Level 3 Certificate in Aeronautical Engineering (2661) · Level 3 Certificate in Aeronautical Engineering (2661) ... Unit 7 Aircraft materials and hardware Unit 8 Aircraft structure

Level 3 Certificate in Aeronautical Engineering (2661)

Scheme Handbook

October 2005

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Contents Section 1 - General 5 Introduction 5 General information 6 General structure 6 Assessment and quality assurance 6 Course design 7 Centre and scheme approval 7 Level 3 Certificate in Aeronautical Engineering 8 The Award 8 Assessment Components 9 Registration and Certification 10 Verification of assignments 10 Health and Safety 11 Relationship to National Standards 12 Identification of Key Skills summary relationship table 16 Identification of opportunities for evidence generation table 17 Test specifications 18 Section 2 – The units Core Units 23 Unit 1 Aviation mathematics & science Unit 2 Electrical & avionics fundamentals Unit 3 Aviation legislation Unit 4 Military aviation policy and regulation (Candidates take either Unit 3 or Unit 4) Unit 5 Basic aerodynamics Unit 6 Human factors in aeronautical engineering Pathway Units Mechanical maintenance pathway Unit 7 Aircraft materials and hardware Unit 8 Aircraft structure and maintenance Unit 9 Aircraft mechanical systems Unit 10 Gas turbine engines and propellers Avionics maintenance pathway Unit 11 Avionics maintenance principles Unit 12 Electronic and further electrical fundamentals Unit 13 Aeronautical digital fundamentals Unit 14 Aircraft avionics systems Mechanical manufacturing pathway Unit 15 Aircraft mechanical systems (manufacturing) Unit 16 Aircraft manufacture Unit 17 Aircraft materials and hardware (manufacturing) Unit 18 Aircraft structure Electrical manufacturing pathway Unit 12 Electronic and further electrical fundamentals Unit 16 Aircraft manufacture Unit 19 Aircraft electrical systems Unit 20 Avionics manufacturing principles

4 Level 3 Certificate in Aeronautical Engineering Scheme Handbook

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Level 3 Certificate in Aeronautical Engineering Scheme Handbook 5

Section 1 - General

Introduction The award consists of five core units and four units in each of four pathways: mechanical maintenance, avionics maintenance, mechanical manufacturing and electrical manufacturing.All units in each pathway are mandatory. There are two core units covering legislation, one for civil trainees and one for military personnel, candidates take one of these units. Successful candidates will achieve one of the following certificates, depending on the pathway chosen: Level 3 Certificate in Aeronautical Engineering (mechanical maintenance) Level 3 Certificate in Aeronautical Engineering (avionics maintenance) Level 3 Certificate in Aeronautical Engineering (mechanical manufacturing) Level 3 Certificate in Aeronautical Engineering (electrical manufacturing) This award is aimed at candidates intending to work or working in Aeronautical Engineering. Its aim is to provide a basic qualification with emphasis on the underlying principles and on practical skills. The scheme has been designed to be complementary to the training and experience candidates will require in employment. This award has been written to meet the knowledge and understanding for the City & Guilds Level 3 NVQ in Aeronautical Engineering and for the NVQ in Engineering Production. It also meets a proportion of the knowledge requirements for the Joint Airworthiness Authority syllabus JAR-66 for Category A Certifying Staff. It therefore provides a worthwhile qualification for those candidates who do not have access to the NVQ.

No specific prior qualifications, learning or experience are required for candidates undertaking the qualification. However, the nature of both the learning and assessment required for the qualification is such that candidates will need basic literacy and numeracy skills: ie the ability to read and interpret written tasks and to write answers in a legible and understandable form. Candidates will also need to be able to organise written information clearly and coherently, although they will not be assessed for spelling or grammatical accuracy unless this is part of the assessment criteria. Without evidence of formal qualifications, candidates must be able to demonstrate prior adequate knowledge and experience necessary to complete the course.

City & Guilds Awards are available in a range of vocational areas. Please contact Customer Relations at City & Guilds for further information.


General information Vocational Certificates have been designed by City & Guilds to support government initiatives towards the National Qualifications Framework. They can contribute towards the knowledge and understanding required for the related NVQ while not requiring or proving evidence of occupational competence. General structure The Award is made up of units expressed in a standard format. Each unit is preceded by details of • the structure of the unit • the aims and general coverage of the unit • the outcomes • the assessment methods. Assessment and quality assurance Each core unit will be assessed by multiple choice questions to be delivered on-line through the City & Guilds GOLA system. Pathway units are assessed by centre devised practical tasks and knowledge questions. Assessment components for the core units are graded (Pass 60%, Credit 70%, Distinction 80%), and are listed on Certificates of Unit Credit. A pass is the achievement level required for the knowledge and understanding in an NVQ and generally represents the ability to follow instructions and procedures. Credit and distinction represent increasing levels of ability to adapt in the face of changing circumstances and independently resolve problems. Certificates (for the full award) do not carry a grade. For candidates with particular requirements, centres should refer to our policy document Access to assessment, candidates with particular requirements. External verifiers act on behalf of City & Guilds to ensure that national standards are maintained. Full details of their role can be found in Providing City & Guilds’ Qualifications – a guide to centre and scheme approval.


Course Design City & Guilds does not itself provide courses of instruction or specify entry requirements Teacher/assessors should familiarise themselves with the structure and content of the award before designing an appropriate course; in particular they are advised to consider the knowledge and understanding requirements of the relevant NVQ. As long as the requirements for the award are met, teachers/assessors may design courses of study in any way that they feel best meets the needs and capabilities of the candidates. It is recommended that centres cover the following in the delivery of the course, where appropriate • Key Skills (such as Communication, Application of Number, Information Technology, Working with others, Improving own learning and performance, Problem solving) • Health and safety considerations, in particular the need to impress on candidates that they must preserve the health and safety of others as well as themselves • Spiritual, moral, social and cultural issues • Environmental education • European dimension It is recommended that a minimum of 450 hours should be allocated for the 5 core and 4 pathway units

required for certification. Furthermore, centres should ensure that candidates do not register for this award if they hold or are registered with City & Guilds or another awarding body for an award of the same level and content. Centre and scheme approval Centres wishing to offer City & Guilds qualifications must gain approval. New centres must apply for centre approval. Existing City & Guilds centres will need to get further scheme approval to run this Certificate. City & Guilds reserves the right to suspend an approved centre, or withdraw its approval from an approved centre to conduct a particular City & Guilds scheme or particular City & Guilds schemes, for reasons of debt, malpractice or for any reason that may be detrimental to the maintenance of authentic, reliable and valid qualifications or that may prejudice the name of City & Guilds. Full details of the process for both centre and scheme approval are given in Providing for City & Guilds qualifications – a guide to centre and scheme approval which is available from our regional offices.


Level 3 Certificate in Aeronautical Engineering The Award For the award of a certificate, candidates must successfully complete the assessment components for nine units: five from Units 1 – 6 and the four Units from one of the specified pathways. Unit 1 Aviation mathematics & science Unit 2 Electrical & avionics fundamentals either Unit 3 Aviation legislation or Unit 4 Military aviation policy and regulation Unit 5 Basic aerodynamics Unit 6 Human factors in aeronautical engineering Mechanical maintenance pathway Unit 7 Aircraft materials and hardware Unit 8 Aircraft structure and maintenance Unit 9 Aircraft mechanical systems* Unit 10 Gas turbine engines and propellers * This Unit has two versions of outcome 3: one for civil trainees the other for military personnel Avionics maintenance pathway Unit 11 Avionics maintenance principles Unit 12 Electronic and further electrical fundamentals Unit 13 Aeronautical digital fundamentals Unit 14 Aircraft avionics systems Mechanical manufacturing pathway Unit 15 Aircraft mechanical systems (manufacturing) Unit 16 Aircraft manufacture Unit 17 Aircraft materials and hardware (manufacturing) Unit 18 Aircraft structure Electrical manufacturing pathway Unit 12 Electronic and further electrical fundamentals Unit 16 Aircraft manufacture Unit 19 Aircraft electrical systems Unit 20 Avionics manufacturing principles


Assessment

Level 3 Certificate in Aeronautical Engineering

Core units Assessment component

Unit 1 Aviation mathematics & science 2661-001 multiple choice

Unit 2 Electrical & avionics fundamentals 2661-002 multiple choice

Unit 3 Aviation legislation 2661-003 multiple choice

Unit 4 Military aviation policy and regulation

2661-004 multiple choice

Unit 5 Basic aerodynamics 2661-005 multiple choice

Unit 6 Human factors in aeronautical engineering

2661-006 multiple choice

Pathway Units Assessment component

Mechanical pathway

Unit 7 Aircraft materials and hardware 2661-007 centre set

Unit 8 Aircraft structure and maintenance 2661-008 centre set

Unit 9 Aircraft mechanical systems 2661-009 centre set

Unit 10 Gas turbine engines and propellers 2661-010 centre set

Avionics pathway

Unit 11 Avionics maintenance principles 2661-011 centre set

Unit 12 Electronic and further electrical fundamentals

2661-012 centre set

Unit 13 Aeronautical digital fundamentals 2661-013 centre set

Unit 14 Aircraft avionics systems 2661-014 centre set

Mechanical manufacturing pathway

Unit 15 Aircraft mechanical systems (manufacturing)

2661-015 centre set

Unit 16 Aircraft manufacture 2661-016 centre set

Unit 17 Aircraft materials and hardware (manufacturing)

2661-017 centre set

Unit 18 Aircraft structure 2661-018 centre set

Electrical manufacturing pathway

Unit 12 Electronic and further electrical fundamentals

2661-012 centre set

Unit 16 Aircraft manufacture 2661-016 centre set

Unit 19 Aircraft electrical systems 2661-019 centre set

Unit 20 Avionics manufacturing principles 2661-020 centre set


Registration and Certification • Candidates must be registered at the beginning of their course. Centres should submit registrations using Form S (Registration), under scheme no. 2661.

• When assignments have been successfully completed, candidate results should be submitted on Form S (Results submission). Centres should note that results will not be processed by City & Guilds until verification records are complete.

• Full details on all the above procedures, together with details of written tests will be found on the City & Guilds Web site http://www.city-and-guilds.co.uk

Verification of Assignments Although Certificates do not imply occupational competence, they have a very close relationship with NVQ programmes. It is for this reason that, when assignments are assessed, it is important that reference is made to NVQ assessment methodology. Certificate assessors/tutors will need to be familiar with the occupational standards for the Aeronautical Engineering NVQ, because a similar system of verification is used. This means that the work of assessors involved in the qualification must be monitored by an Internal verifier/scheme co-ordinator, to ensure they are applying the standards consistently throughout assessment activities. Assessors must ensure that candidates understand why a particular grade has been given for the award. If a candidate’s work is selected for verification, samples of work must be available to the appointed external verifier. An external verifier will make an annual visit to the centre and their role includes the following: • ensuring that internal verifiers are undertaking their duties satisfactorily • monitoring internal quality assurance systems and sampling assessment activities, methods and records • acting as a source of advice and support • promoting best practice • providing prompt, accurate and constructive feedback to all relevant parties on the operation of centres’ assessment systems


Health and safety The requirement to follow safe working practices is an integral part of all City & Guilds qualifications and assessments, and it is the responsibility of centres to ensure that all relevant health and safety requirements are in place before candidates start practical assessments. Should a candidate fail to follow health and safety practice and procedures during an assessment (eg practical assessment, assignment) the test must be stopped and the candidate advised of the reasons why. The candidate should be informed that they have failed the assessment. Candidates may retake the assessment at a later date, at the discretion of the centre. In any cases of doubt, guidance should be sought from the external verifier.


Relationship to SEMTA OSCEng ECS and Level 3 NVQ in Aeronautical Engineering ECS No. ECS Title

1.01 Determine engineering requirements for products and processes

1.02 Identify solutions to meet technical requirements

1.03 Establish engineering objectives

1.04 Recommend methods to achieve engineering objectives

1.05 Identify factors that impact on engineering design briefs

1.06 Produce an analysis of identified factors in engineering design briefs

1.07 Generate engineering design options

1.08 Evaluate and recommend engineering design options for implementation

1.09 Complete designs for engineering products

1.10 Review technical information to produce detailed engineering drawings

1.11 Produce detailed drawings to support engineering activities

1.12 Interpret detailed information from technical sources

1.13 Read and extract information from engineering drawings and specifications

1.14 Provide technical information in required formats

1.15 Review an engineering activity to determine its technical requirements

1.16 Specify technical requirements for engineering activities

1.17 Determine technical requirements to achieve objectives

1.18 Determine resource requirements to achieve objectives

1.19 Plan engineering activities

1.20 Determine procedures for engineering activities

1.21 Determine requirements for safe access to work locations

1.22 Implement safe access systems

1.23 Identify and suggest improvements to working practices and procedures

1.24 Identify potential developments to engineering products and assets

1.25 Evaluate and recommend development options

1.26 Control allocated resources to achieve requirements

1.27 Provide technical information on engineering products and assets

1.28 Provide technical information on the use of engineering products and assets

2.01 Prepare machine tools to achieve material removal requirements

2.02 Mounting and setting work holding devices and workpieces

2.03 Setting and adjusting machine tools

2.04 Marking out to required specification

2.05 Prepare equipment for modifying or processing of materials

2.06 Prepare machines to achieve pressure shaping requirements


2.07 Prepare machines to produce cast products

2.08 Prepare equipment to carry out surface treatment operations

2.09 Prepare thermal joining machines to produce joined products

2.10 Prepare work areas and materials for engineering activities

2.11 Prepare work areas for engineering activities

2.12 Prepare materials for engineering activities

2.13 Prepare equipment for engineering activities

2.14 Prepare loads for moving

2.15 Reinstate the work area after engineering activities

2.16 Store resources for further use

2.17 Prepare a programmable controlled system for operation

2.18 Check a computer controlled system for operation

3.01 Operate computer controlled engineering processes

3.02 Operate programmable controlled engineering processes

3.03 Shape engineering products by material removal using hand tools

3.04 Shape engineering products by material removal using machine tools

3.05 Produce engineering products by moulding or laying-up

3.06 Produce engineering products by machine controlled pressure shaping ` operations

3.07 Produce cast engineering products through manual operations

3.08 Make cast products by machine based operations

3.09 Join materials by manually-controlled thermal processes

3.10 Join materials by machine-controlled thermal processes

3.11 Join materials by bonding

3.12 Assemble components to meet specifications

3.13 Produce one-off components

3.14 Finish engineering products by applying surface treatments

3.15 Process materials to alter their properties

3.16 Shaping of engineering materials by manually-applied pressure

4.01 Configure engineering products or assets

4.02 Install engineering products or assets

4.03 Set up and secure access structures

4.04 Dismantle and remove access structures

4.05 Position engineering construction elements

4.06 Dismantle engineering construction elements

4.07 Dismantle engineering assets

4.08 Move loads

5.01 Carry out planned maintenance procedures

5.02 Adjust engineering assets to meet operating requirements

5.03 Remove components from assemblies or sub-assemblies


5.04 Replace assembly or sub-assembly components

5.05 Determine the feasibility of a component repair

5.06 Restore components to operational condition by repair

5.07 Deal with variations and defects in engineering products or assets

6.01 Establish compliance with specifications

6.02 Conduct specified testing of engineering products or assets

6.03 Analyse and interpret the results of engineering tests

6.04 Monitor the performance and condition of engineering assets

6.05 Assess the performance and condition of engineering assets

6.06 Inspect engineering products and equipment

6.07 Monitor the use of allocated resources

6.08 Diagnose faults in engineering products or assets

7.01 Hand over configured products or assets

7.02 Accept and confirm responsibility for the control of engineering products or assets

7.03 Hand over engineering products and assets to the control of others

7.04 Identify and deal with hazards in the work environment

7.05 Minimise risks to life, property and the environment

7.06 Deal with risks arising from contingencies

7.07 Contribute to technical leadership on engineering activities

7.08 Contribute to the organisation of work activities

7.09 Provide operational support to users of engineering products and assets

8.01 Develop yourself in the work role

8.02 Contribute to effective working relationships National Occupational Standards and NVQ mapping table Relationship to SEMTA OSCEng ECS and Level 3 NVQ in Aeronautical Engineering

Unit Number/Title Related ECS Unit(s)

Related NVQ Aeronautical engineering unit

Core units 001 Aviation mathematics & science 1.12,6.03 N/A 002 Electrical & avionics fundamentals 5.03, 5.04 N/A 003 Aviation legislation N/A N/A 004 Military aviation policy and regulation N/A N/A 005 Basic aerodynamics 6.05 N/A 006 Human factors in aeronautical engineering 8.01, 8.02 3 Pathway units 007 Aircraft materials and hardware 1.13, 5.01,

5.02, 5.03, 5.04, 5.06, 5.07, 6.01, 6.02, 6.05,

13, 14


Unit Number/Title Related ECS Unit(s)

Related NVQ Aeronautical engineering unit

6.06 008 Aircraft structure and maintenance 1.13, 5.03,

5.04, 6.05 13, 14,16, 161,

009 Aircraft mechanical systems 5.01, 6.05 148-160, 165, 167-170, 174

010 Gas turbine engines and propellers 5.01, 5.02, 5.07

52, 53, 148-150, 153,162, 164, 171, 177

011 Avionics maintenance principles 1.13, 5.01, 5.03, 5.04

76, 76, 78, 121, 134

012 Electronic and further electrical fundamentals 1.12, 1.13, 6.03, 6.04

N/A

013 Aeronautical digital fundamentals 1.12, 1.13 N/A 014 Aircraft avionics systems 1.12, 1.13,

5.03, 5.04, 6.02, 6.03

79, 80, 81, 82, 85, 121-134, 136-138, 140-145

015 Aircraft mechanical systems (manufacturing) 5.01, 6.05 12, 41, 42, 43, 44, 45, 46, 49, 50, 51

016 Aircraft manufacture 1.22, 2.02, 2.08, 3.09, 3.11, 3.15, 3.16

2, 5, 6, 9, 10, 11

017 Aircraft materials and hardware (manufacturing) 1.12, 1.13, 5.03, 5.04, 6.02, 6.03

8, 12, 41, 51

018 Aircraft structure (manufacturing) 1.13, 5.03, 5.04, 6.05

8, 13, 14, 15,

019 Aircraft electrical systems 1.12, 1.13, 5.03, 5.04, 6.02, 6.03

62, 63, 64, 65, 66, 67, 68, 69, 86, 87, 88, 120-125, 132-134, 136-138, 145


Identification of Key Skills summary relationship table

Unit number/Title Communication Application ofNumber

InformationTechnology

ProblemSolving

Improvingown learningandperformance

WorkingWithOthers

001 Aviation mathematics & science 2.2 2.1 1.1, 1.2, 1.3002 Electrical & avionics fundamentals 1.1, 1.2, 2.2 2.1 2.1, 2.2 2.1, 2.2, 2.3003 Aviation legislation 2.1a, 2.2004 Military aviation policy and

regulation2.1a, 2.2 2.1

005 Basic aerodynamics 1.1, 1.2, 1.3006 Human factors in aeronautical

engineering2.1a, 2.3 2.1, 2.2, 2.3 2.1, 2.2, 2.3 2.2

007 Aircraft materials and hardware 2.1a, 2.2, 2.3 2.1 2.1 2.1, 2.2, 2.3008 Aircraft structure and maintenance 2.1a, 2.2, 2.3 2.1 2.1, 2.2, 2.3009 Aircraft mechanical systems 2.1a, 2.2, 2.3010 Gas turbine engines and propellers 2.1a, 2.2, 2.3 2.1 1.1, 1.2011 Avionics maintenance principles 2.1a, 2.2, 2.3 2.1 2.1 2.1, 2.2, 2.3012 Electronic and further electrical

fundamentals2.1a, 2.2, 2.3 2.1 2.1, 2.2, 2.3

013 Aeronautical digital fundamentals 2.1a, 2.2, 2.3 2.1 2.1 2.1, 2.2, 2.3014 Aircraft avionics systems 2.1a, 2.2, 2.3 2.1 2.1, 2.2, 2.3015 Aircraft mechanical systems

(manufacturing)2.1a, 2.2, 2.3 2.1 2.1, 2.2, 2.3

016 Aircraft manufacture 2.1a 2.1 2.1, 2.2, 2.3017 Aircraft materials and hardware

(manufacturing)2.1a, 2.2, 2.3 2.1 2.1, 2.2, 2.3

018 Aircraft structure (manufacturing) 2.1a, 2.2, 2.3 2.1 2.1, 2.2, 2.3019 Aircraft electrical systems 2.1a, 2.2, 2.3 2.1 2.1, 2.2, 2.3020 Avionics manufacturing principles 2.1a, 2.2, 2.3 2.1 2.1 2.1, 2.2, 2.3


Level 3 Certificate in Aeronautical Engineering

Identification of opportunities for evidence generation of moral, ethical, spiritual, European dimension, Environmental educationand Health and Safety

Unit No and Title Moral, spiritual and ethical European dimension Environmentaleducation

Health andsafety

001 Aviation mathematics & science002 Electrical & avionics fundamentals *003 Aviation legislation * * * *004 Military aviation policy and

regulation* * * *

005 Basic aerodynamics006 Human factors in aeronautical

engineering* * * *

007 Aircraft materials and hardware * *008 Aircraft structure and maintenance * *009 Aircraft mechanical systems * *010 Gas turbine engines and propellers * *011 Avionics maintenance principles * *012 Electronic and further electrical

fundamentals* *

013 Aeronautical digital fundamentals014 Aircraft avionics systems * * *015 Aircraft mechanical systems

(manufacturing)* * *

016 Aircraft manufacture * * *017 Aircraft materials and hardware

(manufacturing)* *

018 Aircraft structure (manufacturing) * * *019 Aircraft electrical systems * *020 Avionics manufacturing principles * * *


Test specifications Paper 2661- 03 - 001: Aviation Mathematics & Science Test Duration - 1 hour Total no of questions - 40

Unit

Outcome No of items %

1 Arithmetic operations with and without a calculator on SI and Imperial units 8 20

2 Carry out operations involving algebraic expressions and formulae 7 17.5

3 Use graphs to determine values and solve problems 5 12.5

4Demonstrate an understanding of the nature of matter and relate this to chemical compounds and change of state

3 7.5

5Demonstrate an understanding of the principles of statics related to aircraft loading, buoyancy and hydrostatic pressure

5 12.5

6Demonstrate an understanding of the principles of kinetics and dynamics and relate these principles to flight forces, aircraft motion and gyroscopic motion

8 20

1

7Demonstrate an understanding of the principles of fluid motion, heat and temperature and apply these principles to flight and propulsion theory

4 10

Paper 2661- 03 - 002: Electrical & avionics fundamentals Test Duration - 1 hour Total no of questions - 40

Unit

Outcome No of items %

1 Demonstrate an understanding of electrical theory and how this relates to aircraft electrical systems 17 44

2 Demonstrate an understanding of electrical instrumentation systems and power supplies 15 38

2

3

Demonstrate an understanding of electrical and computer controlled instrumentation systems and communication systems

8 18

Paper 2661- 03 - 003: Civil Aviation Legislation Test Duration – 45 minutes Total no of questions - 30

Unit Outcome No of Items

%

1Demonstrate familiarity with the principal elements of aviation legislation as it relates to the certification of aircraft, operators and maintainers

12 40

3

2Demonstrate general knowledge of the theoretical and practical aspects of aviation legislation as it relates to licensing of aircraft engineers and aircraft airworthiness

18 60


Paper 2661- 03 - 004: Military Aviation Policy and Regulation Test Duration – 45 minutes Total no of questions - 30

Unit Outcome No of Items %

1Demonstrate familiarity with the principal elements of military aviation engineering policy, publications and orders

8 60

4

2Demonstrate general knowledge of the theoretical and practical aspects of aviation engineering documentation and IT systems

22 40

Paper 2661- 03 - 005: Basic Aerodynamics Test Duration - 1 hour Total no of questions - 40


%

1 Demonstrate an understanding of the basic principles of flight and stability 18 45

2 Demonstrate an understanding of the principles of aircraft control

16 40 5

3 Demonstrate an understanding of the theory and effects of high speed flight 6 15

Paper 2661- 03 - 006: Human factors in aeronautical engineering

Test Duration - 30 minutes Total no of questions - 20


%

1 Demonstrate a general knowledge of the causes of human error in an aircraft maintenance environment 12 60

62 Demonstrate a general knowledge of the procedures and

practices in place to minimise human error and its effects 8 40


Pathway Unit Assignment Specifications These specifications give the minimum and maximum weighting each learning outcome should carry in the Centre set assignment Assignment Unit 7: Aircraft Materials and Hardware

Unit Outcome Percentage of assignment

1 Investigate the structure and practical properties of aircraft engineering materials

20-30

2 Identify aircraft hardware and carry out replacement and servicing

30-40 7

3Undertake maintenance practices and procedures on aircraft hardware and in workshops 30-40

Assignment Unit 8: Aircraft Structure and Maintenance


1 Undertake maintenance on aircraft structures 30-40 2 Remove and replace airframe structures and components 30-40

83

Demonstrate an understanding of general practices for aircraft maintenance functions 20-30

Assignment Unit 9: Aircraft Mechanical Systems


1 Demonstrate an understanding of aircraft mechanical systems and how they interact

20-30

2 Demonstrate an understanding of Landing Gear systems (ATA 32) 30-50

3(Civil) Demonstrate an understanding of Equipment and Furnishings (ATA 25) 30-50 9

3(Military) Demonstrate an understanding of Aircraft Assisted Escape Systems and their interaction with other aircraft systems 30-50

Assignment Unit 10: Gas Turbine Engines and Propellers


1Demonstrate an understanding of gas turbine engines with respect to aircraft maintenance functions 40-60

10 2

Demonstrate an understanding of aircraft propeller systems with respect to aircraft maintenance functions 40-60

Assignment Unit 11: Avionics Maintenance Practices


1Undertake maintenance practices and procedures on avionics and electrical hardware. 40-60

11 2

Demonstrate an understanding of general practices for aircraft maintenance functions 40-60


Assignment Unit 12: Electronic and further electrical Fundamentals


1 Demonstrate an understanding of electronic components and their use in aircraft applications.

30-40

2 Demonstrate an understanding of AC and DC theory. 30-40 12

3Demonstrate an understanding of AC and DC motors and generators. 30-40

Assignment Unit 13: Aeronautical digital fundamentals


1Demonstrate an understanding of digital electronic theory and architecture. 40-60

13 2 Demonstrate an understanding of data transfer. 40-60

Assignment Unit 14: Aircraft Avionics Systems


1Demonstrate an understanding of air data systems and aircraft instrumentation. 20-30

2Demonstrate an understanding of aircraft communication and navigation systems.

20-30

3Demonstrate an understanding of aircraft flight control and autostabilisation systems. 20-30

14

4Demonstrate an understanding of aircraft electrical power and lighting systems. 20-30

Assignment Unit 15: Aircraft mechanical systems (manufacturing)


1Demonstrate an understanding of aircraft mechanical systems and how they interact 30-50

2 Demonstrate an understanding of Landing Gear systems (ATA 32) 30-50 15

3Demonstrate an understanding of Equipment and Furnishings (ATA 25) 20-30

Assignment Unit 16: Aircraft manufacture


1Describe and understand the need for component manufacturing and material heat treatment techniques 20-30

2Prepare the aircraft structure for assembly by selection and use of the correct jigs/fixtures and hole preparation techniques

20-30

3Identify, select and obtain an appropriate assembly technique, and undertake the assembly and sealing operation correctly and safely

20-30 16

4Ensure a structure has been assembled to the engineering drawing, technical data or other instructions, which determine the aircraft manufacturing requirements

20-30


Assignment Unit 17: Aircraft materials and hardware (manufacturing)


1Investigate the structure and practical properties of aircraft engineering materials 30-40

2Identify aircraft hardware and carry out replacement and servicing 30-40 17

3Undertake manufacturing practices and procedures on aircraft hardware and in workshops 30-40

Assignment Unit 18: Aircraft structure


1 Undertake installation on aircraft structures 30-40

2 Remove and replace airframe structures and components 30-40 18

3Demonstrate an understanding of general practices for aircraft manufacturing 30-40

Assignment Unit 19: Aircraft electrical Systems


1Demonstrate an understanding of air data systems and aircraft instrumentation 30-40

2Demonstrate an understanding of aircraft communication and navigation systems. 30-40 19

3Demonstrate an understanding of aircraft electrical power and lighting systems. 30-40

Assignment Unit 20: Avionics manufacturing principles


1Demonstrate an understanding of general principles for aircraft avionics functions

40-60 20

2Undertake installation practices and procedures on avionics and electrical hardware 40-60


Section 2 – The units

Core Units


Unit 1 Aviation mathematics and science Rationale This unit is concerned with basic mathematical and scientific formula to enable candidates to develop and apply these within the requirements for aerospace engineering and developing the candidates’ understanding of scientific principles and applying these to elements of aviation such as materials, structures and avionic, mechanical, fluid and propulsion systems. There are seven outcomes to this unit. The candidate will be able to: 1 Carry out arithmetic operations with and without a calculator using SI and imperial units 2 Carry out operations involving algebraic expressions and formulae 3 Use graphs to determine values and solve problems. 4 Demonstrate an understanding of the nature of matter and relate this to chemical compounds and change of state 5 Demonstrate an understanding of the principles of statics and relate this to aircraft loading, buoyancy and hydrostatic pressure 6 Demonstrate an understanding of the principles of kinetics and dynamics and, relate these principles to flight forces, aircraft motion and gyroscopic motion 7 Demonstrate an understanding of the principles of fluid motion, heat and temperature and apply these principles to flight and propulsion theory. Assessment The outcomes for this unit will be assessed on evidence resulting from 1 Written Test The knowledge requirements will be assessed by an externally set and marked multiple-choice test.


Outcome 1 Carry out arithmetic operations with and without a calculator on SI and imperial units Practical activities The candidate will be able to: 1 Convert aircraft fuel loads and systems pressure from American and imperial to metric, and from metric to imperial and American 2 Read aircraft gauges and system pressure gauges to confirm calculations Underpinning Knowledge The candidate will be able to: 1 Define and use positive, negative and real numbers 2 Perform the arithmetic operations of addition, subtraction, multiplication and division on expressions, with and without the use of a calculator 3 Find the LCM and HCF of expressions 4 Add, subtract, multiply and divide fractions 5 Simplify fractions by cancellation operations 6 Convert fractions to decimals and vice versa 7 Identify recurring, terminating and non-terminating decimals 8 Distinguish between significant figures and decimal places 9 Convert numbers into standard form and manipulate arithmetic expressions in standard form 10 Determine estimated values for expressions involving decimal values 11 Convert fractions and decimals to percentages 12 Determine percentage values for common engineering variables 13 Define ratio and proportion 14 Perform calculations that require the manipulation of simple arithmetic ratios 15 Define direct and inverse proportion 16 Determine the constant of proportionality for simple expressions 17 Convert basic and derived units between Imperial and SI systems 18 Determine derived unit conversion factors for Imperial and SI systems, using basic units 19 State the meaning of relative and absolute error 20 Apply error arithmetic to simple experimental data


Outcome 2 Carry out operations involving algebraic expressions and formulae Underpinning Knowledge The candidate will be able to: 1 Factorise expressions by grouping and extracting common factors 2 Distinguish between an algebraic expression, an equation and an identity 3 Simplify expressions involving brackets, powers and roots

a) define numbers in ‘index’ form b) state the laws of indices and use these laws to simplify and manipulate

expression in index form 4 Evaluate formulae required for this unit and other units by substitution of given scientific and engineering data 5 Use simple formula in which the subject is equal to an expression whose terms are connected by addition, subtraction, multiplication or division 6 Use formulae involving two or more terms 7 Use formulae which contain roots and/or powers 8 Use simple scientific formulae and evaluate using given data 9 Identify the components of a circle – radius, diameter, circumference 10 Solve simple problems related to area circumference, radius and diameter of circles 11 Use given formulae to calculate areas and perimeters of plane figures – triangle, square, rectangle, parallelogram, circle and semi-circle 12 Use given formulae to calculate the surface area and volume of common solids – cube, cylinder, cone and sphere


Outcome 3 Use graphs to determine values and solve problems Practical Activities The candidate will be able to: 1 Apply graphical techniques to the solution of simple engineering problems Underpinning Knowledge The candidate will be able to: 1 Choose suitable scales and plot graphs from experimental data 2 Plot graphs of linear equations, by forming a data table and plotting the points 3 Read values from graphs and interpolate values between points 4 Determine the intercept of a straight line on the y-axis by extrapolation 5 Determine the gradient of a straight line 6 Evaluate the law of a straight-line graph in the form of y = mx + c

7 Solve graphically a pair of simultaneous equations 8 Draw a sine and cosine wave over one complete cycle 9 Determine data values for pressure, density, relative density and temperature from graphs and tables


Outcome 4 Demonstrate an understanding of the nature of matter and relate this to chemical compounds and change of state

Underpinning Knowledge The candidate will be able to: 1 Identify basic SI units – metre (m), kilogram (kg), second (s), ampere (A), Kelvin (K) 2 Identify names and symbols for preferred SI prefixes – giga (G), mega (M), kilo (k), nano (n) and pico (p) 3 Identify basic Imperial units – foot (ft), pound (lb), minute (min), Fahrenheit (F) 4 Use basic units to convert derived SI units into Imperial and vice-versa 5 Describe the kinetic theory of matter and its relationship to heat energy 6 Identify the common chemical elements used in engineering by both name and chemical symbol 7 Explain the nature of the gaseous, liquid and solid states of matter, including the change of state of common substances such as water 8 Describe Brownian motion 9 Describe the nature of the metallic, ionic and covalent bond including their relative strengths, giving reasons for atoms and molecules forming such bonds 10 Describe the nature of the molecules found in both metals and non-metals.


Outcome 5 Demonstrate an understanding of the principles of statics and relate this to aircraft loading, buoyancy and hydrostatic pressure Practical Activities The candidate will be able to: 1 Use fundamental principles to solve problems for aircraft loading and buoyancy Underpinning Knowledge The candidate will be able to: 1 Represent force as a vector 2 Explain the concept of equilibrium 3 Define the moment of a force about a point 4 Define the centre of gravity and identify the position of the centre of gravity of symmetrically shaped solids 5 Explain the principles of moments and solve simple problems involving straight levers, bell crank levers and aircraft loading 6 Explain the triangle of forces theorem, and solve graphically problems using the triangle of forces theorem 7 Explain the parallelogram of forces, and solve graphically problems involving the resultant and equilibrant of two inclined forces 8 Define pressure and its units (N/m2, Pa and lbf/in2)

9 Explain the distinction between absolute and gauge pressure 10 Solve problems involving atmospheric, differential and ambient pressure, for varying altitudes 11 Calculate pressures for liquids of varying relative density, by measuring liquid height and using the formula p = ∆gh


Outcome 6 Demonstrate an understanding of the principles of kinetics and dynamics and, relate these principles to flight forces, aircraft motion and gyroscopic motion Underpinning Knowledge The candidate will be able to: 1 Define speed, velocity and acceleration (including acceleration due to gravity) 2 State Newton’s laws of motion 3 Explain and use the relationships: F = ma and W = mg 4 Define the equations of linear motion for constant acceleration 5 Define centripetal acceleration, centrifugal force and, angular velocity 6 Use the equations of motion and Newton laws to solve simple problems involving the forces imposed on aircraft and the resultant motion 7 Define free vibration, simple harmonic motion, forced vibration, resonance, time period, cycle, frequency and amplitude of elastic systems 8 Relate simple harmonic motion to mass-spring and simple pendulum systems 9 Find the natural frequency of small oscillations of a simple pendulum using f = 1/T = 1/2

g/L

10 Define velocity ratio, mechanical advantage and efficiency with respect to simple machines 11 Solve simple problems involving pulley systems, worm and wheel, levers, gears and the screw jack 12 Define momentum and inertia and relate these to the simple gyroscope 13 Explain the terms: rigidity and precession, with respect to gyroscopic motion 14 Define work and power, stating the unit used for each 15 Explain the concept of the conservation of energy and define the common forms of energy: potential, kinetic, heat, electrical and chemical 16 Solve simple problems involving potential and kinetic energy 17 Define static and dynamic friction, coefficient of friction, reaction and normal force 18 Solve simple problems involving friction for objects in contact with horizontal surfaces


Outcome 7 Demonstrate an understanding of the principles of fluid motion, heat and temperature, applying these principles to flight and propulsion theory Personal Activities The candidate will be able to: 1 Use elementary principles to solve problems related to flight and propulsion theory Underpinning Knowledge The candidate will be able to: 1 Define: density and relative density (specific gravity) 2 Solve simple problems involving changes in density, pressure and temperature of air, with changing altitude 3 Define viscosity in terms of the resistance to fluid flow and the shear stresses set up within the fluid close to the system boundary 4 Describe the effects of streamlining on the velocity and resistance of air over aerofoil surfaces 5 State Bernoulli’s theorem ie: in the streamline of a non-viscous fluid the sum of the energy of position (potential energy) plus the energy of motion (kinetic energy) plus the pressure energy will remain constant 6 Explain how Bernoulli’s theorem accounts for the behaviour of a fluid passing through a venturi and how this relates to the fundamental concept of lift 7 Explain the difference between heat and temperature, giving a definition for both 8 Describe the Celsius and Fahrenheit scales of temperature and explain the relationship between the Celsius c) and Kelvin k) scales 9 Convert degrees Celsius to Kelvin and Fahrenheit and vice-versa 10 Use and determine values from the ISA tables, using interpolation and extrapolation techniques where necessary


Unit 2 Electrical & avionics fundamentals Rationale This unit is concerned with the understanding of avionic principles and their relationship to aircraft servicing and maintenance. There are three outcomes to this unit. The candidate will be able to: 1 Demonstrate an understanding of electrical theory and how this relates to aircraft electrical systems 2 Demonstrate an understanding of electrical instrumentation systems and power supplies 3 Demonstrate an understanding of electronic and computer controlled instrumentation systems including communication systems. Assessment The outcomes for this unit will be assessed on evidence resulting from 1 Written Test The knowledge requirements will be assessed by an externally set and marked multiple-choice test.


Outcome 1 Demonstrate an understanding of electrical theory and how this relates to aircraft electrical systems Practical Activities The candidate will be able to: 1 Undertake simple crimping tasks on cables and construct cable looms 2 Use the ATA 100 system to identify aircraft cables Underpinning Knowledge The candidate will be able to: 1 Describe the structure of the atom and the distribution of electrical charge within atom molecules and compounds 2 Describe the molecular structure of conductors, semiconductors and insulators 3 Describe the nature of static electricity 4 State the laws of attraction and repulsion 5 State the safety precautions necessary to avoid injury or damage resulting from electro-static hazards 6 Define the following terms stating the units used with each

a) coulomb b) charge c) current d) resistance e) potential difference f) electromotive force g) voltage h) electrical power

7 State and apply the relationship between voltage, current and resistance in a theoretical and practical manner 8 Calculate the internal resistance of a battery 9 Describe how electricity may be produced using the following methods

a) light (photoelectric cells) b) heat (thermocouples) c) pressure (piezoelectric) d) chemical action (batteries) e) magnetism and motion (generators)

10 Describe the nature of a sinusoidal waveform and define phase, frequency and cycle 11 Define: instantaneous, average, root mean square, peak and peak-to-peak sinusoidal values 12 Carry out simple calculations for voltage current and power for the values identified in 10 above 13 Describe the construction and operation of the following sensors piezoelectric crystal, thermocouple, and photoelectric cell, giving an aircraft application for each


14 Describe the construction and principles of operation of the dry cell, lead acid battery, and nickel cadmium battery 15 Explain (qualitatively) the chemical action of primary and secondary cells 16 Describe how the state of charge of aircraft batteries (lead acid and nickel cadmium) may be determined 17 Describe the mandatory safety precautions and servicing procedures associated with aircraft lead acid and nickel cadmium batteries 18 Describe the method and explain the reasons for capacity testing aircraft lead acid and nickel cadmium batteries 19 Explain the nature and reasons for constant voltage and constant current charging of aircraft batteries 20 Explain the term ‘thermal runaway’ 21 Describe the construction, nature and general purpose of high tension, coaxial, and special-to-purpose aircraft electrical cables 22 Identify and describe the different types of crimping tool used for terminating cables with ring tongue terminals, splices and miniature connectors 23 Explain the effects on the current carrying capacity when cables are placed in a loom or conduit 24 Correctly use wire selection charts to determine wire size for a specific installation 25 Describe the safety precautions and installation procedures that must be adopted when routing and securing aircraft cables and looms 26 Describe soft soldering and explain when these methods would be employed 27 Describe the operation, function and use of avionic general test equipment

a) ammeter b) voltmeter c) multimeter – digital and analogue d) basic oscilloscope


28 Describe electrical techniques and testing for a) continuity b) insulation, c) screening d) bonding

29 Explain the function of relays, circuit breakers and fuses


Outcome 2 Demonstrate an understanding of electrical instrumentation systems and power supplies Practical Activities The candidate will be able to: 1 Read and interpret instruments 2 Remove and refit system components Underpinning Knowledge The candidate will be able to: 1 Describe (at block diagram level) the layout and purpose of the components within a typical aircraft battery system 2 Describe (at block diagram level) the layout of a typical multi-engine electrical power distribution system 3 State the function of the following components fitted to typical aircraft electrical power distribution systems

a) generator b) constant speed drive unit c) battery d) emergency battery e) rotary and static inverters f) transformer rectifier units g) generator control unit h) bus tie relay i) generator control relay j) battery isolation switch

4 Define

a) vital services b) essential services c) non-essential services

5 Explain how electrical power is maintained in the event of emergencies by using standby generators, duplication of provision, batteries, emergency batteries, ram air turbines, transformer rectifier units and static inverters 6 State the procedure for the connection and disconnection of ground/external electrical power 7 Describe the nature of d.c. and a.c. ground power connectors and state the use for the connecting pins


8 State the purpose, describe the construction and explain the operation of the following pitot-static instruments:

a) altimeter b) air speed indicator c) vertical speed indicator d) machmeter

9 Explain (qualitatively) the nature of gyroscopic motion and define the following terms related to gyroscopic motion

a) rigidity b) precession c) gimballing d) topple

10 Explain in simple terms the purpose and operation of the following gyroscopic instruments

a) artificial horizon b) attitude indicator c) direction indicator d) turn e) slip indicator

11 State the differences between direct reading and remote reading compasses 12 Describe the layout and operation of a simple stall warning system 13 Describe the layout and principle of operation of the following lighting systems

a) External - navigation, landing, taxiing, ice b) Internal - cabin, cockpit, cargo c) emergency


Outcome 3 Demonstrate an understanding of electronic and computer controlled instrumentation systems including communication systems Practical Activities The candidate will be able to: 1 Identify appropriate controls and systems 2 Remove and refit components Underpinning Knowledge The candidate will be able to: 1 Explain (qualitatively) the nature of analogue and digital signals 2 Define computer terminology

a) bit b) byte c) software d) hardware e) CPU f) IC g) memory devices

i. RAM ii. ROM

iii. PROM 3 Describe (at block diagram level) the nature, use and range of the following computer hardware:

a) input devices b) microprocessor and interface units c) visual display units d) output devices e) storage devices

4 Identify (without the use of calculations) the nature of radio signals 5 Describe (at block diagram level) the layout and operation of typical aircraft radio and audio communication systems such as HF, VHF, UHF, Intercom 6 Describe (at block diagram level) the function, inputs, component sequence and readout information for the following navigation aids:

a) VHF Omni-directional Ranging (VOR) b) Instrument Landing System (ILS) c) Automatic Direction Finding (ADF) d) Distance Measuring Equipment (DME) e) Global Positioning System (GPS) f) ATC Transponder g) Traffic alert and Collision Avoidance System (TCAS) h) Weather Radar i) Radio Altimeter j) Flight management System (FMS)/Area Navigation (RNAV)

7 Define the term ‘databus’ 8 Describe (at block diagram level) the typical system arrangement and cockpit layout/readout of aircraft Electronic Instrument Systems such as:


a) Electronic Flight Instrument System (EFIS) b) Engine Indication and Crew Alerting System (EICAS) c) Electronic Centralised Aircraft Monitoring (ECAM) d) Autopilot and Flight Control Systems (AFCS)

9 State all necessary safety precautions when working on avionic systems or handling electronic equipment sensitive to electrostatic discharge 10 Describe (at block diagram level) the typical arrangement and readout information for an onboard maintenance system (OBMS) 11 Identify typical components with an OBMS, including those used for structural monitoring.


Unit 3 Civil Aviation Legislation Rationale This unit is concerned with the understanding the background and criteria of aviation legislation as it applies to aircraft maintenance. There are two outcomes to this unit. The candidate will be able to: 1 Demonstrate familiarisation with the principal elements of aviation legislation as it relates to the certification of aircraft, operators and maintainers 2 Demonstrate general knowledge of the theoretical and practical aspects of aviation legislation as it relates to the licensing of aircraft engineers and the maintenance of aircraft air worthiness Assessment The outcomes for this unit will be assessed on the basis of evidence resulting from 1 Written test The knowledge requirements will be assessed by an externally set and marked multiple-choice test


Outcome 1 Demonstrate familiarisation with the principal elements of aviation legislation as it relates to the certification of aircraft operators and maintainers Practical Activities The candidate will be able to: 1 Determine the validity of certification items

a) Aircraft Type Certificate (Authority, Registration, Date) b) Aircraft Operator’s Certificate (Authority, Company and address, Currency) c) Engineer’s Licence (Aircraft Type, Validity, Authority)

Underpinning knowledge The candidate will be able to: 1 Identify the principal elements of the Regulatory Framework:

a) The role of International Civil Aviation Organisation b) The role of European Aviation Safety Agency (EASA) c) The role of the Member States d) Relationship between Part 145, Part 66, Part 147 and Part M

2. Explain the basic requirements for Commercial Air Transport

a) Air Operators’ Certificates b) Operators’ Responsibilities c) Documents to be Carried d) Aircraft Placarding (Markings) e) Aircraft Certification: General


Outcome 2 Demonstrate general knowledge of the theoretical and practical aspects of aviation legislation as it relates to the licensing of aircraft engineers and the maintenance of airworthiness Practical Activities The candidate will be able to 1 Detail the typical procedure to process an item of aircraft equipment from delivery by the supplier to availability for fitment to the aircraft. 2 Detail the necessary steps to be taken to replace a time expired, rotatable component to an aircraft above 5700 kg MTWA within a Part 145 Maintenance Organisation Underpinning knowledge The candidate will be able to: 1 Explain the practical application of the following:

a) Part 66; Certifying Staff – Maintenance b) Part 145 - Approved Maintenance Organisations c) Part M Continuing Airworthiness

i. Maintenance Responsibility ii. Maintenance Management

iii. Aircraft Maintenance Programme iv. Aircraft Technical Log v. Maintenance Records and Log Books

vi. Accident/Occurrence Reporting d) Applicable National and International Requirements for:

i. Maintenance Programmes, Maintenance checks and inspections ii. Master Minimum Equipment Lists, Minimum Equipment Lists

iii. Despatch Deviation Lists iv. Airworthiness Directives v. Service Bulletins, Manufacturers’ Service Information

vi. Modifications and Repairs vii. Maintenance Documentation, Maintenance Manuals, Structural

Repair Manuals, Illustrated Parts Catalogues, etc.


Unit 4 Military Aviation Policy and Regulation Rationale This unit is concerned with understanding the background and criteria of military aviation policy and regulation as they apply to aircraft maintenance. There are two outcomes to this unit. The candidate will be able to: 1 Demonstrate familiarity with the principal elements of military aviation engineering policy, publications and orders 2 Demonstrate general knowledge of the theoretical and practical aspects of aviation engineering documentation and IT systems Assessment The outcomes for this unit will be assessed on the basis of evidence resulting from 1 Written test The knowledge requirements will be assessed by an externally set and marked multiple-choice test


Outcome 1 Demonstrate familiarity with the principal elements of military aviation engineering policy, publications and orders Underpinning knowledge The candidate will be able to: 1 Identify the principal sources of military aviation policy:

a) AP 100A-01 (RAF Engineering) b) AP 100B-01 (RAF Engineering Orders & Procedures) c) JAP 100A (Military Aviation Engineering Policy & Regulations) d) Engineering Staff Instructions (ESIs)

2 State the purpose of and responsibilities toward the Engineering Wing Order Book (or equivalent local publication) 3 Describe the function of AP 3376 including:

a) Job Description b) Job Performance Statements c) Trade Qualification Annotations

4 State the significance of engineering tradesmen/women’s signatures on aircraft maintenance documentation 5 Demonstrate an understanding of authority levels as defined by Military Aviation Engineering Policy


Outcome 2 Demonstrate general knowledge of the theoretical and practical aspects of aviation engineering documentation and IT systems Practical activities The candidate will be able to: 1 Carry out the actions necessary to place an aircraft unserviceable 2 Complete the relevant fields of the MOD F731 to condition an item of technical equipment ‘Repairable 2nd Line (R2)’ 3 Raise MOD F707B and MOD F731 using LITS processes and update LITS system on completion of task Underpinning knowledge The candidate will be able to: 1 Describe the structure of aircraft maintenance publications by topic content 2 Demonstrate an awareness of the content of the MOD F700C 3 Use MOD F700 series documentation to accurately record work undertaken during an aircraft maintenance task. 4 Record details of scheduled aircraft maintenance tasks and maintenance procedures on the following MOD forms:

a) F707MC b) F707MP c) F707MS d) F2988

5 Explain the independent check regulations appropriate to their trade 6 State the purpose of LITS and explain the structure of the processes and securities involved in its operation 7 Interpret terminology as found in the Glossary of Terms in the Aircraft Safety and Maintenance Notes 8 Extract information from engineering Air Publications (APs) for tasks appropriate to their trade 9 Recognise and state the purpose of the following:

a) Special Technical Instructions (STIs) b) Servicing Instructions (SIs) c) Urgent Technical Instructions (UTIs) d) Routine Technical Instructions (RTIs) e) Modifications (Mods) f) Special Trial Fits (STFs).


Unit 5 Basic Aerodynamics

Rationale This unit has been designed to provide potential aviation engineers with the skills and knowledge necessary to understand aeroplane aerodynamics, and flight controls. There are three outcomes for this unit. The candidate will be able to: 1 Demonstrate an understanding of the basic principles of flight and stability 2 Demonstrate an understanding of the principles of aircraft control 3 Demonstrate an understanding of the theory and effects of high speed flight Assessment The outcomes for this unit will be assessed on evidence resulting from 1 Written test The knowledge requirements will be assessed by an externally set and marked multiple-choice test.


Outcome 1 Demonstrate an understanding of the basic principles of flight and stability Practical Activities The candidate will be able to: 1 Demonstrate flow behaviour and aerodynamic forces Underpinning Knowledge The candidate will be able to: 1 Identify the basic nature, properties and composition of the atmosphere in relation to

a. air composition b. temperature c. pressure d. density e. position on the earth’s surface f. climatic conditions.

2 Identify the layers of the atmosphere and the region where temperature remains constant. 3 Carry out simple calculations using the basic gas laws:

a. Boyle’s law b. Charles Law c. Combined gas law.

4 Relate the use of International Standard Atmosphere (ISA) to current aviation, quoting values at sea level in metric and imperial units of

a. Pressure i. Psi ii. N/m2

iii. Bar,milli bar b. Density

i. Kg/m3

c. Temperature i. ocii. Kelvin iii. oF

5 Identify the major properties of airflow and establish how aerodynamic forces (Lift/drag) affect aircraft performance: e.g. total pressure, dynamic pressure, static pressure, and change in velocity and temperature. 6. Describe how air flows around an aerodynamic body, relating this to the different

types of flow and flow characteristics including free stream airflow, boundary layer (laminar and turbulent), stagnation point or region, transition and separation points, up and down wash, and the generation of vortices.

7. Identify and describe the main characteristics of symmetrical and cambered aerofoils including the following terms.

a. chord and mean camber lines.


b. angle of attack and angle of incidence. c. fineness ratio. d. thickness to chord ratio (expressed as a percentage)

8. Describe the characteristics of the airflow and the resulting static pressure changes, with reference to Bernoulli’s theorem, around aerofoils with changes in angle of attack and velocity, including changes in pressure distribution, total air reaction, lift, drag, centre of pressure and the stall.

9. State and use the lift and drag equations to explain how lift and drag can vary

including simple calculations and explain how the coefficients of lift and drag and lift to drag ratio change with angle of attack for cambered and symmetrical aerofoils.

10. Describe how the total drag of an aircraft is generated and methods of drag

reduction including an explanation of the following types of drag:

a. induced. b. pressure (form). c. skin friction. d. interference. e. parasite.

11. Identify and describe the characteristics of the basic wing planforms, rectangular,

tapered, swept, and delta including simple dimensional calculations and their effect on the airflow. (Eg. span, aspect ratio, taper ratio, gross wing area, and wash in and out.)

12. Describe the effect of ice, snow and frost build-up on the performance of aerofoils. 13. Describe the relationship between the four main forces acting on an aircraft and the

balancing effect of the tail plane. 14. Describe performance in straight and level flight, climb, glide and turn 15. Describe how turning flight is related to stall and structural problems 16. Describe the use and operation of high lift devices, highlighting flow characteristics

involved: e.g airflow separation and changes in coefficient lift and drag. 17. Identify and determine the nature of flight stability eg. Active and passive stability,

static and dynamic stability. 18. State the three axes of freedom for an aircraft and link this to the three types of stability. 19. Distinguish between statically stable, unstable and neutral. 20. Describe the methods used to enhance lateral, longitudinal and directional stability

and identify the major components on an aircraft that affect stability.


Outcome 2 Demonstrate an understanding of the principles of aircraft control Practical Activities The candidate will be able to: 1 Carry out aerodynamic experiments to investigate the effects of flight control on aircraft movement 2 Carry out practical investigations and tasks on aircraft to analyse the operation of flight controls. Underpinning Knowledge

1. Define aircraft control and state the 3 axes of rotation of an aircraft and describe how it pitches rolls and yaws.

2. Describe the aerodynamic effect of conventional control surfaces including the

factors that govern the magnitude of forces and turning moment produced. 3. Describe how the following primary flying controls are used to manoeuvre a

conventional aircraft about the 3 axes of rotation:

a. ailerons.

b. elevators.

c. rudder 4. State the need for instinctive control and describe the relationship between the

control movements made by the pilot, control surface movement and the movement of the aircraft.

5. Describe the effects of airspeed on flight and controls and explain the need for

aerodynamic balancing and power operated flying controls. 6. Describe adverse aileron yaw and the following methods used to overcome it:

a. differential ailerons.

b. Frise ailerons. 7. Identify and describe the use and basic operation of the following alternative flying

controls:

a. spoilers.

b. all moving tailplane (slab/stabilator).

c. tailerons.

d. canards.

e. elevons.

f. ruddervators.


g. flaperons. 8. Describe the following high lift devices fitted to the trailing edge and state the

advantages and disadvantages with respect to aerodynamic effectiveness and operation:

a. plain flap.

b. split flap.

c. slotted flap.

d. Fowler flap.

9. Describe the aerodynamic problems caused by asymmetric flap operation. 10. Describe the following leading edge devices and state the advantages and

disadvantages with respect to aerodynamic effectiveness and operation:

a. Kreuger flap.

b. leading edge droop.

c. slots.

d. slats. 11. State the purpose of stall wedges (stall strips). 12. Describe methods of boundary layer control. 13. Describe and differentiate between the following high drag devices and state their

operation limitations both in flight and on the ground.

a. spoilers.

b. lift dumpers.

c. speed brakes.


14. Describe the operation and aerodynamic characteristics of the following flight control tabs and trimming devices.

a. balance tab.

b. anti-balance tab.

c. spring tab.

d. trim tab.

e. servo tab.

f. variable incidence tailplanes. 15. Describe control surface flutter and its detrimental effect on the control system and

structure. 16. State the reason for mass balancing and how it may be achieved on of primary

controls, including an explanation of the following terms:

a. out of balance force.

b. forward and rear limits.

d. centre of gravity.


Outcome 3 Demonstrate an understanding of the theory and effects of high speed flight Underpinning Knowledge The candidate will be able to: 1. Explain the term ‘speed of sound’, and state why it is important to aircraft flight, and how it varies with atmospheric conditions. 2. Differentiate between subsonic, transonic and supersonic flight. 3. Describe Mach number and critical Mach number and explain their significance to aircraft flight. 4. Describe the formation and development of shock waves, their properties and effect on the airflow including the movement of the centre of pressure. 5. Describe the following terms and problems associated with transonic flight:

a. compressibility b. buffet.

c. shock wave formation. d. spanwise flow.

e. shock stall f. boundary layer flow separation. g. control ineffectiveness. h. instability 6. Describe how the problems in 5) can be overcome by using the following:

a. swept wings. b. wing fences. c. saw tooth leading edges.

d. notched leading edge. e. vortex generators. f. area rule

g. spoilers and all moving tailplanes (slab/stabilator) h. active stability devices.

7. Describe the factors affecting the airflow through an intake of a high speed

aircraft and how any problems may be over come.


Unit 6 Human factors in aeronautical engineering

Rationale This unit is concerned with an understanding of the factors affecting human performance and its relationship to airworthiness with regard to aircraft servicing and maintenance. There are two outcomes to this unit. The candidate will be able to: 1 Demonstrate a general knowledge of the causes of human error in an aircraft maintenance environment 2 Demonstrate a general knowledge of the procedures and practices in place to minimise human error and its effects Assessment The outcomes for this unit will be assessed on evidence resulting from 1 Written test The knowledge requirements will be assessed by an externally set and marked multiple-choice test


Outcome 1 Demonstrate a general knowledge of the causes of human error in an aircraft maintenance environment

Practical activities The candidate will be able to: 1. Conduct a case study into an ac accident identifying contributory human factors. Underpinning knowledge The candidate will be able to: 1 Explain the need to account for human factors in the workplace with regard to People, Practices and Procedures to improve quality 2 Analyse aircraft incidents where human error was the root cause 3 Describe in general terms the functions and limitations of the senses of vision and hearing a) low light conditions b) stroboscopic effects of propellers c) peripheral vision d) high noise environments 4 Describe in simple terms the limitations of human memory a) time from exposure to information b) fatigue c) age d) complexity of information e) artificial stimulants/suppressants 5 Describe the factors that affect mental attention span a) overconfidence b) boredom c) fatigue d) complexity of information e) artificial stimulants/suppressants 6 Demonstrate awareness of variations in sensory perception and the implications for human behaviour a) long/short sight b) impaired hearing: i high/low tone deafness ii tinnitus 7 Identify the risks to airworthiness of working in confined spaces and where access is limited 8 List areas of personal and group responsibility within an aircraft maintenance environment 9 Explain how motivation and de-motivation can be internal and/or external 10 Describe the advantages and disadvantages of peer pressure in regard to performance of maintenance tasks


11 Describe how Company ‘culture’ (‘can-do attitude’, ‘must be ready by’) can create a conflict of interest with best/correct practice 12 State arguments for and against team working within the maintenance context 13 Identify the primary responsibilities of maintenance managers and supervisors regarding prioritisation, planning and delegation 14 Describe the concept that any person might provide leadership when circumstances dictate 15 Describe how bad health and lack of fitness can affect performance 16 Identify sources of stress: a) personal b) domestic c) work 17 Explain how time pressure and the imposition of deadlines may affect maintenance outcomes 18 Describe the symptoms of a person overloaded with work and the errors that may occur 19 Explain the long-term risks to human performance of insufficient work activity 20 Describe the effects of shift-work patterns on sleep and the consequences of fatigue 21 List common medicines and their affects on performance


Outcome 2 Demonstrate a general knowledge of the procedures and practices in place to minimise human error and its effects Practical activities The candidate will be able to: 1 Carry out simple risk assessments Underpinning knowledge The candidate will be able to: 1 Identify aviation regulations concerning alcohol and drug abuse and explain why they exist 2 Describe the effects on performance of the following and list regulatory guidelines available to control them:

a) noise and fumes b) illumination c) climate and temperature d) motion and vibration e) working environment

3 Describe how physical limitations in reach and strength may affect maintenance performance 4 State the effect on reliable performance when tasks are repetitive in nature 5 Define workplace requirements where visual inspection is required 6 State the reasons behind aviation regulations concerned with complex tasks;

a) work order open entries b) stage checks c) independent checks

7 Explain the importance of proper communication between

a) departments b) work teams c) shifts

8 Explain why the logging and recording of maintenance tasks is necessary 9 Explain why an aircraft technician needs to ensure that maintenance manuals and procedures are current:

a) amendment states b) compliance with aircraft modification states c) inclusion of warning/hazard information

10 Give examples of how to ensure that technical and procedural information may be circulated to those who require it 11 Describe error models and theories with regard to aircraft maintenance 12 Identify types of errors most commonly occurring in aircraft maintenance [ICAO & UNITED Statistics; CAA Papers 95005/96004] 13 Analyse examples of the error- incident - accident chain


14 Describe methods of avoiding and managing errors 15 List common hazards in the workplace 16 Describe ways and means of avoiding workplace hazards. 17 Explain the procedures for dealing with emergencies in the workplace

a) fire b) electrical shock c) substance spillage

18 Describe their responsibilities under the Health and Safety at Work Act 1974, COSHH Regulations 1992, and any subsequent amendments


Mechanical maintenance Pathway units


Unit 7 Aircraft Materials and Hardware Rationale This unit is concerned with developing the candidates’ understanding of aircraft materials and hardware. It covers the use of materials and maintenance practices. There are three outcomes to this unit. The candidate will be able to: 1 Investigate the structure and practical properties of aircraft engineering materials 2 Identify aircraft hardware and carry out replacement and servicing 3 Undertake maintenance practices and procedures on aircraft hardware and in workshops Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge


Outcome 1 Investigate the structure and practical properties of aircraft engineering materials Practical activities The candidate will be able to: 1 Carry out the visual detection of defects in aircraft materials 2 Carry out visual examinations of aircraft structures for corrosion and identify correctly the type of corrosion and report the findings Underpinning Knowledge The candidate will be able to: 1 Describe the characteristics, properties and identification of ferrous, non-ferrous, composite and non-metallic materials, including wood and fabric, used in aircraft

engineering 2 Describe the characteristics, properties and identification of sealant and bonding agents 3 Define the terminology used to indicate the physical properties of aircraft

engineering materials 4 Distinguish between the main groups of plastics

a) thermosetting b) thermoplastic c) catalytic

5 Explain the reasons for modifying the properties of metallic materials, and describe the methods used to modify the properties of metallic materials 6 Describe the influence of the following alloying elements on the basic properties of plain carbon steel:

a) nickel b) chromium c) vanadium d) molybdenum e) tungsten f) magnesium g) silicon


7 Describe the characteristics of the following common non-ferrous materials a) bronze b) brass c) aluminium d) magnesium e) soft solder f) white metal

8 Outline the effects of alloying elements in steels, and hot and cold working on grain size and shape, and describe the basic procedures for hot and cold working 9 State the purpose of heat treatment processes used to modify the properties of plain carbon steels, and describe their basic properties 10 State the purpose of the following heat treatment processes

a) annealing b) normalising c) hardening d) tempering

11 Describe basic heat treatment procedures for surface hardening of steel

a) case hardening (solid, liquid and gaseous) b) nitriding c) flame hardening d) induction hardening

12 State the heat treatment processes used to modify the properties of aluminium alloys and other non-ferrous metals

a) annealing b) solution c) precipitation d) refrigeration

13 Describe the chemical fundamentals of corrosion

a) direct chemical action b) galvanic action process

14 Describe the formation of corrosion by

a) microbiological action b) stress


15 Identify types of corrosion likely to occur in aircraft structures and state the areas where they may occur:

a) surface b) pitting c) stress d) fatigue e) intergranular f) fretting g) crevice h) exfoliation i) filiform

16 Describe corrosion prevention techniques

17 List techniques and re-agents used for removing corrosion, freeing parts and protecting structures on a temporary or a semi-permanent basis

18 Describe the types of defects found in wood and wooden structures 19 Describe the types of defects found in fabric


Outcome 2 Identify aircraft hardware and carry out replacement and servicing Practical Activities The candidate will be able to: 1 Identify materials and tools from drawings, technical data and specifications for servicing 2 Carry out routine servicing of hardware 3 Remove and refit aircraft hardware 4 Use positive and friction locking devices, as appropriate Underpinning Knowledge The candidate will be able to: 1 Interpret engineering drawings, technical data and instructions to determine the fastening requirements for aircraft 2 Distinguish between aircraft specification, nuts, bolts, screws, studs and thread forms 3 Measure screw threads 4 Identify and describe the following nuts, bolts, studs and screws

a) self locking b) anchor nuts c) standard types d) machine screws e) aircraft specification stud types and uses

5 Describe the insertion and removal of studs 6 Describe the specification, identification and marking of aircraft bolts and international standard nuts 7 Describe the purpose of and procedure for torque loading:

a) different types of torque wrench b) torque wrench inspection c) standard torque values d) upper and lower torque values e) the effects of lubrication on threaded fasteners f) run down torque and selective fitting of nuts


8 Identify and describe the following types and applications of standard aircraft locking devices

a) tab and spring washers b) locking plates c) split pins d) pal-nuts e) wire locking f) quick release fasteners g) circlips h) cotter pins i) rivnuts

9 Distinguish between the applications of plain and taper washers 10 Identify and describe the types of aircraft rivets

a) solid b) blind

11 Identify and describe standard rivet specifications, identification methods and heat treatment processes 12 Explain the purpose and type of bearings 13 Identify and describe rigid and flexible pipes, unions and their connectors used on hydraulic, fuel, oil, pneumatic, air and oxygen systems 14 Identify the ICAO geometric symbols for the following pipeline contents

a) hydraulic b) fuel c) air conditioning d) oxygen e) de-icing f) lubricant g) instrument air

15 Describe the types and application of springs used in aircraft engineering applications 16 Describe the different types of gear transmission systems and their applications a) gear ratios; reduction and multiplication gear systems; b) driven and driving gears; idler gears; mesh patterns; c) belts and pulleys; chains and sprockets 17 Identify the main components of a mechanical control system

a) cable types b) end fittings c) Bowden cables d) pulleys and cable systems components e) turnbuckles f) compensation devices g) aircraft flexible control systems


Outcome 3 Undertake maintenance practices and procedures on aircraft hardware and in workshops Practical Activities The candidate will be able to: 1 Carry out routine inspection, testing and repair of mechanical systems and components using the relevant maintenance manuals Underpinning Knowledge The candidate will be able to: 1 Define and determine the appropriate riveting requirements relating to aircraft maintenance activities 2 Explain the reasons for aircraft riveting as the construction of a permanent joint 3 Identify and describe the following features of the rivet

a) pre-formed head b) shank c) formed head

4 Describe riveting terminology

a) allowance b) clearance c) pitch d) spacing e) land (edge margin) f) sphere of influence

5 Identify and describe the following types of aircraft riveted joints

a) lap joint b) single strap butt joint c) chain pitch d) staggered zig-zag pitch

6 Distinguish between different types of standard rivet in terms of

a) materials b) types of solid rivet head c) types of blind rivet


7 Describe the factors that determine the selection of the most suitable rivet for a particular application in terms of

a) thickness b) hole diameter c) shape; the rivet head appropriate to:

i strength ii clearance iii situation of the joint

A) material of the joint B) riveting process C) aerodynamic considerations

8 Identify and describe the different types of riveting equipment

a) tools for hand riveting i hand riveting tools ii hammers iii drawers iv snaps v mechanical, pneumatic vi hydraulic tools vii rivet cutters viii rivet gauge

b) supporting tools i anvils ii dollies iii pneumatic dollies iv skin gripper pins

c) hollow and blind riveting tools i hand ii pneumatic iii hydraulic

9 Describe the preparatory operations for riveting

a) selection of rivets b) surface preparation prior to riveting c) determining the correct size of drill d) alignment of parts to be drilled e) removing burrs f) methods of ensuring close contact between parts g) heat treatment of non-ferrous parts h) countersinking or dimpling

10 Describe the operational procedures for riveting structure using

a) snap rivets b) countersunk


11 Identify and account for the common defects in riveted joints a) rivet in shear b) badly formed head c) buckled shank d) cracking of head e) separation of component parts f) distortion or cracking of plate edges g) shear failure h) bearing failure i) head failure

12 State the safety precautions specific to aircraft riveting on and off the aircraft 13 State the purpose of pipes and hoses 14 State the basic procedures for bending/flaring aircraft pipes 15 Describe the routine inspection and testing of aircraft pipes and hoses 16 Describe typical procedures for removing, replacing and clamping of pipes 17 Describe how to inspect or test springs for serviceability 18 Describe how to inspect, test and clean bearings 19 List the equipment necessary to carry out routine servicing and lubrication of bearings 20 State the common defects likely to occur in bearings and describe the symptom of faults 21 State the basic circuits and components in transmission systems

a) gears b) belts and pulleys c) chains and sprockets d) screw jacks e) lever devices f) push-pull rods

22 Describe the purpose of transmission systems 23 Describe the working principles of the components in a transmission system 24 Identify, name and state the function or purpose of transmission components 25 Describe typical procedures for removing and replacing transmission components 26 State the purpose of carrying out routine inspection and servicing of transmission systems and their components 27 Describe the procedure for routine inspection and servicing of transmission components 28 List the equipment necessary to carry out routine inspection and servicing of transmission components and describe the selection, use and maintenance of this equipment 29 State the common faults likely to occur in a transmission system


30 State safe working practices and any special precautions to be observed when carrying out routine inspection of transmission systems 31 State the purpose of control cables 32 Identify the basic components in a control cable system

a) swaged end fittings b) bowden cables c) flexible control systems

33 Describe the working principles of a cable control operated system 34 Identify the main statutory requirements for control cables 35 Identify, name and state the function or purpose of cable control operated system components 36 Explain how cable control operated system components work 37 Describe typical procedures for removing and replacing control cables and their components 38 Describe how to test control cable components 39 State the purpose of carrying out routine inspection and servicing on aircraft control cables and their components 40 Describe how the routine inspection and servicing necessary for control cable components is carried out 41 Identify the equipment necessary to carry out routine servicing of control cables and components and describe the selection, use and maintenance of this equipment 42 State safe working practices and any special precautions to be observed when carrying out routine inspection and servicing to control cable and components 43 List the common faults likely to occur in a control system and describe the symptoms of these faults


Unit 8 Aircraft Structure and Maintenance Rationale This unit is concerned with developing the candidates’ understanding of aircraft, structures and maintenance practices. It covers the structural requirements and classification of aircraft structures and maintenance practices when repairing, removing and replacing aircraft structural components. There are three outcomes to this unit. The candidate will be able to: 1 Undertake maintenance on aircraft structures 2 Remove and replace airframe structures and components 3 Demonstrate an understanding of general practices for aircraft maintenance functions Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge.


Outcome 1 Undertake maintenance on aircraft structures Practical activities The candidate will be able to: 1. Carry out routine servicing, inspection and structural classification of airframe structures Underpinning knowledge The candidate will be able to: 1 State the airworthiness requirements for structural strength and the need for structural classification

a) primary b) secondary c) tertiary

2 Describe structural and damage tolerance concepts

a) safe life b) fail safe

3 Describe zonal and station identification systems 4 Describe loadings in aircraft structures with relation to

a) stress b) strain c) bending d) compression e) shear f) torsion g) tension h) hoop i) fatigue j) provision for system installation

5 Recognise and state the function of drains and ventilation provision 6 Describe the methods of lightning strike protection 7 Identify types of airframe structure

a) truss b) monocoque c) semi monocoque


8 Identify and state the relationship of the following to airframe structures a) stressed skin fuselage b) formers c) stringers d) longerons e) bulkheads f) frames g) doublers h) struts i) ties j) floor beams k) floor structures l) reinforcement m) methods of skinning n) anti-corrosive protection o) wing, empennage and engine attachments p) intercostals

9 Describe structural assembly techniques

a) riveting b) bolting c) bonding

10 Describe the following methods of surface protection

a) chromating b) anodising c) painting

11 Describe the methods of surface cleaning 12 Describe the purpose and typical procedures for carrying out airframe symmetry checks 13 Describe methods of alignment and symmetry checks 14 State safe working practices and any special precautions to be observed when carrying out servicing and inspection of airframe structures 15 Describe the method of detection of defects in composite materials

a) tap test b) ultrasonics

16 Describe methods of repair to composite materials

a) injection repairs b) stepped repairs c) scarf repairs d) honeycomb repairs

17 Describe the method of detection of defects in wooden structures 18 Describe the methods of repair to wooden structures 19 Describe the methods used to preserve and maintain wooden structure 20 Describe the inspection methods for fabric 21 Describe the methods of repair to fabric covered structures


Outcome 2 Remove and replace airframe structures and components Practical activities The candidate will be able to: 1 Remove and replace typical airframe components Underpinning knowledge The candidate will be able to: 1 Describe the basic construction and pressurisation sealing of the fuselage 2 Describe the construction methods of wooden structures 3 Describe the construction and purpose of fuselage and wing attachment points for

a) wing b) stabiliser c) pylon and undercarriage attachments

4 Describe routine inspection and servicing of fuselage and wing attachment points 5 Describe the typical procedures for removing and replacing major components 6 State the safe working practices and any special precautions to be observed when carrying out routine inspection and servicing to attachment points 7 Identify, name and state the function of fuselage doors, their construction, mechanisms, operation and safety devices 8 State safe working practices and any special precautions to be observed when

carrying out routine inspection and servicing of crew/passenger access/egress systems and their methods of operation

9 Describe how to inspect airframe structural components for serviceability 10 Describe the main structural components and construction of wings (ATA 57) 11 Describe the construction of wing fuel storage 12 State safe working practices and any special precautions to be observed when carrying out routine inspection and servicing of fuel storage systems 13 Describe the construction of wing attachment devices

a) landing gear b) pylon c) control surfaces d) high lift/drag devices

14 Describe the construction of the stabilisers and their attachment devices (ATA 57) 15 Describe the construction of flight control surfaces and their attachment devices (ATA 55/57) 16 State the purpose of aerodynamic balancing as a means of decreasing the force necessary to operate flying controls during flight


17 Identify the listed types of aerodynamic balance

a) inset hinge b) horn balance c) balance tab d) servo tab e) spring tab f) pressure balance

18 State the purpose of mass balancing of a control surface 19 Explain the importance of the position of the Centre of Gravity (C of G) of a control surface 20 State safe working practices and any special precautions to be observed when carrying out routine inspection and servicing of moving control surfaces 21 Describe the construction of nacelle/pylons, firewalls (ATA 57) and their attachment devices 22 Identify the function of firewalls 22 Describe the construction of engine mounts


Outcome 3 Demonstrate an understanding of general practices for aircraft maintenance functions

Practical activities The candidate will be able to: 1 Carry out a simulated emergency procedure in relation to

a) fire b) electricity c) gases (especially oxygen) d) oils e) chemicals

2 Select correct tools when working in a workshop/hangar environment 3 Select correct drawings to use with appropriate workshop tasks and identify relevant title block and other information from the drawings 4 Use microfilm, microfiche or computerised information when carrying out appropriate maintenance tasks 5 Measure to the appropriate degree of accuracy a variety of aircraft components using various measuring devices including micrometers and verniers Underpinning knowledge The candidate will be able to: 1 State the appropriate safety procedures necessary when working with electricity, high pressure gases (especially oxygen), oils and chemicals 2 State the remedial action to be taken in the event of a fire or other accident with electricity, high pressure gases (especially oxygen), oils and chemicals 3 Identify the correct tools for carrying out practical workshop tasks 4 State the procedures necessary to control the use of tools and workshop materials 5 Describe the procedures used to calibrate tools and to ensure tools are maintained to a satisfactory standard 6 Describe the common hand and power tools used on aircraft and in the workshop 7 Describe the construction and use of precision measuring tools such as micrometers and vernier measuring tools 8 Explain the principles of lubrication and describe the methods of lubrication used on aircraft and in the workshop 9 Identify the basic drawing types and diagrams, their symbols dimensions, tolerances and projections 10 Identify and state the purpose of the title block registration


11 Recognise, name and state the function of a) microfilm b) microfiche c) computerised presentation

12 Identify the main statutory requirements for engineering drawings, diagrams and standards

a) Air Transport Association (ATA) of America b) Aeronautical and other applicable standards

i ISO ii AN iii MS iv NAS v MIL

c) Wiring diagrams and other schematic diagrams 13 State the purpose of fits and clearances 14 Describe the working principles of the common system of fits and clearances 15 State the schedule of fits and clearances for aircraft and engines 16 Describe the systems of fits and clearances in common use for aircraft and engines 17 State where the limits for bow, twist and wear would be detailed 18 Describe the standard methods for checking shafts, bearings and other parts 19 Describe the correct procedures to be followed and the associated safety precautions necessary when a) taxiing/towing aircraft b) jacking, chocking and securing aircraft c) storing aircraft d) refuelling or defuelling aircraft e) ground de-icing/anti-icing aircraft f) using electrical, hydraulic and pneumatic ground supplies 20 Describe the effects of environmental conditions on aircraft handling and operation 21 State the inspection techniques used and describe the types of defects to be found when carrying out inspection of aircraft and associated equipment 22 Describe typical correct and safe disassembly and re-assembly techniques 23 State where to find information on, and describe how to carry out an inspection after the following abnormal events

a) lighting strike and HIRF penetration b) heavy landings c) flight through turbulence

24 Describe the basic operation of the Maintenance Planning department of an aircraft maintenance facility 25 Explain why modifications may be necessary and describe the procedures for carrying out modifications


26 Describe the layout of a typical aircraft store and the procedures to ensure safe storage of aircraft parts and materials 27 Describe the procedures for certification and release of aircraft parts and materials 28 Describe the basic operation of the Inspection/Quality Control/Quality Assurance department of an aircraft maintenance facility 29 Explain the need for control of life-limited components associated with aircraft


Unit 9 Aircraft Mechanical Systems Rationale This unit has been designed to provide potential aviation engineers with the skills and knowledge necessary to understand aeroplane systems. There are three outcomes for this unit. The candidate will be able to: 1 Demonstrate an understanding of aircraft mechanical systems and how they interact 2 Demonstrate an understanding of Landing Gear systems (ATA 32) 3 (Civil) Demonstrate an understanding of Equipment and Furnishings (ATA 25) (Military) Demonstrate an understanding of Aircraft Assisted Escape Systems and their interaction with other aircraft systems Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge.


Outcome 1 Demonstrate an understanding of aircraft mechanical systems and how they interact Underpinning Knowledge The candidate will able to: 1 Describe in simple terms the function, basic layout and principle of operation of an aircraft air conditioning system (ATA 21)

a) sources of supply including engine bleed, APU and ground cart b) air conditioning system c) air cycle and vapour cycle machines d) distribution systems e) flow, temperature and humidity control system f) protection and warning devices

2 Describe in simple terms the function, basic layout and principle of operation of an aircraft cabin pressurisation system (ATA 21)

a) pressurisation systems b) control and indication including control and safety valves c) cabin pressure controllers d) protection and warning devices

3 Describe in simple terms the function, basic layout and principle of operation of an aircraft fire protection system (ATA 26)

a) fire and smoke detection and warning systems b) fire extinguishing systems c) system tests

4 Describe in simple terms the function, basic layout and principle of operation of an aircraft flight control system (ATA 27)

a) primary controls: aileron, elevator, rudder b) spoilers c) trim control d) active load control e) high lift devices f) lift dump, speed brakes g) system operation: manual, hydraulic, pneumatic, electrical, fly-by-wire h) artificial feel, yaw damper, mach trim, rudder limiter, gust locks i) balancing and rigging j) stall protection system

5 Describe in simple terms the function, basic layout and principle of operation of an aircraft fuel system (ATA 28)

a) system lay-out b) fuel tanks c) supply systems d) dumping, venting and draining e) cross-feed and transfer f) indications and warnings g) refuelling and defuelling h) longitudinal balance fuel systems


6 Describe in simple terms the function, basic layout and principle of operation of an aircraft hydraulic power system (ATA 29)

a) system lay-out b) hydraulic fluids c) hydraulic reservoirs and accumulators d) pressure generation: electrical, mechanical and pneumatic e) emergency pressure generation f) pressure control g) power distribution h) indication and warning systems i) interface with other systems

7 Describe in simple terms the function, basic layout and principle of operation of an aircraft ice and rain protection system (ATA 30)

a) ice formation, classification and detection b) anti-icing systems: electrical, hot air and chemical c) de-icing systems: electrical, pneumatic and chemical d) rain repellent and removal e) probe and drain heating

8 Describe in simple terms the function, basic layout and principle of operation of an aircraft oxygen system (ATA 35)

a) system lay-out: cockpit, cabin b) sources, storage, charging and distribution c) supply regulation d) indication and warnings

9 Describe in simple terms the function, basic layout and principle of operation of an aircraft pneumatic/vacuum system (ATA 36)

a) system lay-out b) sources: engine/APU, compressors, reservoirs, ground supply c) pressure control d) distribution e) indications and warnings f) interfaces with other systems

10 Describe in simple terms the function, basic layout and principle of operation of an aircraft water/waste system (ATA 38)

a) water system lay-out, supply, distribution, servicing and draining b) toilet systems lay-out, flushing and servicing c) corrosion aspects


Outcome 2 Demonstrate an understanding of Landing Gear Systems (ATA 32)

Practical Activities The candidate will be able to: 1 Undertake routine tasks for the maintenance of landing gear Underpinning Knowledge The candidate will be able to: 1 Identify the following types of landing gear

a) wheeled – nose wheel, tail wheel and bicycle wheel layouts b) skids c) skis

2 Describe the following components of a conventional wheeled landing gear

a) shock absorber b) wheel c) brake unit d) steering system e) torque link f) axle g) retraction h) locking mechanisms

3 Describe the following wheel arrangements and state the reasons for their use

a) single b) double c) bogie d) articulated

4 Identify the problem of nose wheel shimmy and describe methods of shimmy damping

a) twin-tread contact tyre b) twin wheels mounted on a live axle c) mechanical shimmy dampers d) hydraulic shimmy dampers

5 Identify the appropriate use, inspection and adjustment of torque links 6 Identify the power sources for retractable landing gear actuation

a) electric b) hydraulic


7 State the mandatory requirements of a retractable landing gear and describe the purpose of

a) mechanical up-locks b) mechanical down-locks c) side stays d) drag struts e) position indicators f) throttle warning switch g) selector baulk h) weight on wheels switch i) ground locks

8 Describe a typical hydraulic operated landing gear system including

a) sequence with doors and bogie tilting operation b) micro and proximity switches c) cockpit indications d) mechanical indicators e) emergency methods of lowering

9 Describe the sequence of operations and function of the following components in a hydraulically operated landing gear system

a) non-return valve b) selector c) mechanical sequence valve d) actuators e) restrictor valve f) shuttle valve g) fluid jettison valve

10 Describe the sequence of operations required to lower a landing gear in an emergency by

a) free fall b) nitrogen blow-down c) electrical actuation

11 Describe the procedures, safety precautions, inspection and checks to be carried out before and during a landing gear retraction test using an external power source 12 Describe the construction and operation of the following shock absorbers

a) oleo-pneumatic with separator b) oleo-pneumatic without separator

13 Describe the inspections and servicing operations to be carried out on oleo- pneumatic shock absorbers

a) inspections – leakage, corrosion damage, correct gas charge, the use of load extension graphs

b) servicing operations – filling with oil, charging with nitrogen 14 Identify the construction of well based, loose or detachable flange and divided wheel hubs, listing the advantages and disadvantages of each 15 Identify the design provision in a wheel to overcome the problems of tyre creep and heating 16 Describe fusible plugs and their use in a tubeless tyre wheel assembly


17 Describe the dismantling of a wheel/tyre assembly and the relevant safety precautions 18 Describe the inspections carried out on an assembled and a dismantled wheel 19 Describe and identify aircraft wheel bearings and the inspection criteria applied to them 20 Describe the principal features and design considerations of the following aircraft tyres

a) cross ply b) radial c) tubed d) tubeless

21 Explain the following identification marks on the side wall of a tyre and their importance

a) size coding b) date code c) serial number d) part number e) ply rating f) speed rating g) fitting rings

22 Describe the inspection procedure for

a) mounted tyres b) mounted tubes

23 Define common tyre defects and limits of serviceability for:

a) tyres b) tubes

24 State the safety precautions and procedures to be observed when inflating tyres 25 Explain the importance of correct tyre inflation pressure 26 Describe the dismantling procedure for tubeless and tubed wheel/tyre assemblies 27 Describe the advantages of a structural carbon brake unit compared with steel brakes 28 Describe an aircraft hydraulic brake system and state the function and operation of the components:

a) brake control valve b) accumulator c) park brake d) anti-skid units e) pressure gauge f) duplicated supply for emergency operation

29 Describe the components and operation of an autobrake system 30 Describe typical maintenance, defects and rectification procedures in relation to brake units and systems 31 Identify mechanical and electronic anti-skid units and describe their operating principles and construction


32 Describe the inspection criteria and functional checks for anti-skid units 33 Describe typical maintenance procedures in relation to anti-skid units 34 State the requirements for a nose-wheel steering system 35 Describe a hydraulic nose-wheel steering system

a) control valve b) non-return valve c) dual pressure relief valve d) double acting actuator e) feed-back system

36 Describe the inspection and test criteria for a hydraulic nose wheel steering system 37 Describe typical maintenance for nose wheel steering systems


Outcome 3(civil) Demonstrate an understanding of Equipment and Furnishings (ATA 25) Practical activities The candidate will be able to: 1 Undertake tasks for the maintenance of equipment furnishings Underpinning Knowledge The candidate will be able to: 1 Identify the legal requirements for emergency equipment to be fitted and operated on civil aircraft as specified in ANOs; BCARs and JARs 2 Identify the following types and installation of aircraft seats and describe the differences between them

a) flight crew b) cabin crew c) passengers

3 Describe the seat belt appropriate to each type of seat 4 Describe the inspections and maintenance required on the seats and harness assembly 5 Describe a typical cabin layout for a passenger transport aircraft with regard to the following criteria

a) seat arrangement b) location of galley(s) c) locations of toilets d) temporary bulkheads e) access to doors f) access to escape hatches g) the provision of air stairs h) passenger loading

6 Identify various types of cabin entertainment equipment and the care required for its continued operation 7 Describe a typical galley installation with regard to ovens, potable water; waste disposal 8 Describe location, stowage and operation of the following cabin safety equipment

a) fire extinguishers b) gloves c) axes d) life jackets e) life rafts f) torches g) loud hailers h) escape slides

9 Identify the potential maintenance problems that may occur in a galley

a) overheating b) corrosion


10 Describe the different styles of cargo retention equipment and the methods employed to handle and load the cargo

a) pallets b) nets c) containerisation


Outcome 3(military) Demonstrate an understanding of Aircraft Assisted Escape Systems and their interaction with other aircraft systems

Underpinning Knowledge 1 The candidate will be able to: 2 State the safety precautions applicable to Aircraft Assisted Escape Systems (AAES) 3 Identify AAES safety devices and determine their state

a) Safe for parking b) Safe for maintenance

4 State the action to be taken if an AAES safety device is found in an unrecognized or incorrect state 5 Describe the markings used to identify AAES operating handles/switches/levers 6 Identify AAES explosive components and state the precautions to be taken when maintaining supporting/attached structure 7 Describe the interaction between emergency and normal modes of operation of

a) Aircraft canopies b) Aircraft hatches c) Crew access doors

8 Describe the aircraft systems that interface with AAES and state the precautions to be taken prior to their maintenance

a) Oxygen system b) Communications c) Anti-g d) Night vision e) IFF

9 Identify airframe attachment components for Aircraft Assisted Escape Systems 10 State the safety precautions applicable to Aircraft Assisted Escape Systems (AAES) 11 State the action to be taken if an AAES safety device is found in an unrecognized or incorrect state 12 Describe the markings used to identify AAES operating handles/switches/levers 13 Identify AAES explosive components and state the precautions to be taken when maintaining supporting/attached structure 14 Describe the interaction between emergency and normal modes of operation of

a) Aircraft canopies b) Aircraft hatches c) Crew access doors


15 Describe the aircraft systems that interface with AAES and state the precautions to be taken prior to their maintenance

a) Oxygen system b) Communications c) Anti-g d) Night vision e) IFF

16 Identify airframe attachment components for AAES systems


Unit 10 Gas Turbines Engines and Propellers Rationale This unit aims to introduce the fundamental knowledge, principles and understanding of gas turbine propulsion systems in aircraft maintenance. There are two outcomes to this unit. The candidate will be able to: 1 Demonstrate an understanding of gas turbine engines with respect to aircraft maintenance functions 2 Demonstrate an understanding of aircraft propeller systems with respect to aircraft maintenance functions Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge.


Outcome 1 Demonstrate an understanding of gas turbine engines with respect to aircraft maintenance functions Practical Activities The candidate will be able to: 1 Perform scheduled and unscheduled maintenance operations Underpinning Knowledge The candidate will be able to: 1 Describe in simple terms the fundamentals of gas turbine theory 2 State the relationship between force, work, power, energy, velocity and acceleration 3 Describe the constructional arrangement and operation of

a) turbojet b) turbofan c) turboshaft d) turboprop

4 Describe the construction and theory behind typical intake design both fixed and variable, and the effects on engines to which these types are applicable throughout the speed range 5 Describe the principle of operation of electrical and hot air anti-icing systems 6 Describe in simple terms the general construction and principle of operation of

a) compressors: use of variable inlet guide vanes and bleed valves b) compression ratio c) combustion section: multiple can, can annular and annular combustion

systems, types of burner d) exhaust section: convergent, divergent and variable area nozzles, noise

reduction, thrust reversers 7 Describe the construction and operation of turbine systems

a) impulse turbine blades b) reaction turbine blades c) impulse reaction turbine blades d) blade to disc attachment e) nozzle guide vanes f) causes and effects of turbine blade stress and creep

10 Describe in simple terms the properties and specification of fuels, fuel additives and lubricants and their associated safely precautions


11 Describe (to block diagram level) the principles of operation of the following systems and their components

a) lubrication systems; the three basic types of system and general layout b) fuel systems; operation of basic engine control and fuel metering including

basic FADEC c) air systems; operation of engine air distribution and anti-ice control

including cooling, sealing and external air services d) starting and ignition systems; description of both with emphasis on safety e) engine indication systems; engine gas, interstage turbine temperature,

thrust, engine pressure ratio, turbine discharge or exhaust pressure systems, oil pressure and temperature, fuel pressure and flow, engine speed, vibration

f) measurement and indication, torque, power g) fire protection; detection and extinguisher systems

12 Describe the layout and principal features of the following power units

a) turbo-prop engines (gas coupled, free turbine and gear coupled turbines), reduction gears, integrated engine and propeller controls, overspeed safety devices

b) turbo-shaft engines, arrangements, drive systems, reduction gearing couplings, control systems

c) Auxiliary Power Units (APUs) purpose, operation and protective systems 13 State the general principle of power plant installation with emphasis on

a) firewall configuration b) cowlings c) acoustic panels d) engine mounts e) anti-vibration mounts f) hoses g) pipes h) feeders i) connectors j) wiring looms k) control cables and rods l) lifting points m) drains

14 State the general principles of the following ground operations and engine monitoring

a) engine start and ground run b) interpretation of power output indications and associated parameters. c) trend monitoring: oil analysis, vibration analyses and boroscope inspection. d) inspection of components; checking against given criteria, tolerance and

data e) compressor washing/cleaning. f) foreign object damage


Outcome 2 Demonstrate an understanding of aircraft propeller systems with respect to aircraft maintenance functions Practical Activities The candidate will be able to: 1 Perform scheduled and unscheduled maintenance operations Underpinning Knowledge The candidate will be able to: 1 Describe in simple terms the fundamentals of propeller theory

a) blade element theory b) high, low and reverse blade angle of attack c) rotational speed d) propeller slip e) aerodynamic centrifugal and thrust forces f) torque g) relative airflow on blade angle of attack h) vibration and resonance

2 Describe construction and basic principles of operation including

a) materials used for composite and metal blades b) position of blade station, blade face, blade shank, hub assembly c) assembly of fixed, variable and constant speed propellers d) basic propeller/spinner installation

3 Describe the basic principles of propeller pitch control

a) speed control and pitch change methods b) feathering and reverse pitch c) overspeed protection

4 Describe basic fluid and electrical propeller ice protection 5 Outline the following propeller maintenance operations

a) static and dynamic balancing b) blade tracking c) assessment of blade damage: erosion, corrosion, delamination and impact

damage d) propeller engine running


Avionics maintenance Pathway units


Unit 11 Avionics Maintenance Practices Rationale This unit is concerned with the understanding of avionics maintenance practices and their application in the aircraft and workshop environment. There are two outcomes to this unit. The candidate will be able to: 1 Demonstrate an understanding of general practices for aircraft maintenance functions 2 Undertake maintenance practices and procedures on avionics and electrical hardware

Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge.


Outcome 1 Demonstrate an understanding of general practices for aircraft maintenance functions. Practical activities The candidate will be able to: 1 Carry out a simulated emergency procedure in relation to


2 Select correct tools when working in a workshop/hangar environment 3 Select correct drawings to use with appropriate workshop tasks and identify relevant title block and other information from the drawings 4 Use microfilm, microfiche or computerised information when carrying out appropriate maintenance tasks Underpinning knowledge The candidate will be able to: 1 State the appropriate safety procedures necessary when working with electricity, high-pressure gases (especially oxygen), oils and chemicals 2 State the remedial action to be taken in the event of a fire or other accident with electricity, high-pressure gases (especially oxygen), oils and chemicals 3 Identify the correct tools for carrying out practical workshop tasks 4 State the procedures necessary to control the use of tools and workshop materials 5 Describe the procedures used to calibrate tools and to ensure tools are maintained to a satisfactory standard 6 Describe the common hand tools used on aircraft and in the workshop 7 Identify the basic drawing types and diagrams, their symbols dimensions, tolerances and projections 8 Identify and describe the purpose of the title block registration 9 Recognise, name and state the function of

a) microfilm b) microfiche c) computerised presentation





c) Wiring diagrams and other schematic diagrams 11 Describe the correct procedures to be followed and the associated safety precautions necessary when

a) taxiing/towing aircraft b) jacking, chocking and securing aircraft c) storing aircraft d) refuelling or defuelling aircraft e) ground de-icing/anti-icing aircraft f) using electrical, hydraulic and pneumatic ground supplies

12 Describe the effects of environmental conditions on aircraft handling and operation 13 State the inspection techniques used and describe the types of defects to be found when carrying out inspection of aircraft and associated equipment 14 Describe typical correct and safe disassembly and re-assembly techniques 15 State where to find information on, and describe how to carry out an inspection after the following abnormal events

a) lightning strike and HIRF penetration b) heavy landings c) flight through turbulence

16 Describe the basic operation of the Maintenance Planning department of an aircraft maintenance facility 17 Explain why modifications may be necessary and describe the procedures for carrying out modifications 18 Describe the layout of a typical aircraft store and the procedures to ensure safe storage of aircraft parts and materials 19 Describe the basic operation of the Inspection/Quality Control/Quality Assurance department of an aircraft maintenance facility 20 Explain the need for control of life-limited components associated with aircraft


Outcome 2 Undertake maintenance practices and procedures on avionics and electrical hardware Practical activities The candidate will be able to: 1 Carry out preparation of aircraft cables for electrical termination 2 Carry out soldering and de-soldering of prepared cables to electrical terminals 3 Carry out crimping of electrical contacts and terminations to cables and conductors 4 Carry out dismantling, assembly, connection and disconnection of modern representative electrical connectors 5 Manufacture and repair cable assemblies 6 Use Avionics General Test Equipment safely and in accordance with the instructions for use

Underpinning knowledge The candidate will be able to: 1 Describe the safety precautions to be followed when working on, or in the vicinity of aircraft electrical power supplies 2 Identify and describe the types of cable, their construction and application 3 Describe the need for the correct husbandry of aircraft wiring and Fibre - Optic (FO) cable and explain how this is achieved 4 Describe methods of cable protection and support 5 Describe the procedure for aircraft wiring installation examination 6 Describe the handling precautions to be observed when working with aircraft electrical wiring and assemblies 7 Identify the correct tools for carrying out practical workshop tasks 8 Describe the limitations applicable to and governing the use of Precision Termination Tools (PTT) 9 Identify and state the need and purpose of test equipment (TE), maintenance, calibration and its associated documentation 10 Describe the purpose of single function meters 11 Describe the purpose of and safety precautions to be observed when using a digital or analogue multi-meter 12 Describe the purpose of and safety precautions to be observed when using an insulation and line continuity tester


13 Describe the need for Bonding of the aircraft structure and techniques used 14 Identify typical Bonding Resistance values of the aircraft structure


Unit 12 Electronic and further electrical fundamentals Rationale This unit is concerned with the understanding of electronic principles and their relationship to aircraft servicing and maintenance. There are three outcomes to this unit. The candidate will be able to: 1 Demonstrate an understanding of electronic components and their use in aircraft applications. 2 Demonstrate an understanding of AC and DC theory. 3 Demonstrate an understanding of AC and DC motors and generators. Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge.


Outcome 1 Demonstrate an understanding of electronic components and their use in aircraft applications Practical activities The candidate will be able to: 1 Identify electronic components and state their function. 2 Assemble simple electronic circuits to demonstrate component properties. 3 Use circuit diagrams and standard symbols to identify and classify components. Underpinning Knowledge The candidate will be able to: 1 Describe the properties and applications of a) diodes b) resistors c) capacitors d) inductors 2 Describe the principles and identify applications of transformers 3 Apply transformer theory to the solution of problems including regulation and impedance matching 4 Describe the characteristics, composition and uses of simple filters 5 Describe the nature, construction and uses of simple integrated circuits 6 Describe the nature, construction and use of printed circuit boards 7 Describe the principles and techniques of servomechanisms a) open loop b) closed loop c) feedback d) control systems e) indication systems


Outcome 2 Demonstrate an understanding of AC and DC theory Practical activities The candidate will be able to: 1 Use circuit theory to solve simple circuit problems 2 Apply AC circuit theory in the solution of series and parallel network problems 3 Construct and test smoothed and stabilised power supplies 4 Construct a simple electrical circuit to prove Ohm’s and Kirchoff’s Laws Underpinning knowledge The candidate will be able to: 1 Describe in simple terms the following a) conductors b) insulators c) current d) voltage e) resistance 2 Describe the relationship between voltage current and resistance 3 Describe Kirchoff’s laws of current and voltage 4 Explain how energy is dissipated in DC circuits 5 Describe the construction and properties of the following rectifiers a) half-wave b) bi-phase full-wave c) 4 diode bridge 6 Describe the effects of reservoir capacitors on output voltages 7 Explain the need to reduce output voltage ripple 8 Demonstrate AC waveforms and determine the following parameters a) phase b) period c) frequency d) cycle e) amplitude f) peak-to-peak value g) peak value e) rms value f) average value 9 Use phasor representation of sinusoidal quantities 10 Describe the relationship of voltage and current in Resistive, Capacitive and Inductive circuits 11 Describe the production of a three phase AC waveform


Outcome 3 Demonstrate an understanding of AC and DC motors and generators Practical activities The candidate will be able to: 1 Identify and explain the purpose of the component parts of a DC motor 2 Identify and explain the purpose of the component parts of a DC generator 3 Identify and explain the purpose of the component parts of an AC motor 4 Identify and explain the purpose of the component parts of an AC generator

Underpinning knowledge The candidate will be able to: 1 Describe the fundamental laws governing magnetism 2 Describe the fundamental principles and laws governing electromagnetic induction 3 Explain in simple terms the operation and characteristics of shunt and series connected DC generators 4 Explain in simple terms the principle of DC compound generators 5 Describe in simple terms the requirements for parallel operation of DC generators 6 Describe the basic operation and control of DC shunt motors 7 Describe the basic operation and control of DC series motors 8 Describe the basic principles of DC compound motors 9 Describe the basic operation of AC generators 10 Explain in simple terms the requirements for parallel operation of AC generators 11 Describe the basic operation of an AC synchronous motor 12 Describe the basic operation of AC induction motors


Unit 13 Aeronautical digital fundamentals Rationale This unit is concerned with the understanding of digital electronic principles and their relationship to aircraft servicing and maintenance. There are two outcomes to this unit. The candidate will be able to: 1 Demonstrate an understanding of digital electronic theory and architecture. 2 Demonstrate an understanding of data transfer.



Outcome 1 Demonstrate an understanding of digital electronic theory and architecture Practical activities The candidate will be able to: 1 Use different number systems applicable to digital electronics 2 Evaluate the outcome of a combination of logic gates Underpinning Knowledge The candidate will be able to: 1 Define the characteristics of the following number systems

a) Decimal b) Binary c) Octal d) Hexadecimal

2 Convert between the following number systems

a) Decimal to Binary b) Binary to Decimal c) Octal to Binary d) Binary to Octal e) Hexadecimal to Binary f) Binary to Hexadecimal

3 Identify and use combinational gate functions 4 Draw the symbols, BSI and ANSI; state the Boolean expression and produce a truth table for each of the following logic gates

a) AND b) OR c) NAND d) NOR e) NOT f) EX-OR g) EX-NOR

5 Explain the meaning of the terms ‘Positive’ and ‘Negative’ logic 6 State the meaning of the terms ‘TTL’ and ‘CMOS’ and the typical supply voltages and logic levels used with each type of device 7 Investigate the use of logic gates in the construction of simple go/no-go circuits involving up to 4 variables 8 Describe the operation of a simple Bistable Element and its application in a basic counter and register 9 Explain the function of the components in a computer block diagram


10 With respect to a computer block diagram, explain the basic purpose of the a) Address Bus b) Data Bus c) Control Bus

11 Identify the above buses from a computer block diagram


Outcome 2 Demonstrate an understanding of data transfer Practical activities The candidate will be able to: 1 Utilise a data bus network tester to establish data bus integrity Underpinning knowledge The candidate will be able to: 1 State the advantages of a multiplexing data bus system over a conventional interconnecting system 2 Define the term ‘Data Transmission Protocol’ 3 Describe the use to which a data bus may be put 4 Explain the function of terminals operating in the following

a) Bus Controller b) Remote Terminal c) Bus Monitor

5 State the transmission media employed and how terminals are connected and matched to it 6 Explain the following terms

a) Word b) Command Word c) Data Word d) Status Word

7 Explain Data Encoding with reference to ‘Bipolar Return to Zero’ (ARINC 429) and ‘Manchester Bi-Phase’ (MIL-STD-1553, ARINC 629) 8 Describe the operation of a basic aircraft system using data bus 9 Explain the term ‘Redundancy’ and how it is incorporated in a basic data bus system 10 Explain and describe the principles and techniques used in applicable Data Bus systems

a) MIL-STD-1553 (STANAG 3838) b) STANAG 3910 c) ARINC 429 d) ARINC 629 e) ARINC 453

11 Describe the advantages, disadvantages and typical applications of the databuses listed in item 10


Unit 14 Aircraft Avionics Systems Rationale This unit is concerned with the understanding of avionics systems and their application to representative aircraft types. There are four outcomes to this unit. The candidate will be able to: 1 Demonstrate an understanding of air data systems and aircraft instrumentation. 2 Demonstrate an understanding of aircraft communication and navigation systems. 3 Demonstrate an understanding of aircraft flight control and autostabilisation systems. 4 Demonstrate an understanding of aircraft electrical power and lighting systems.



Outcome 1 Demonstrate an understanding of aircraft air data systems and aircraft instrumentation Practical activities The candidate will be able to: 1 Identify aircraft instrumentation 2 Connect and operate test equipment 3 Read and interpret instruments 4 Remove and refit system components Underpinning Knowledge The candidate will be able to: 1 Describe in basic terms the need for aircraft flight instrumentation 2 Describe the components and explain the principle of operation of a representative pitot/static system 3 Identify and describe the purpose of and explain the principle of operation of the following pitot/static test equipment

a) Precession pressure indicators b) Digital pressure indicators c) Vacuum and differential pressure chambers

4 Describe the need and explain the procedures to carry out aircraft pitot/static system functional checks 5 Explain how the following outputs are computed within an air data system

a) Altitude b) Vertical speed c) Indicated air speed d) True air speed e) Mach number

6 Explain the basic principles of the following

a) Pressure transducers b) Total temperature probe c) Angle of attack probe d) Accelerometers

7 Describe in basic terms aircraft propulsion instrumentation


8 Describe the purpose and explain the principle of operation of a) a fluid pressure indicating system and associated test equipment b) a position indicating system and associated test equipment c) an engine speed indicating system and associated test equipment d) an aircraft temperature indicating system and associated test equipment e) an engine temperature indicating system and associated test equipment f) a fuel contents indicating system and associated test equipment g) a fuel flow indicating system and associated test equipment


Outcome 2 Demonstrate an understanding of aircraft communication and navigation systems Practical activities The candidate will be able to: 1 Identify aircraft communication and navigation system components 2 Connect and operate test equipment 3 Read and interpret instruments 4 Remove and refit system components Underpinning knowledge The candidate will be able to: 1 Describe the principles and techniques of a) radio transmitters b) radio receivers 2 Explain, using block schematic diagrams, the principles and operation of the following transmitters a) AM b) FM c) CW d) SSB 3 Describe communications systems using a basic block schematic diagram a) HF b) V/UHF c) Cabin interphone d) SAT comm 4 Describe radio navigation systems using a basic block schematic diagram a) VOR b) ILS c) DME d) GPS 5 State the methods for generating high transmitter frequencies 6 State the benefits and limitations of each of the transmitters listed at item 2 7 Describe the basic principles of RF transmission lines 8 Describe the features of current airborne aerial systems 9 Describe techniques employed in matching aerials 10 Describe the basic principles of propagation of EM waves 11 Carry out tests on aerial and associated cable systems using a Time Domain Reflectometer (TDR), to determine the serviceability of the system 12 Describe the basic principles of satellite communications transmission


13 Perform Functional Tests and fault analysis to LRU level on an Air Radio Installation 14 Describe and explain the terms applied to a) attitude b) heading c) track d) drift angle e) longitude and latitude 15 State the purpose, operating principles and major components of a compass system/ Magnetic Heading Reference System (MHRS) 16 Explain basic compass principles with reference to errors and corrections, direct and remote compasses 17 Describe the construction and properties of

a) Single degree of freedom rate gyros b) Ring laser gyros c) Force re-balanced accelerometer

18 Explain the principles and techniques used within inertial navigation systems 19 Describe a typical IN Align sequence 20 Explain using a block system diagram the operation of an IN system 21 Show how an IN systems performance may be updated using

a) DME b) GPS

22 Explain using a block system diagram the principles and operation of a strap down IN system 23 Explain the operating principles and state the elements of analogue computing systems as used in navigation systems


Outcome 3 Demonstrate an understanding of aircraft flight controls and autostabilisation systems. Practical activities The candidate will be able to: 1 Assist with the operation of an aircraft flying control system 2 Undertake maintenance of an aircraft flying control system in accordance with the relevant aircraft maintenance manual 3 Test a representative autostabilisation system in accordance with the aircraft maintenance manual Underpinning Knowledge The candidate will be able to: 1 Explain the principles and techniques of servomechanisms 2 Explain the principles and operation of

a) Control/indication systems b) RPC servomechanisms used in aircraft control

3 Explain compensation techniques applied to RPC servo systems 4 Explain the application of digital and analogue techniques to control systems 5 Describe the basic principles of the following

a) loop RPC system b) closed loop RPC system

6 Using a block schematic diagram, describe the operation of a ‘fly-by-wire’ system 7 Using a block schematic diagram, describe the operation of a basic Autopilot in ‘control wheel steering’ (CWS) / Auto-stab mode 8 Using a block schematic diagram describe the operation of a basic Autopilot in response to the following inputs

a) Compass b) Manometric c) Radio / INS


Outcome 4 Demonstrate an understanding of aircraft electrical systems Practical activities The candidate will be able to: 1 Identify, operate and maintain aircraft electrical system components 2 Connect and operate test equipment 3 Read and interpret instruments 4 Remove and refit system components Underpinning knowledge The candidate will be able to: 1 Describe the need for and the requirements of aircraft power supply systems 2 Describe the need for and purpose of the components within an aircraft electrical primary and secondary power supply system 3 Describe the purpose and typical location of aircraft electrical distribution panels 4 Describe the types, purpose, and classification of aircraft busbars 5 Describe the purpose and principle of operation of circuit breakers and fuses 6 Describe the purpose and principle of operation of manually and automatically operated switches 7 Describe the purpose, function and application of terminal blocks used within aircraft electrical circuits 8 Identify aircraft lamps and state the safety precautions to be observed when working with these components 9 Describe the need, purpose and function of an aircraft Visual and Audio warning system 10 Describe the purpose and describe the operation of a representative aircraft internal and external lighting system 11 Describe the safety precautions and hazards to be observed when operating aircraft internal and external lighting systems 12 Describe and state, the purpose and principle of aircraft Primary and Secondary bonding 13 Describe the procedure and method to be followed when maintaining aircraft earth joints and bonding systems 14 Describe the need and procedure for insulation testing on aircraft wiring assemblies 15 Describe the purpose and principle of operation of Airborne Auxiliary Power Units (AAPU)


16 Describe the component parts, describe the function of and explain in basic terms the operation of the following aircraft turbine engine systems a) Aircraft Turbine Engine Starting Systems b) Aircraft Turbine Engine Ignition Systems 17 Describe the purpose and explain the principle of operation of a representative engine control system 18 Describe the purpose and principle of operation of, the following secondary power supply systems

a) Static Inverter b) Transformer Rectifier Unit

19 Describe the purpose and explain the basic principle of operation of a representative single generator system 20 Describe the purpose and explain the principle of operation of the following electrical systems a) multi generator/starter generator system b) non-paralleling a.c. generator system c) paralleling a.c. generator system 21 Describe the purpose and explain the principle of operation of a.c. generator drive systems


Mechanical manufacturing Pathway units


Unit 15 Aircraft Mechanical Systems (manufacturing) Rationale This unit has been designed to provide potential aviation engineers with the skills and knowledge necessary to understand aeroplane systems. There are three outcomes for this unit. The candidate will be able to: 1 Demonstrate an understanding of aircraft mechanical systems and how they interact 2 Demonstrate an understanding of Landing Gear systems (ATA 32) 3 Demonstrate an understanding of Equipment and Furnishings (ATA 25) Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge.


Outcome 1 Demonstrate an understanding of aircraft mechanical systems and how they interact Underpinning Knowledge The candidate will able to: 1 Describe in simple terms the function, basic layout and principle of operation of an aircraft air conditioning system (ATA 21)

a) sources of supply including engine bleed, APU and ground cart b) air conditioning system c) air cycle and vapour cycle machines d) distribution systems e) flow, temperature and humidity control system f) protection and warning devices

2 Describe in simple terms the function, basic layout and principle of operation of an aircraft cabin pressurisation system (ATA 21)

a) pressurisation systems b) control and indication including control and safety valves c) cabin pressure controllers d) protection and warning devices

3 Describe in simple terms the function, basic layout and principle of operation of an aircraft fire protection system (ATA 26)

a) fire and smoke detection and warning systems b) fire extinguishing systems c) system tests

4 Describe in simple terms the function, basic layout and principle of operation of an aircraft flight control system (ATA 27)

a) primary controls: aileron, elevator, rudder b) spoilers c) trim control d) active load control e) high lift devices f) lift dump, speed brakes g) system operation: manual, hydraulic, pneumatic, electrical, fly-by-wire h) artificial feel, yaw damper, mach trim, rudder limiter, gust locks i) balancing and rigging j) stall protection system

5 Describe in simple terms the function, basic layout and principle of operation of an aircraft fuel system (ATA 28)

a) system lay-out b) fuel tanks c) supply systems d) dumping, venting and draining e) cross-feed and transfer f) indications and warnings g) refuelling and defuelling h) longitudinal balance fuel systems


6 Describe in simple terms the function, basic layout and principle of operation of an aircraft hydraulic power system (ATA 29)

a) system lay-out b) hydraulic fluids c) hydraulic reservoirs and accumulators d) pressure generation: electrical, mechanical and pneumatic e) emergency pressure generation f) pressure control g) power distribution h) indication and warning systems i) interface with other systems

7 Describe in simple terms the function, basic layout and principle of operation of an aircraft ice and rain protection system (ATA 30)

a) ice formation, classification and detection b) anti-icing systems: electrical, hot air and chemical c) de-icing systems: electrical, pneumatic and chemical d) rain repellent and removal e) probe and drain heating

8 Describe in simple terms the function, basic layout and principle of operation of an aircraft oxygen system (ATA 35)

a) system lay-out: cockpit, cabin b) sources, storage, charging and distribution c) supply regulation d) indication and warnings

9 Describe in simple terms the function, basic layout and principle of operation of an aircraft pneumatic/vacuum system (ATA 36)

a) system lay-out b) sources: engine/APU, compressors, reservoirs, ground supply c) pressure control d) distribution e) indications and warnings f) interfaces with other systems

10 Describe in simple terms the function, basic layout and principle of operation of an aircraft water/waste system (ATA 38)

a) water system lay-out, supply, distribution, servicing and draining b) toilet systems lay-out, flushing and servicing c) corrosion aspects


Outcome 2 Demonstrate an understanding of Landing Gear Systems (ATA 32)

Practical Activities The candidate will be able to: 1 Undertake routine tasks on landing gear Underpinning Knowledge The candidate will be able to: 1 Identify the following types of landing gear

a) wheeled – nose wheel, tail wheel and bicycle wheel layouts b) skids c) skis

2 Describe the following components of a conventional wheeled landing gear

a) shock absorber b) wheel c) brake unit d) steering system e) torque link f) axle g) retraction h) locking mechanisms

3 Describe the following wheel arrangements and state the reasons for their use

a) single b) double c) bogie d) articulated

4 Identify the problem of nose wheel shimmy and describe methods of shimmy damping

a) twin-tread contact tyre b) twin wheels mounted on a live axle c) mechanical shimmy dampers d) hydraulic shimmy dampers

5 Identify the appropriate use, inspection and adjustment of torque links 6 Identify the power sources for retractable landing gear actuation

a) electric b) hydraulic


7 State the mandatory requirements of a retractable landing gear and describe the purpose of

a) mechanical up-locks b) mechanical down-locks c) side stays d) drag struts e) position indicators f) throttle warning switch g) selector baulk h) weight on wheels switch i) ground locks

8 Describe a typical hydraulic operated landing gear system

a) sequence with doors and bogie tilting operation b) micro and proximity switches c) cockpit indications d) mechanical indicators e) emergency methods of lowering

9 Describe the sequence of operations and function of the following components in an hydraulically operated landing gear system

a) non-return valve b) selector c) mechanical sequence valve d) actuators e) restrictor valve f) shuttle valve g) fluid jettison valve

10 Describe the sequence of operations required to lower a landing gear in an emergency by

a) free fall b) nitrogen blow-down c) electrical actuation

11 Describe the procedures, safety precautions, inspection and checks to be carried out before and during a landing gear retraction test using an external power source 12 Describe the construction and operation of the following shock absorbers

a) oleo-pneumatic with separator b) oleo-pneumatic without separator

13 Describe the inspections and servicing operations to be carried out on oleo- pneumatic shock absorbers

a) inspections – leakage, corrosion damage, correct gas charge, the use of load extension graphs

b) servicing operations – filling with oil, charging with nitrogen 14 Identify the construction of well based, loose or detachable flange and divided wheel hubs, listing the advantages and disadvantages of each 15 Identify the design provision in a wheel to overcome the problems of tyre creep and heating 16 Describe fusible plugs and their use in a tubeless tyre wheel assembly 17 Describe the dismantling of a wheel/tyre assembly and the relevant safety precautions


18 Describe the inspections carried out on an assembled and a dismantled wheel 19 Describe and identify aircraft wheel bearings and the inspection criteria applied to them 20 Describe the principal features and design considerations of the following aircraft tyres

a) cross ply b) radial c) tubed d) tubeless

21 Explain the following identification marks on the side wall of a tyre and their importance

a) size coding b) date code c) serial number d) part number e) ply rating f) speed rating g) fitting rings

22 Describe the inspection procedure for a) mounted tyres b) mounted tubes

23 Define common tyre defects and limits of serviceability for

a) tyres b) tubes

24 State the safety precautions and procedures to be observed when inflating tyres 25 Explain the importance of correct tyre inflation pressure 26 Describe the dismantling procedure for tubeless and tubed wheel/tyre assemblies 27 Describe the advantages of a structural carbon brake unit compared with steel brakes 28 Describe an aircraft hydraulic brake system and state the function and operation of the components

a) brake control valve b) accumulator c) park brake d) anti-skid units e) pressure gauge f) duplicated supply for emergency operation

29 Describe the components and operation of an autobrake system 30 Describe typical operations, defects and rectification procedures in relation to brake units and systems 31 Identify mechanical and electronic anti-skid units and describe their operating principles and construction 32 Describe the inspection criteria and functional checks for anti-skid units 33 Describe typical procedures in relation to anti-skid units


34 State the requirements for a nose-wheel steering system 35 Describe a hydraulic nose-wheel steering system:

a) control valve b) non-return valve c) dual pressure relief valve d) double acting actuator e) feed-back system

36 Describe the inspection and test criteria for a hydraulic nose wheel steering system 37 Describe typical operations on nose wheel steering systems


Outcome 3 Demonstrate an understanding of Equipment and furnishings (ATA 25) Practical activities The candidate will be able to: 1 Undertake tasks for the installation of equipment and furnishings Underpinning Knowledge The candidate will be able to: 1 Identify the legal requirements for emergency equipment to be fitted and operated on civil aircraft as specified in ANOs; BCARs and JARs 2 Identify the following types and installation of aircraft seats and describe the differences between them

a) flight crew b) cabin crew c) passengers

3 Describe the seat belt appropriate to each type of seat 4 Describe the inspections required on the seats and harness assembly 5 Describe a typical cabin layout for a passenger transport aircraft with regard to the following criteria

a) seat arrangement b) location of galley(s) c) locations of toilets d) temporary bulkheads e) access to doors f) access to escape hatches g) the provision of air stairs h) passenger loading

6 Identify various types of cabin entertainment equipment and the care required for continued operation 7 Describe a typical galley installation with regard to ovens, potable water; waste disposal 8 Describe location, stowage and operation of the following cabin safety equipment

a) fire extinguishers b) gloves c) axes d) life jackets e) liferafts f) torches g) loud hailers h) escape slides

9 Identify the potential problems that may occur in a galley

a) overheating b) corrosion


10 Describe the different styles of cargo retention equipment and the methods employed to handle and load the cargo

a) pallets b) nets c) containerisation


Unit 16 Aircraft Manufacture Rationale This unit has been designed to provide potential aviation engineers with the skills and knowledge necessary to perform fixed wing aircraft production functions. It will also provide them with the knowledge of modern production techniques and safety factors related to aircraft production. There are four outcomes for this unit. The candidate will be able to: 1 Describe and understand the need for component manufacturing and material heat treatment techniques 2 Prepare the aircraft structure for assembly by selection and use of the correct jigs/fixtures and hole preparation techniques 3 Identify, select and obtain an appropriate assembly technique, and undertake the assembly and sealing operation correctly and safely 4 Ensure a structure has been assembled to the engineering drawing, technical data or other instructions, which determine the aircraft manufacturing requirements

Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge


Outcome 1 Describe and understand the need for component manufacturing and material heat treatment techniques Practical Activities The candidate will be able to: 1 Interpret engineering drawings, technical data and other instructions to determine the component manufacturing and heat treatment requirements 2 Plan the work to meet operational requirements 3 Cold form bar, sheet, pipe and section material by bending, ensuring that appropriate heat treatments have been carried out, where required Underpinning Knowledge The candidate will be able to: 1 Distinguish between, and state the applications of the following component manufacturing and material heat treatment

a) machining; turning, milling, grinding, routing b) casting; sand casting, die casting, investment casting c) hot forming; rolling, extruding, drawing, forging d) cold forming; bending, cold working, work hardening, presswork e) steels; annealing, normalising, hardening, tempering f) aluminium alloys; annealing, solution treatment, precipitation g) composite material manufacture; GRF/P, CRF/P, core materials

2 Describe the working processes, equipment, allowances and tolerance, temperature ranges, and changes in material properties for the given processes to include changes in

a) hardness b) toughness c) ductility d) strength e) grain structure

3 Select and justify which manufacturing processes and/or heat treatment might have been employed to produce given simple components 4 State the hazards and safety precautions involved in the given processes


Outcome 2 Prepare the aircraft structure for assembly by selection and use of the correct jigs/fixtures and hole preparation techniques Practical Activities The candidate will be able to: 1 Interpret engineering drawings, technical data or other instructions to determine the hole preparation techniques that are needed to be carried out prior to assembly 2 Plan the whole preparation operation to meet operational requirements 3 Carry out the hole preparation technique, ensuring that all relevant engineering standards are complied with Underpinning Knowledge The candidate will be able to: 1 Distinguish between, and state the application of the following hole production equipment and techniques

a) drilling; datum holes, back drilling, angle drilling, pilot drilling, drill reaming, final drilling (fits and tolerances)

b) reaming; parallel and taper c) cold-working; equipment and changes in material properties d) jigs, fixtures, templates e) automatic and semi-automatic hole preparation f) hole finishing; countersinking, counter boring, spot facing

2 Describe the working processes, equipment, tolerances achievable and any changes in material properties for the given processes

a) pneumatic drills b) semi-automatic drilling (Spacematic) c) rack feed d) automatic drilling e) producing tapered holes

3 Select and justify which hole production equipment and techniques might be employed to produce given simple components 4 State the hazards and safety precautions involved in the given processes


Outcome 3 Identify, select and obtain an appropriate assembly technique, and undertake the assembly and sealing operation correctly and safely Practical Activities The candidate will be able to: 1 Interpret engineering drawings, technical data and other instructions to determine the assembly, fastening and sealing requirements 2 Plan the work to meet operational requirements 3 Undertake the assembly, fastening and sealing process correctly and safely ensuring that all relevant engineering standards are complied with Underpinning Knowledge The candidate will be able to: 1 Distinguish between, and state the applications of the following assembly, fastening and sealing techniques

a) automatic; NC assembly machines b) welding; gas, arc, inert gas, resistance (flash, spot, seam) c) welding electrodes and fluxes d) surface preparation and cleanliness e) automatic welding

2 Select and justify which assembly techniques and sealing process might be employed to produce given simple components 3 State the hazards and safety precautions involved in the given processes 4 Select and justify which checking and inspection techniques might be employed for the fastening and assembly techniques 5 State the hazards and safety precautions involved in the given processes


Outcome 4 Ensure a structure has been assembled to the engineering drawing, technical data to other instructions, which determine the aircraft manufacturing requirements Practical Activities The candidate will be able to: 1 Interpret engineering drawings, technical data, and other instructions to determine the post assembly checking, inspection and finish requirements 2 Plan the task to meet the appropriate requirements in terms of

a) selecting the appropriate checking, inspection and finish procedures b) identifying and obtaining the correct tools and equipment c) identifying and obtaining the correct materials d) determining the correct operational sequences e) identifying safety precautions

3 Carry out a full inspection of the assembly and apply any finishes required, ensuring that all relevant engineering standards are complied with Underpinning Knowledge The candidate will be able to: 1 Describe correct techniques for completion and checking in accordance with relevant airframe production standards 2 State the action to be taken in cases of non-conformity of standards 3 Distinguish between and state the applications of the following checking and inspection procedures

a) inspection and checking: I.C.Y rigging, symmetry, locking, bonding checks b) finishes: anti-electrolysis, anodic, chromate, primer, paints and metallic coatings c) pressure, functional and operational checks

4 Describe the checking and inspection procedures, equipment needed, tolerance achievable and remedial procedures to rectify differences from the standards 5 Select and justify which checking and inspection techniques might be employed for the fastening and assembly techniques 6 State the hazards and safety precautions involved in the given processes


Unit 17 Aircraft Materials and Hardware (manufacturing) Rationale This unit is concerned with developing the candidates’ understanding of aircraft materials and hardware. It covers the use of materials and manufacturing practices. There are three outcomes to this unit. The candidate will be able to: 1 Investigate the structure and practical properties of aircraft engineering materials 2 Identify aircraft hardware and carry out replacement and servicing 3 Undertake manufacturing practices and procedures on aircraft hardware and in workshops Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge


Outcome 1 Investigate the structure and practical properties of aircraft engineering materials Practical activities The candidate will be able to: 1 Carry out the visual detection of defects in aircraft materials 2 Carry out visual examinations of aircraft structures for corrosion and identify correctly the type of corrosion and report the findings Underpinning Knowledge The candidate will be able to: 1 Describe the characteristics, properties and identification of ferrous, non-ferrous, composite and non-metallic materials used in aircraft engineering 2 Describe the characteristics, properties and identification of sealant and bonding agents 3 Define the terminology used to indicate the physical properties of aircraft engineering materials 4 Distinguish between the main groups of plastics

a) thermosetting b) thermoplastic c) catalytic

5 Explain the reasons for modifying the properties of metallic materials, and describe the methods used to modify the properties of metallic materials 6 Describe the influence of the following alloying elements on the basic properties of plain carbon steel

a) nickel b) chromium c) vanadium d) molybdenum e) tungsten f) magnesium g) silicon


7 Describe the characteristics of the following common non-ferrous materials a) bronze b) brass c) aluminium d) magnesium e) soft solder f) white metal

8 Outline the effects of alloying elements in steels, and hot and cold working on grain size and shape, and describe the basic procedures for hot and cold working 9 State the purpose of heat treatment processes used to modify the properties of plain carbon steels, and describe their basic properties 10 State the purpose of the following heat treatment processes

a) annealing b) normalising c) hardening d) tempering

11 Describe basic heat treatment procedures for surface hardening of steel

a) case hardening (solid, liquid and gaseous) b) nitriding c) flame hardening d) induction hardening

12 State the heat treatment processes used to modify the properties of aluminium alloys and other non-ferrous metals

a) annealing b) solution c) precipitation d) refrigeration

13 Describe the chemical fundamentals of corrosion

a) direct chemical action b) galvanic action process

14 Describe the formation of corrosion by

a) microbiological action b) stress


15 Identify types of corrosion likely to occur in aircraft structures and state the areas where they may occur

a) surface b) pitting c) stress d) fatigue e) intergranular f) fretting g) crevice h) exfoliation i) filiform

16 Describe corrosion prevention techniques 17 List techniques and re-agents used for removing corrosion, freeing parts and protecting structures on a temporary or a semi-permanent basis


Outcome 2 Identify aircraft hardware and carry out replacement and servicing Practical Activities The candidate will be able to: 1 Identify materials and tools from drawings, technical data and specifications for servicing 2 Carry out routine inspection of hardware 3 Remove and refit aircraft hardware 4 Use positive and friction locking devices, as appropriate Underpinning Knowledge The candidate will be able to: 1 Interpret engineering drawings, technical data and instructions to determine the fastening requirements for aircraft 2 Distinguish between aircraft specification, nuts, bolts, screws, studs and thread forms 3 Measure screw threads 4 Identify and describe the following nuts, bolts, studs and screws

a) self locking b) anchor nuts c) standard types d) machine screws e) aircraft specification stud types and uses

5 Describe the insertion and removal of studs 6 Describe the specification, identification and marking of aircraft bolts and international standard nuts 7 Describe the purpose of and procedure for torque loading

a) different types of torque wrench b) torque wrench inspection c) standard torque values d) upper and lower torque values e) the effects of lubrication on threaded fasteners f) run down torque and selective fitting of nuts


8 Identify and describe the following types and applications of standard aircraft locking devices

a) tab and spring washers b) locking plates c) split pins d) pal-nuts e) wire locking f) quick release fasteners g) circlips h) cotter pins i) rivnuts

9 Distinguish between the applications of plain and taper washers 10 Identify and describe the types of aircraft rivets

a) solid b) blind

11 Identify and describe standard rivet specifications, identification methods and heat treatment processes 12 Explain the purpose and type of bearings 13 Identify and describe rigid and flexible pipes, unions and their connectors used on hydraulic, fuel, oil, pneumatic, air and oxygen systems 14 Identify the ICAO geometric symbols for the following pipeline contents

a) hydraulic b) fuel c) air conditioning d) oxygen e) de-icing f) lubricant g) instrument air

15 Describe the types and application of springs used in aircraft engineering applications 16 Describe the different types of gear transmission systems and their applications a) gear ratios; reduction and multiplication gear systems b) driven and driving gears; idler gears; mesh patterns c) belts and pulleys; chains and sprockets 17 Identify the main components of a mechanical control system

a) cable types b) end fittings c) Bowden cables d) pulleys and cable systems components e) turnbuckles f) compensation devices g) aircraft flexible control systems


Outcome 3 Undertake manufacturing practices and procedures on aircraft hardware and in workshops Practical Activities The candidate will be able to: 1 Carry out routine inspection, testing and repair of mechanical systems and components using the relevant manuals Underpinning Knowledge The candidate will be able to: 1 Define and determine the appropriate riveting requirements relating to aircraft activities 2 Explain the reasons for aircraft riveting as the construction of a permanent joint 3 Identify and describe the following features of the rivet

a) pre-formed head b) shank c) formed head

4 Describe riveting terminology

a) allowance b) clearance c) pitch d) spacing e) land (edge margin) f) sphere of influence

5 Identify and describe the following types of aircraft riveted joints

a) lap joint b) single strap butt joint c) chain pitch d) staggered zig-zag pitch

6 Distinguish between different types of standard rivet in terms of

a) materials b) types of solid rivet head c) types of blind rivet


7 Describe the factors that determine the selection of the most suitable rivet for a particular application in terms of

a) thickness b) hole diameter c) shape; the rivet head appropriate to

i strength ii clearance iii situation of the joint

A) material of the joint B) riveting process C) aerodynamic considerations

8 Identify and describe the different types of riveting equipment

a) tools for hand riveting i hand riveting tools ii hammers iii drawers iv snaps v mechanical, pneumatic vi hydraulic tools vii rivet cutters viii rivet gauge

b) supporting tools i anvils ii dollies iii pneumatic dollies iv skin gripper pins

c) hollow and blind riveting tools i hand ii pneumatic iii hydraulic

9 Describe the preparatory operations for riveting

a) selection of rivets b) surface preparation prior to riveting c) determining the correct size of drill d) alignment of parts to be drilled e) removing burrs f) methods of ensuring close contact between parts g) heat treatment of non-ferrous parts h) countersinking or dimpling

10 Describe the operational procedures for riveting structure using

a) snap rivets b) countersunk


11 Identify and account for the common defects in riveted joints a) rivet in shear b) badly formed head c) buckled shank d) cracking of head e) separation of component parts f) distortion or cracking of plate edges g) shear failure h) bearing failure i) head failure

12 State the safety precautions specific to aircraft riveting on and off the aircraft 13 State the purpose of pipes and hoses 14 State the basic procedures for bending/flaring aircraft pipes 15 Describe the routine inspection and testing of aircraft pipes and hoses 16 Describe typical procedures for removing, replacing and clamping of pipes 17 Describe how to inspect or test springs for serviceability 18 Describe how to inspect, test and clean bearings 19 List the equipment necessary to carry out routine servicing and lubrication of bearings 20 State the common defects likely to occur in bearings and describe the symptom of faults 21 State the basic circuits and components in transmission systems

a) gears b) belts and pulleys c) chains and sprockets d) screw jacks e) lever devices f) push-pull rods

22 Describe the purpose of transmission systems 23 Describe the working principles of the components in a transmission system 24 Identify, name and state the function or purpose of transmission components 25 Describe typical procedures for removing and replacing transmission components 26 State the purpose of carrying out routine inspection and servicing of transmission systems and their components 27 Describe the procedure for routine inspection and servicing of transmission components 28 List the equipment necessary to carry out routine inspection and servicing of transmission components and describe the selection, use and maintenance of this equipment 29 State the common faults likely to occur in a transmission system


30 State safe working practices and any special precautions to be observed when carrying out routine inspection of transmission systems 31 State the purpose of control cables 32 Identify the basic components in a control cable system

a) swaged end fittings b) bowden cables c) flexible control systems

33 Describe the working principles of a cable control operated system 34 Identify the main statutory requirements for control cables 35 Identify, name and state the function or purpose of cable control operated system components 36 Explain how cable control operated system components work 37 Describe typical procedures for removing and replacing control cables and their components 38 Describe how to test control cable components 39 State the purpose of carrying out routine inspection and servicing on aircraft control cables and their components 40 Describe how the routine inspection and servicing necessary for control cable components is carried out 41 Identify the equipment necessary to carry out routine inspection of control cables and components and describe the selection, use and maintenance of this equipment 42 State safe working practices and any special precautions to be observed when carrying out routine inspection and servicing to control cable and components 43 List the common faults likely to occur in a control system and describe the symptoms of these faults


Unit 18 Aircraft Structure (manufacturing) Rationale This unit is concerned with developing the candidates’ understanding of aircraft, structures. It covers the structural requirements and classification of aircraft structures when installing, removing and replacing aircraft structural components. There are three outcomes to this unit. The candidate will be able to: 1 Undertake installation on aircraft structures 2 Remove and replace airframe structures and components 3 Demonstrate an understanding of general practices for aircraft manufacturing Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge.


Outcome 1 Undertake installation on aircraft structures Practical activities The candidate will be able to: 1. Carry out routine installation, inspection and structural classification of airframe structures Underpinning knowledge The candidate will be able to: 1 State the airworthiness requirements for structural strength and the need for structural classification

a) primary b) secondary c) tertiary

2 Describe structural and damage tolerance concepts

a) safe life b) fail safe

3 Describe zonal and station identification systems 4 Describe loadings in aircraft structures with relation to

a) stress b) strain c) bending d) compression e) shear f) torsion g) tension h) hoop i) fatigue j) provision for system installation

5 Recognise and state the function of drains and ventilation provision 6 Describe the methods of lightning strike protection 7 Identify types of airframe structure

a) truss b) monocoque c) semi monocoque


8 Identify and state the relationship of the following to airframe structures a) stressed skin fuselage b) formers c) stringers d) longerons e) bulkheads f) frames g) doublers h) struts i) ties j) floor beams k) floor structures l) reinforcement m) methods of skinning n) anti-corrosive protection o) wing, empennage and engine attachments p) intercostals

9 Describe structural assembly techniques

a) riveting b) bolting c) bonding

10 Describe the following methods of surface protection

a) chromating b) anodising c) painting

11 Describe the methods of surface cleaning 12 Describe the purpose and typical procedures for carrying out airframe symmetry checks 13 Describe methods of alignment and symmetry checks 14 State safe working practices and any special precautions to be observed when carrying out installation and inspection of airframe structures 15 Describe the method of detection of defects in composite materials

a) tap test b) ultrasonics

16 Describe methods of repair to composite materials

a) injection repairs b) stepped repairs c) scarf repairs d) honeycomb repairs


Outcome 2 Remove and replace airframe structures and components Practical activities The candidate will be able to: 1 Remove and replace typical airframe components Underpinning knowledge The candidate will be able to: 1 Describe the basic construction and pressurisation sealing of the fuselage 2 Describe the construction and purpose of fuselage and wing attachment points for

a) wing b) stabiliser c) pylon and undercarriage attachments

3 Describe routine inspection and servicing of fuselage and wing attachment points 4 Describe the typical procedures for removing and replacing major components 5 State the safe working practices and any special precautions to be observed when carrying out routine inspection and servicing to attachment points 6 Identify, name and state the function of fuselage doors, their construction, mechanisms, operation and safety devices 5 State safe working practices and any special precautions to be observed when carrying out routine inspection and servicing of crew/passenger access/egress systems and their methods of operation 6 Describe how to inspect airframe structural components for serviceability 7 Describe the main structural components and construction of wings (ATA 57) 10 Describe the construction of wing fuel storage 11 State safe working practices and any special precautions to be observed when carrying out routine inspection and servicing of fuel storage systems 12 Describe the construction of wing attachment devices

a) landing gear b) pylon c) control surfaces d) high lift/drag devices

13 Describe the construction of the stabilisers and their attachment devices (ATA 57) 14 Describe the construction of flight control surfaces and their attachment devices (ATA 5/57) 15 State the purpose of aerodynamic balancing as a means of decreasing the force necessary to operate flying controls during flight


16 Identify the listed types of aerodynamic balance a) inset hinge b) horn balance c) balance tab d) servo tab e) spring tab f) pressure balance

17 State the purpose of mass balancing of a control surface 18 Explain the importance of the position of the Centre of Gravity (C of G) of a control surface 19 State safe working practices and any special precautions to be observed when carrying out routine inspection and servicing of moving control surfaces 20 Describe the construction of nacelle/pylons, firewalls (ATA 57) and their attachment devices 21 Identify the function of firewalls 22 Describe the construction of engine mounts


Outcome 3 Demonstrate an understanding of general practices for aircraft manufacturing

Practical activities The candidate will be able to: 1 Carry out a simulated emergency procedure in relation to


2 Select correct tools when working in a workshop/hangar environment 3 Select correct drawings to use with appropriate workshop tasks and identify relevant title block and other information from the drawings 4 Use microfilm, microfiche or computerised information when carrying out appropriate manufacturing tasks 5 Measure to the appropriate degree of accuracy a variety of aircraft components using various measuring devices including micrometers and verniers Underpinning knowledge The candidate will be able to: 1 State the appropriate safety procedures necessary when working with electricity, high pressure gases (especially oxygen), oils and chemicals 2 State the remedial action to be taken in the event of a fire or other accident with electricity, high pressure gases (especially oxygen), oils and chemicals 3 Identify the correct tools for carrying out practical workshop tasks 4 State the procedures necessary to control the use of tools and workshop materials 5 Describe the procedures used to calibrate tools and to ensure tools are maintained to a satisfactory standard 6 Describe the common hand and power tools used on aircraft and in the workshop 7 Describe the construction and use of precision measuring tools such as micrometers and vernier measuring tools 8 Explain the principles of lubrication and describe the methods of lubrication used on aircraft and in the workshop 9 Identify the basic drawing types and diagrams, their symbols dimensions, tolerances and projections 10 Identify and state the purpose of the title block registration


11 Recognise, name and state the function of a) microfilm b) microfiche c) computerised presentation

12 Identify the main statutory requirements for engineering drawings, diagrams and

standards a) Air Transport Association (ATA) of America b) Aeronautical and other applicable standards


c) Wiring diagrams and other schematic diagrams 13 State the purpose of fits and clearances 14 Describe the working principles of the common system of fits and clearances 15 State the schedule of fits and clearances for aircraft and engines 16 Describe the systems of fits and clearances in common use for aircraft and engines 17 State where the limits for bow, twist and wear would be detailed 18 Describe the standard methods for checking shafts, bearings and other parts 19 Describe the correct procedures to be followed and the associated safety precautions necessary when


20 Describe the effects of environmental conditions on aircraft handling and operation 21 State the inspection techniques used and describe the types of defects to be found when carrying out inspection of aircraft and associated equipment 22 Describe typical correct and safe disassembly and re-assembly techniques 23 Explain why modifications may be necessary and describe the procedures for carrying out modifications 24 Describe the layout of a typical aircraft store and the procedures to ensure safe storage of aircraft parts and materials 25 Describe the procedures for certification and release of aircraft parts and materials 26 Explain the need for control of life-limited components associated with aircraft


Electrical manufacturing pathway units


Unit 12 Electronic and further electrical fundamentals Rationale This unit is concerned with the understanding of electronic principles and their relationship to aircraft servicing and maintenance. There are three outcomes to this unit. The candidate will be able to: 1 Demonstrate an understanding of electronic components and their use in aircraft applications. 2 Demonstrate an understanding of AC and DC theory. 3 Demonstrate an understanding of AC and DC motors and generators. Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge.


Outcome 1 Demonstrate an understanding of electronic components and their use in aircraft applications. Practical activities The candidate will be able to: 1 Identify electronic components and state their function 2 Assemble simple electronic circuits to demonstrate component properties 3 Use circuit diagrams and standard symbols to identify and classify components Underpinning Knowledge The candidate will be able to: 1 Describe the properties and applications of a) diodes b) resistors c) capacitors d) inductors 2 Describe the principles and identify applications of transformers 3 Apply transformer theory to the solution of problems including regulation and impedance matching 4 Describe the characteristics, composition and uses of simple filters 5 Describe the nature, construction and uses of simple integrated circuits 6 Describe the nature, construction and use of printed circuit boards 7 Describe the principles and techniques of servomechanisms a) open loop b) closed loop c) feedback d) control systems e) indication systems


Outcome 2 Demonstrate an understanding of AC and DC theory. Practical activities The candidate will be able to: 1 Use circuit theory to solve simple circuit problems 2 Apply AC circuit theory in the solution of series and parallel network problems 3 Construct and test smoothed and stabilised power supplies 4 Construct a simple electrical circuit to prove Ohm’s and Kirchoff’s Laws Underpinning knowledge The candidate will be able to: 1 Describe in simple terms the following a) conductors b) insulators c) current d) voltage e) resistance 2 Describe the relationship between voltage current and resistance 3 Describe Kirchoff’s laws of current and voltage 4 Explain how energy is dissipated in DC circuits 5 Describe the construction and properties of the following rectifiers a) half-wave b) bi-phase full-wave c) 4 diode bridge 6 Describe the effects of reservoir capacitors on output voltages 7 Explain the need to reduce output voltage ripple 8 Demonstrate AC waveforms and determine the following parameters a) phase b) period c) frequency d) cycle e) amplitude f) peak-to-peak value g) peak value e) rms value f) average value 9 Use phasor representation of sinusoidal quantities 10 Describe the relationship of voltage and current in Resistive, Capacitive and Inductive circuits 11 Describe the production of a three phase AC waveform


Outcome 3 Demonstrate an understanding of AC and DC motors and generators. Practical activities The candidate will be able to: 1 Identify and explain the purpose of the component parts of a DC motor 2 Identify and explain the purpose of the component parts of a DC generator 3 Identify and explain the purpose of the component parts of an AC motor 4 Identify and explain the purpose of the component parts of an AC generator

Underpinning knowledge The candidate will be able to: 1 Describe the fundamental laws governing magnetism 2 Describe the fundamental principles and laws governing electromagnetic induction 3 Explain in simple terms the operation and characteristics of shunt and series connected DC generators 4 Explain in simple terms the principle of DC compound generators 5 Describe in simple terms the requirements for parallel operation of DC generators 6 Describe the basic operation and control of DC shunt motors 7 Describe the basic operation and control of DC series motors 8 Describe the basic principles of DC compound motors 9 Describe the basic operation of AC generators 10 Explain in simple terms the requirements for parallel operation of AC generators 11 Describe the basic operation of an AC synchronous motor 12 Describe the basic operation of AC induction motors


Unit 16 Aircraft Manufacture Rationale This unit has been designed to provide potential aviation engineers with the skills and knowledge necessary to perform fixed wing aircraft production functions. It will also provide them with the knowledge of modern production techniques and safety factors related to aircraft production. There are four outcomes for this unit. The candidate will be able to: 1 Describe and understand the need for component manufacturing and material heat treatment techniques 2 Prepare the aircraft structure for assembly by selection and use of the correct jigs/fixtures and hole preparation techniques 3 Identify, select and obtain an appropriate assembly technique, and undertake the assembly and sealing operation correctly and safely 4 Ensure a structure has been assembled to the engineering drawing, technical data or other instructions, which determine the aircraft manufacturing requirements

Assessment The outcomes for this unit will be assessed on the basis of evidence produced as a result of: 1 A centre set assignment covering both practical activities and underpinning knowledge


Outcome 1 Describe and understand the need for component manufacturing and material heat treatment techniques Practical Activities The candidate will be able to: 1 Interpret engineering drawings, technical data and other instructions to determine the component manufacturing and heat treatment requirements 2 Plan the work to meet operational requirements 3 Cold form bar, sheet, pipe and section material by bending, ensuring that appropriate heat treatments have been carried out, where required Underpinning Knowledge The candidate will be able to: 1 Distinguish between, and state the applications of the following component manufacturing and material heat treatment

a) machining; turning, milling, grinding, routing b) casting; sand casting, die casting, investment casting c) hot forming; rolling, extruding, drawing, forging d) cold forming; bending, cold working, work hardening, presswork e) steels; annealing, normalising, hardening, tempering f) aluminium alloys; annealing, solution treatment, precipitation g) composite material manufacture; GRF/P, CRF/P, core materials

2 Describe the working processes, equipment, allowances and tolerance, temperature ranges, and changes in material properties for the given processes to include changes in

a) hardness b) toughness c) ductility d) strength e) grain structure

3 Select and justify which manufacturing processes and/or heat treatment might have been employed to produce given simple components 4 State the hazards and safety precautions involved in the given processes.


Outcome 2 Prepare the aircraft structure for assembly by selection and use of the correct jigs/fixtures and hole preparation techniques Practical Activities The candidate will be able to: 1 Interpret engineering drawings, technical data or other instructions to determine the hole preparation techniques that are needed to be carried out prior to assembly 2 Plan the hole preparation operation to meet operational requirements 3 Carry out the hole preparation technique, ensuring that all relevant engineering standards are complied with Underpinning Knowledge The candidate will be able to: 1 Distinguish between, and state the application of the following hole production equipment and techniques

a) drilling; datum holes, back drilling, angle drilling, pilot drilling, drill reaming, final drilling (fits and tolerances) b) reaming; parallel and taper c) cold-working; equipment and changes in material properties d) jigs, fixtures, templates e) automatic and semi-automatic hole preparation f) hole finishing; countersinking, counter boring, spot facing

2 Describe the working processes, equipment, tolerances achievable and any changes in material properties for the given processes

a) pneumatic drills b) semi-automatic drilling (Spacematic) c) rack feed d) automatic drilling e) producing tapered holes

3 Select and justify which hole production equipment and techniques might be employed to produce given simple components 4 State the hazards and safety precautions involved in the given processes


Outcome 3 Identify, select and obtain an appropriate assembly technique, and undertake the assembly and sealing operation correctly and safely Practical Activities The candidate will be able to: 1 Interpret engineering drawings, technical data and other instructions to determine the assembly, fastening and sealing requirements 2 Plan the work to meet operational requirements 3 Undertake the assembly, fastening and sealing process correctly and safely ensuring that all relevant engineering standards are complied with Underpinning Knowledge The candidate will be able to: 1 Distinguish between, and state the applications of the following assembly, fastening and sealing techniques

a) automatic; NC assembly machines b) welding; gas, arc, inert gas, resistance (flash, spot, seam) c) welding electrodes and fluxes d) surface preparation and cleanliness e) automatic welding

2 Select and justify which assembly techniques and sealing process might be employed to produce given simple components 3 State the hazards and safety precautions involved in the given processes 4 Select and justify which checking and inspection techniques might be employed for the fastening and assembly techniques 5 State the hazards and safety precautions involved in the given processes


Outcome 4 Ensure a structure has been assembled to the engineering drawing, technical data to other instructions, which determine the aircraft manufacturing requirements Practical Activities The candidate will be able to: 1 Interpret engineering drawings, technical data, and other instructions to determine the post assembly checking, inspection and finish requirements 2 Plan the task to meet the appropriate requirements in terms of

a) selecting the appropriate checking, inspection and finish procedures b) identifying and obtaining the correct tools and equipment c) identifying and obtaining the correct materials d) determining the correct operational sequences e) identifying safety precautions

3 Carry out a full inspection of the assembly and apply any finishes required, ensuring that all relevant engineering standards are complied with Underpinning Knowledge The candidate will be able to: 1 Describe correct techniques for completion and checking in accordance with relevant airframe production standards 2 State the action to be taken in cases of non-conformity of standards 3 Distinguish between and state the applications of the following checking and inspection procedures

a) inspection and checking: I.C.Y rigging, symmetry, locking, bonding checks b) finishes: anti-electrolysis, anodic, chromate, primer, paints and metallic coatings c) pressure, functional and operational checks

4 Describe the checking and inspection procedures, equipment needed, tolerance achievable and remedial procedures to rectify differences from the standards 5 Select and justify which checking and inspection techniques might be employed for the fastening and assembly techniques 6 State the hazards and safety precautions involved in the given processes


Unit 19 Aircraft electrical Systems Rationale This unit is concerned with the understanding of electrical systems and their application to representative aircraft types. There are three outcomes to this unit. The candidate will be able to: 1 Demonstrate an understanding of air data systems and aircraft instrumentation. 2 Demonstrate an understanding of aircraft flight control and autostabilisation systems. 3 Demonstrate an understanding of aircraft electrical power and lighting systems.



Outcome 1 Demonstrate an understanding of aircraft air data systems and aircraft instrumentation Practical activities The candidate will be able to: 1 Identify aircraft instrumentation 2 Connect and operate test equipment 3 Read and interpret instruments 4 Remove and refit system components Underpinning Knowledge The candidate will be able to: 1 Describe in basic terms the need for aircraft flight instrumentation 2 Describe the components and explain the principle of operation of a representative pitot/static system 3 Identify and describe the purpose of and explain the principle of operation of the following pitot/static test equipment

a) precession pressure indicators b) digital pressure indicators c) vacuum and differential pressure chambers

4 Describe the need and explain the procedures to carry out aircraft pitot/static system functional checks 5 Explain how the following outputs are computed within an air data system

a) altitude b) vertical speed c) indicated air speed d) true air speed e) mach number

6 Explain the basic principles of the following

a) pressure transducers b) total temperature probe c) angle of attack probe d) accelerometers

7 Describe in basic terms aircraft propulsion instrumentation


8 Describe the purpose and explain the principle of operation of a) a fluid pressure indicating system and associated test equipment b) a position indicating system and associated test equipment c) an engine speed indicating system and associated test equipment d) an aircraft temperature indicating system and associated test equipment e) an engine temperature indicating system and associated test equipment f) a fuel contents indicating system and associated test equipment g) a fuel flow indicating system and associated test equipment


Outcome 2 Demonstrate an understanding of aircraft flight controls and autostabilisation systems. Practical activities The candidate will be able to: 1 Assist with the operation of an aircraft flying control system 2 Undertake operations on an aircraft flying control system in accordance with the relevant aircraft manual 3 Test a representative autostabilisation system in accordance with the aircraft manual Underpinning Knowledge The candidate will be able to: 1 Explain the principles and techniques of servomechanisms 2 Explain the principles and operation of

a) control/indication systems b) RPC servomechanisms used in aircraft control

3 Explain compensation techniques applied to RPC servo systems 4 Explain the application of digital and analogue techniques to control systems 5 Describe the basic principles of the following

a) loop RPC system b) closed loop RPC system

6 Using a block schematic diagram, describe the operation of a ‘fly-by-wire’ system 7 Using a block schematic diagram, describe the operation of a basic Autopilot in ‘control wheel steering’ (CWS) / Auto-stab mode 8 Using a block schematic diagram describe the operation of a basic Autopilot in response to the following inputs

a) Compass b) Manometric c) Radio/INS

Outcome 3 Demonstrate an understanding of aircraft electrical systems. Practical activities The candidate will be able to: 1 Identify, operate and maintain aircraft electrical system components 2 Connect and operate test equipment 3 Read and interpret instruments 4 Remove and refit system components Underpinning knowledge The candidate will be able to: 1 Describe the need for and the requirements of aircraft power supply systems 2 Describe the need for and purpose of the components within an aircraft electrical primary and secondary power supply system 3 Describe the purpose and typical location of aircraft electrical distribution panels 4 Describe the types, purpose, and classification of aircraft busbars 5 Describe the purpose and principle of operation of circuit breakers and fuses 6 Describe the purpose and principle of operation of manually and automatically operated switches 7 Describe the purpose, function and application of terminal blocks used within aircraft electrical circuits 8 Identify aircraft lamps and state the safety precautions to be observed when working with these components 9 Describe the need, purpose and function of an aircraft Visual and Audio warning system 10 Describe the purpose and describe the operation of a representative aircraft internal and external lighting system 11 Describe the safety precautions and hazards to be observed when operating aircraft internal and external lighting systems 12 Describe and state, the purpose and principle of aircraft Primary and Secondary bonding 13 Describe the procedure and method to be followed when maintaining aircraft earth points and bonding systems 14 Describe the need and procedure for insulation testing on aircraft wiring assemblies 15 Describe the purpose and principle of operation of Airborne Auxiliary Power Units (AAPU)


16 Describe the component parts, describe the function of and explain in basic terms the operation of the following aircraft turbine engine systems a) Aircraft Turbine Engine Starting Systems b) Aircraft Turbine Engine Ignition Systems 17 Describe the purpose and explain the principle of operation of a representative engine control system 18 Describe the purpose and principle of operation of, the following secondary power supply systems

a) Static Inverter. b) Transformer Rectifier Unit

19 Describe the purpose and explain the basic principle of operation of a representative single generator system 20 Describe the purpose and explain the principle of operation of the following electrical systems a) multi generator/starter generator system b) non-paralleling a.c. generator system c) paralleling a.c. generator system 21 Describe the purpose and explain the principle of operation of a.c. generator drive systems

Unit 20 Avionics manufacturing principles Rationale This unit is concerned with the understanding of avionics manufacturing principles and their application in the aircraft and workshop environment. There are two outcomes to this unit. The candidate will be able to: 1 Demonstrate an understanding of general principles for aircraft avionics functions 2 Undertake installation practices and procedures on avionics and electrical hardware



Outcome 1 Demonstrate an understanding of general principles for aircraft avionics functions Practical activities The candidate will be able to: 1 Carry out a simulated emergency procedure in relation to


2 Select correct tools when working in a workshop/hangar environment 3 Select correct drawings to use with appropriate workshop tasks and identify relevant title block and other information from the drawings 4 Use microfilm, microfiche or computerised information when carrying out appropriate manufacturing tasks

Underpinning knowledge The candidate will be able to: 1 State the appropriate safety procedures necessary when working with electricity, high-pressure gases (especially oxygen), oils and chemicals 2 State the remedial action to be taken in the event of a fire or other accident with electricity, high-pressure gases (especially oxygen), oils and chemicals 3 Identify the correct tools for carrying out practical workshop tasks 4 State the procedures necessary to control the use of tools and workshop materials 5 Describe the procedures used to calibrate tools and to ensure tools are maintained to a satisfactory standard 6 Describe the common hand tools used on aircraft and in the workshop 7 Identify the basic drawing types and diagrams, their symbols dimensions, tolerances and projections 8 Identify and describe the purpose of the title block registration 9 Recognise, name and state the function of

a) microfilm b) microfiche c) computerised presentation




c) Wiring diagrams and other schematic diagrams 11 Describe the correct procedures to be followed and the associated safety precautions necessary when


12 Describe the effects of environmental conditions on aircraft handling and operation 13 State the inspection techniques used and describe the types of defects to be found when carrying out inspection of aircraft and associated equipment 14 Describe typical correct and safe disassembly and re-assembly techniques 15 State where to find information on, and describe how to carry out an inspection after the following abnormal events

a) lightning strike and HIRF penetration b) heavy landings c) flight through turbulence

16 Explain why modifications may be necessary and describe the procedures for carrying out modifications 17 Describe the layout of a typical aircraft store and the procedures to ensure safe storage of aircraft parts and materials 18 Describe the basic operation of the Inspection/Quality Control/Quality Assurance department of an aircraft manufacturing facility 19 Explain the need for control of life-limited components associated with aircraft


Outcome 2 Undertake installation practices and procedures on avionics and electrical hardware Practical activities The candidate will be able to: 1 Carry out preparation of aircraft cables for electrical termination 2 Carry out soldering and de-soldering of prepared cables to electrical terminals 3 Carry out crimping of electrical contacts and terminations to cables and conductors 4 Carry out dismantling, assembly, connection and disconnection of modern representative electrical connectors 5 Manufacture and repair cable assemblies 6 Use Avionics General Test Equipment safely and in accordance with the instructions for use

Underpinning knowledge The candidate will be able to: 1 Describe the safety precautions to be followed when working on, or in the vicinity of aircraft electrical power supplies 2 Identify and describe the types of cable, their construction and application 3 Describe the need for the correct husbandry of aircraft wiring and Fibre - Optic (FO) cable and explain how this is achieved 4 Describe methods of cable protection and support 5 Describe the procedure for aircraft wiring installation examination 6 Describe the handling precautions to be observed when working with aircraft electrical wiring and assemblies 7 Identify the correct tools for carrying out practical workshop tasks 8 Describe the limitations applicable to and governing the use of Precision Termination Tools (PTT) 9 Identify and state the need and purpose of test equipment (TE), installation, calibration and its associated documentation 10 Describe the purpose of single function meters 11 Describe the purpose of and safety precautions to be observed when using a digital or analogue multi-meter 12 Describe the purpose of and safety precautions to be observed when using an insulation and line continuity tester 13 Describe the need for bonding of the aircraft structure and techniques used

14 Identify typical bonding resistance values of the aircraft structure


Stock Code: SP-03-2661