,,
What are the main reasons that excessive heat in reciprocating engine is undesirable?
(3 )
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Augmentors consist of two pairs of tubes running from the engine compartment to the rear of
the nacelle. The exhaust gas collector feeds exhaust gases Into the inner augmentor tubes. Air
that has passed over the engine Is fed into the outer tubes where it Is heated, by the exhaust
tUbes, and then expelled to mix. \\Iit.h..the exhaust ases. The heating of the air causes It to form
ust which draws additi,?naLcooIiD!uilLQlleLtb!!
a ~ow pressure, jet-like
<mgloe. The heated air is sometimes used for .:.abln heating, dJostlng, and anti-IcinG:.
12. What is the source of air that is directed to turbine engine bearings for cool1ng?
It is bleed
air from the compressor section of the engine.
.
88
Ail?
They are made of stainless steel, with layers of aluminUfTl_f()ll, fiIl.!jr.glass, and silver fall.
15. What areas of a turbine engine are cooled by the secondary air passing through the engine?
The combustion chambers and the turbines.
1.
2.
3.
4.
5.
Check cowl flap travel and determine if the open and closed positions are within limits.
6.
Inspect cylinder cooling fins for damage and determine if the damage is repairable.
7.
Locate and point out all the parts of an augmenter cooling system.
S.
9.
now path
13. On a drawing of a turbine engine, point out the areas where an insulation blanket Is requiredc
Depending on the location and type of exhaust system failure, it can result in carbon monoxide
poisoning of the crew and passengers, partial or complet~s of engine power, and an <;I~ft
Jjre.
89
3.
What type of exhaust system is generally used on low powered non-supercharged engines?
The short (open) stack system.
4.
6.
-"--
7.
What happens when lead, zinc, or galvanized marks are made on an exhaust system?
The mark Is absorbed by the metal when it Is~~eated and 2auses a change In the molecula~
structure of the metal.
L\..A. it
<.;: (?cl7.J; So
8.
What type of visual Indication can usually be seen In the area of an exhaust leak?
Exhaust leaks usually leave flat gray or sooty black streaks on the pipes in the area of the leak.
&
By degreasing only.
What I: the usual cause 'Of muffler and heat exchanger failures?
(0 \
They are usually caused by thermal and vibration cracking or ruptures in areas of stress
concentration.
.
@ Where are exhaust manifold and stack failures most likely to occur?
These failures usually occur at welded or clamped points In the system.
12. What is a common cause of the waste gate unit malfunctioning in a turbocharger system?
i5
The most common cause of waste gate malfunctioning Is carbon buildup, causing the waste
gate valve to stick in the "closed" position.
What factors are affected if the area of the exhaust nozzle of a turbine engine is changed? (
The size of the exhaust nozzle affects both the engine performance and the exhaust gas
temperature.
.-
14. What are the probes In a turbine exhaust tail pipe used for?
They are used to measure exhaust gas temperature (EGT).
90
'L)
1.
2,
3,
4,
5,
6,
7,
8.
9.
10. Determine if three exhaust system components with damage are repairable.
11. Inspect an exhaust system Internal baffles or dlrlusers and list any damage found.
12. Determine the calise of a malfunction in a thrust reverser system.
PROPELLERS ORAL
1.
a~d
3.
It v.jJ~
''( ! , ~l. \
The tractor type and the' pusner'lype.
16
What type of propeller has the blade angle built into the propeller and cannot be changed?
A fixed pitch propeller.
4.
What is the purpose of Ihe metal tipping on the leading edge of a wooden propeller?
It is to protect the propeller lrom damage caused by flying particles In the air during landln.\L.
taxllng;-and takeoff.
<
5.
What is the Pf~C!,ss.. of determining Jhe positions of the tips of the propeller blades relative to each
other.':;; \,y),.!:l
\: (Qc\k"--~I
6.
7,
What are the aerodynamic forces and loads acting on a rotating propeller blade?
A rotating propeller is acted upon by centrifugal. twisting, and bending forces.
91
8.
9.
What should be used to clean aluminum and steel propeller blades and hubs?
They should be washed with a suitable cleaning solvent using ~rush or cloth.
10. What positions are used on a balance stand to check a two bladed propeller for static balance?
First the vertical position and then a horizontal position.
11. When centrifugal force acts on the cOUnterweights of a hydraulic cOUnterweight propeller It tends to
rotate the blades in which direction?
Centrifugal force tends to Increase the blade pitch.
12. Why do you put the blades of a counterweight propeller Into high pitch before stopping the engine?
This type propeller has a movable cylinder that slides over the propeller piston. In the low pitch
position, the cylinder Is outboard and the .Riston is exposed to the open air, but In the high pitch
position, the cylinder moves Inboard and covers the propeller piston. In this position the piston
Is protected from dirt !!!!.d ~olsture in the alL This Is particularly Important if the airplane engine
will not be operated for se eral days.
1
t~.
proP~r? (3)
Releasing governor oil pressure allows the counterweights and featherIng spring to move the
blades to the feathered position.
~----15. What type ice control systems are used for propellers?
Either fluid or electrical deicing systems are used for deicing propellers.
16. What is the purpose of a slinger ring on some propeller Installations?
Propeller deiCing fluid Is ejected from a stationary nozzle on the engine into a scoop attached to
the rear of the propeller assembly. This U-shaped channel Is called the slinger ring. The fluid
under pressure of centrifugal force Is transferred through a nozzle to the propeller blades.
PROPELLER PROJECTS
1.
Using reference material, check vertical and horizontal unbalance on a ,two blade propeller and
determine if the propeller Is within balance limits as prescribed,
2.
3.
4.
92
5.
6.
Detect and correct front cone bottoming of a propeller installed on a splined shaft.
7.
Adjust a propeller governor so that lhe propeller will operate within the correct range.
8.
9.
10. Using reference material, iocate the inspection procedures for propeller ice control systems.
11. Using reference malerial, find and list the critical range of operation for a specific propeller/engine
combination.
12. Check a propeller blade feather angle and determine If It Is correct for that installation.
13. Inspect a wooden propeller metal tipping and list any defects.
14. Using reference material, repair a metal propeller with slight nicks and scratches.
15. Remove, desludge, and reilistall a propeller dome on a hydromatic propeller.
16. Remove a fixed pitch propeller, inspect the shaft, and reinstall the propeller as prescribed In
reference material.
17. Check the track of a propeller and determine If It Is within limits.
18. Identify the components of a turboprop propeller system.
19. On a drawing of a constant speed propeller, Indicate the path of the oil flow for an on speed, an
overspeed, and an underspeed condition of the propeller.
20. Operate an engine and check a reversing type propeller for proper operation.
93
Notes
94
Notes
95
- I
-
Notes
=-
96