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					                        2011 Maintenance Skills Competition
                                Criteria Handbook

General Rules

The AMTSociety Maintenance Skills Competition gives teams of licensed AMTs, AMEs, students enrolled in
FAA, EASA, CASA or equivalently authorized schools as well as personnel of any country's Armed Forces
involved in the aircraft maintenance field the opportunity to test their combined abilities against those of their
peers. This competition will help enable the constant upgrading of the standards by which today's skilled
AMT/AMEs hold themselves to. The second purpose is to showcase the knowledge, skill and integrity that
each and every AMT/AME, both current and future, possesses. Showcasing these cornerstones of the
AMT/AME craft and profession will help raise awareness of the training and skill needed for today's
AMT/AME to carry the great responsibility of providing safe, airworthy aircraft.

Who Can Enter: To enter the AMTSociety Maintenance Skills Competition as a member of a team, you
must be a licensed AMT or AME involved in, and/or supporting aircraft maintenance functions at any
organization, company or corporation. Also, any currently enrolled student in an FAA, EASA, CASA or
equivalently authorized schools may enter. Personnel of any country's Armed Forces involved in the aircraft
maintenance field are also eligible.

Team Costs: $500 USD per team, also each member of the team must be a current AMTSociety member.
Not a current member? Join at www.amtsociety.org. Pricing varies.

Liability Release Form: Each team member will be required to sign a general release of liability form in
order to participate in the competition. New this year, forms will not be collected in advance; forms will be
available on-site in the Registration Lobby.

How to Register: NEW - Registration can be completed online at www.cygnusaviationexpo.com, click on
the Register Today button, and then on the Click Here to Register copy, select Maintenance Skills
Competition to begin your registration.

It is important to include an email address for each person; this is how you will receive your registration
confirmation which also includes information on how to book your special MSC discounted hotel rate and
other important MSC updates.

Teams: Each team must select one main person to register every team member, guests, and other company
representatives involved with MSC. ALL registrations must be completed at the same time, you cannot go
back and add other registrants later. If you do not know all registrants, use a “dummy” name as a place
holder, you can change names at anytime. To change a name you will need the registration confirmation email
which includes the following: the link to the website for changes/updates, the badge number and email
address.

The main person will complete his/her registration information; select add another registrant on Step 5 and
some of the information will be pre-populated into the next person’s registration.

The main person should have the following information available when registering team members, guests,
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and other company representatives: individual names, job title, email address, contact phone number,
AMTSociety member number (team members only), and any other contact information that would be
different from the first registration. The main person will need to choose the relationship of the registrant to
the MSC, example, team member, captain, coach, guest, company representative, etc.

Judges: Follow directions above. Select Judge as your MSC Member Type.

Guests: Each MSC member/judge is allowed 1 guest. All guests should be registered at the same time as the
team/judge using the above directions. Select Guest as your MSC Member Type.

Registration and payment must be completed by February 5, 2011.

If you have questions regarding the registration process, please call 800-827-8009.

If you have any questions regarding the 2011 Maintenance Skills Competition, please contact
AMTSociety Director and Maintenance Skills Competition Chairman, Kenneth MacTiernan at
jetdr@san.rr.com.



Team Competition
The AMTSociety Maintenance Skills Competition will consist of 12 planned events for the Team
Competition.

Each Team will be given different events to complete at each stage of the competition. Team Members will
compete at assigned events. The Coach, if applicable, may offer advice to any Team Member during any
event at all stages of the competition, but he/she may not assist physically. Each Team Captain will inform
the MSC Committee as to which Team Member will compete in which event no less than 20 minutes prior
to the start of the MSC. Each event will be given a specific time frame to be completed in. At the end of the
time frame given, the Team Member is to stop and put down any tool or test equipment. If a Team Member
finishes his/her event before the allotted time, he/she may assist any other Team Member still performing
their event.

Each event will have at least one judge. Each event will be scored upon total time used to complete the event
plus any discrepancies assessed in the form of time penalties. The combined times from all 12 planned events
will determine a team’s final score.

There are five team categories to be competed in: Commercial, General Aviation, Schools, Military and
MRO/OEM. The team with the lowest total time will be declared the winner for their category. The top
three teams in each category will receive a plaque and the team with the lowest overall time will be awarded
the William F. O’Brien Award of Excellence in Aircraft Maintenance.

The AMTSociety’s Maintenance Skills Competition Committee reserves the right to remove any Team
Member(s) competing in the Maintenance Skills Competition for behavior and/or actions not promoting the
craft and profession of today’s skilled, professional AMT.

The AMTSociety’s Maintenance Skills Competition Committee reserves the right to alter the structure of the
Maintenance Skills Competition but not before informing all Team Member participants of such changes.

An orientation meeting will take place with all Team Member participants who enter the proper entry forms
prior to the start of the Maintenance Skills Competition. This meeting will enable all participants to ask any
questions directly to the judges of the respective events making up the Maintenance Skills Competition, as
well as ask questions to the Maintenance Skills Competition Committee Members. The orientation meeting
will be held at 1:00 pm on February 22, 2011 at the Las Vegas Convention Center, Central Hall C3 in

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AMTSociety’s IA Renewal Theatre. This meeting is mandatory for all participating AMT/AMEs.

Events
The AMTSociety Maintenance Skills Team Competition events will consist of the following events:

Charles E. Taylor Exam

This written test consists of 20 questions relating to Charles E. Taylor’s life. All questions are multiple choice.
All answers can be found in the autobiography on Taylor titled: “Charles E. Taylor 1868 – 1956 The Wright
Brothers Mechanician” written by Howard R. DuFour with Peter J. Unitt. This book can be purchased
through Wright State University. Visit http://www.libraries.wright.edu/special/services/store/. A total of 20
minutes will be given to complete this event. Each wrong answer will be assessed a 6 minute penalty. The
AMTA will provide a judge for this event.

NOTE: If there are problems accessing the Wright State University Book Store to purchase this book call
937-775-2092 and ask for the Director of Library Administration and Computing for assistance in buying this
book.

Safety Wiring Event

This event will test each participant’s skill and speed while accomplishing a series of safety wire patterns.
Scores will be based upon the time it takes to complete as many of the patterns given, as well as the quality
and safety of the work performed, such as but not limited to tautness of the safety wire, closeness and
tightness of the pigtail to the securing hardware, and negative safety. (Reference FAR 43.13) The only tools
which will be allowed and provided for this event are safety wire pliers, wire cutters, needle nose/duck bill
pliers, and 32/1000 safety wire. A total of 20 minutes will be given to complete this event. Embry-Riddle
Aeronautical University is scheduled to provide a judge for this event.


Regulatory and Maintenance Technical Publication Research Event

This event will test each team's skill and speed in locating and correctly interpreting regulatory and
maintenance information used in a typical inspection and return to service. AMTs will be given a series of
questions to research and answer using ATP NavigatorV(R) software and digital libraries. A total of 20
minutes will be given to complete this event. ATP will provide the judge for this event.

Electrical Troubleshooting Event

This event will test each Technician's ability to troubleshoot a given simple circuit. Each Technician will have
4 individual squawks induced into the circuit. The task will be to troubleshoot each problem using a multi-
meter and establish the likely cause. Once one squawk has been found, the Technician will write down the
probable cause and signal the judge to move onto the next squawk. That squawk will be reset and a new
problem induced by the judge. Once all squawks have been found, the Technician must signal that they are
finished. A total of 20 minutes will be given to complete this event. DUNCAN AVIATION will provide the
judge for this event.

Avionic Troubleshooting Event

This event will test each team’s ability to troubleshoot aircraft component faults on a computer based format.
The AMT will be given an aircraft system’s wire diagram and given a particular discrepancy. The AMT will
then determine what the fault is and “replace” the suspect component. For each component “replaced” a
dollar value will be given for that part. The goal of this event is to display the skills needed to repair a given

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“squawk” with as little cost as possible in finding the damaged component. There will be anywhere from 14
to 20 different discrepancies to accomplish. Total time used and total dollar value of parts used to repair the
system will be used for the judging criteria. This event will be given 20 minutes to complete. CAE will
provide the judge for this event.

Advanced Composite Materials Repair Event

This event will test each participant's skill and speed in identifying composite ancillary materials. Technicians
will be given a composite flight control surface (rudder) with simulated damage repaired and a pre-cured
repair patch to simulate bonding and constructing a vacuum bag, using the materials provided. Technicians
will document their results/findings and determine the proper ancillary materials stacking sequence.
Centering of the patch, vacuum bagging the repair and time utilized during the event. Equipment provided
for this event are composite sandwich panel, pre-cured patch, adhesive comb, assorted items that should not
be incorporated into a vacuum bag, vacuum bagging film, porous release film, non-porous release film, heat
blanket, caul plate, three thermal couples, vacuum bagging tape (tacky tape), vacuum valve, vacuum hose,
vacuum gauge, vacuum pump, plastic masking material, felt tip marking pen, breather material and bleeder
material. FRCSW will provide the judge for this event. A total of 20 minutes will be given to complete this
event.

Rigid Line Troubleshooting Event

This event will test each Technician's ability to troubleshoot defects to rigid tubing lines and determine which
two lines have leaks. The Technician will remove the lines and fabricate new lines as per sample with the
materials provided. The Technician will then replace and leak check the lines. All lines will be made from
6061-T4 .025 od. X .035 wall with AN818-4D sleeves. Scores will be based upon the total time it takes to
complete the event, quality and safety of the work performed, such as but not limited to quality of bends and
degree of flares. (Ref. NAVAIR 01-1A-20, T.O. 42E1-1-1). All materials and equipment will be provided.
Each Team's Coach may participate in this event. Ten minutes will be assessed for each penalty. A total of 20
minutes will be given to complete this event. The USAF will provide a judge for this event.

Flight Control Rigging Event

This event will test each team's ability to rig a cable system for a flight control surface to the proper surface
position in reference to a wing surface. The example to be used for this event will be similar to a B737-300
aileron system. The AMT will be given a mock-up of an aileron system with reference materials. Items to be
judged for, but not limited to are: safe tying of turn-buckles with safety pins and safety wire, use of rig pins
and correct control cable tension. There will also be control cable inspection for potential defects such as, but
not limited to wear, corrosion and kinks. A work sheet will be provided for documentation of required data
for the rig, rig tension, control surface position, size and type of cable (stainless or steel), plus other required
items for the rig such as identifying cable damage and if damage is within limits. Maintenance Manual
references will be provided. A total of 20 minutes will be given to complete this event. AMT Society will
provide a judge for this event.

Event #1: Cable Damage Identification

1. Determine serviceability of cables 1 – 5 using AMM 20-20-31.
2. Using provided form note if cable is serviceable or unserviceable and why.
       Cable is 1/8” 7 X 19 tinned Mil Spec W-83420 Type 1 Comp A TZ
       Use Caution when examining cables, they may have damage!
       Inspection of the control cable wire rope:
3. Perform a detailed visual inspection of the cable runs for incorrect routing, kinks in the wire rope, or
   other damage.
       (a) Replace the cable assembly if:


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                 1) The individual wires in a strand appear to blend together (outer wires worn 40 to 50
                     percent) (Fig. 601).
                 2) If a kink is found.
                 3) If corrosion is found.
4.   Perform a detailed visual inspection of the cable. To do a check for broken wires, rub a cloth along the
     cable. The cloth will identify broken wires by catching on them.
        (a) Replace the 7 X 7 cable assembly if:
                 1) There is two or more broken wires in 12 continuous inches of cable.
                 2) There is three or more broken wires anywhere in the total cable assembly.
        (b) Replace the 7 X 19 cable assembly if:
                 1) There is four or more broken wires in 12 continuous inches of cable.
                 2) There is six or more broken wires anywhere in the total cable assembly.

Event #2: Cable Rigging Event

TURNOVER: All damaged cables are replaced and routed properly and Part Numbers verified.

 1. Continue cable installation from step 5. D. Ref. AMM 27-10-605.
 2. Safety one turn barrel using pin method and one turn barrel using safety wire Ref. MM (Alternate
    method). {Brass safety wire will be used in place of stainless steel.}
 3. Adjust aileron using MM.
 4. “Do Not Operate” tags must be attached to control wheel during maintenance action, and removed
    after completion. (3 minutes added if not performed.)

                         ======================================

Current temperature is 70 degrees Fahrenheit.
Aircraft has been in a climate controlled hangar for 12 hours.
Aircraft should be ready for test flight when you are finished.
After successful rigging all flight tests pass.
All steps should be followed; missing steps will have time penalties.
Inspection required at steps noted in AMM – Cable Adjustment steps 11., 12. and 13. / Aileron Adjustment
steps 8., 9. and 10.
Perform tool inventory upon completion, shadow board style.
Aileron Cable Replacement AMM 27-10-605 (Ref. Figure 101)

1. Install “DO NOT OPERAE” tag on control column.
2. Center Aileron Control wheel.
3. Install rig pins R-1 and R-2.
4. Install cable blocks to isolate cable to be replaced.
5. Replace cable.

        A. Remove required pulleys.
        B. Remove cable.
        C. Route new cable as required.
        D. Connect cables with turnbuckle.

6. Remove cable blocks.
7. Remove rig pins R-1 and R-2.
8. Tension cable to 2 times rig load. (Ref. table 501)
NOTE: !!! Not required if using pre-stretched cable.!!!
9. Rig per AMM 27-10-108

Special tools required: Provided by AMT Society.

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Rig pins R-1 and R-2
Trammel bar T-56
6 inch scale
0 – 10 lb. push pull scale
Tensiometer 0 – 200 lb.
Cable blocks
Basic hand tools
.032 safety wire
Turnbuckle safety clips


Aircraft Power Distribution Troubleshooting

General Information
1. You will be required to identify faults in a General Aviation Power Distribution System and a Multi-
   Engine Power Distribution System within a specified time limit. Examples of the schematics are
   provided; however, the details of the schematics are subject to change.
2. The power distribution systems are generic in nature and include features found on several different types
   of aircraft.
3. Each fault will be described via a “pilot write up”. Contestants should perform an operational check of
   the system to verify each fault.
4. Notify the event judge when you have identified the fault and a new write up will be provided. Nida
   Corporation will provide the judge for this event.
5. Multimeters will be provided; however, personal multimeters are authorized for use during the event.

General Aviation Power Distribution System Description
1. This circuit emulates a single engine GA aircraft.
2. The ACU (regulator) can be assumed “Good” if proper system power or wire continuity is correct at the
    ACU connector.
3. LED’s are used to indicate power to an aircraft system. Under normal operating conditions, LED’s on
    the instrument panel indicate that the engine is running, alternator power is detected, and the avionics
    bus has been selected.
4. The engine must be running (Engine On light illuminated) for the alternator to be providing an output.
5. The ground power plug must be connected to the GND PWR RECEP for external power to be applied
    to the system.
6. The BAT/ALT MASTER switch on the instrument panel provides 24 VDC through relay K002 to the
    Main Bus when placed in the “ON” position. This switch also provides 24 VDC to the ACU for power
    and field voltage.
7. When the ENG RUN SW is place in the “ON” position, the alternator provides power to the Main Bus.
    The POWER DETECT LIGHT will illuminate when the alternator is providing power to the main bus.
    The alternator output is sensed by the ACU for regulation. The alternator field is regulated from by the
    ACU via fuse F3 to the alternator.
8. The NAV LTS and PITOT HEAT LED’s indicate main bus power to those systems.
9. The avionics bus is powered by the main bus when the AVI SW is placed in the “ON” position. The
    AVI ON light will indicate power to the avionics bus.
10. All relays and switches are shown in their powered-off condition.


General Aviation Power Distribution System Operation
1. Normal Operation – Battery Power
   • BAT/ALT MASTER switch “ON”
   • #1 and #2 Batteries (in series) provide 24 VDC to the Main Bus and ACU
2. Normal Operation – Alternator Power
   • BAT/ALT MASTER switch “ON”
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    • Nav light and Pitot Heat LED’s illuminate
    • Engine Run switch “ON”. Ensure ENG RUN light is illuminated
    • Power Detect light will be on when engine reaches operating RPM and alternator voltage exceeds
      battery voltage.
   • AVI switch “ON”. Nav/Com 1 and Transponder LED’s illuminate
3. Normal Operation – Ground Power
   • Connect the GND PWR Plug to the GND PWR RECEP
   • BAT/ALT MASTER switch “ON”
   • Nav light and Pitot Heat LED’s illuminate
   • AVI switch “ON”. Nav/Com 1 and Transponder LED’s illuminate

Multi-engine Power Distribution System Description
1. The circuit emulates a split-bus/auto transfer system with APU and emergency generators.
2. All measurements will be taken at the generator, relay, battery and TR test points, or at the busses.
3. The external power plug must be connected for external power to be applied to the system.
4. In addition to power at the bus, an LED for each bus will indicate the bus’s condition. These LED’s are
   not shown on the schematic.
5. With external power connected, the emergency power system can be tested using the GND TEST
   switch on the instrument panel.
6. All relays and switches are shown in their powered-off condition.
7. WARNING: The Bus Tie switches should never be connected simultaneously with both #1 and #2
   generators on.

Multi-engine Power Distribution System Operation
1. Normal Operation – DC Power
   • #1 and #2 DC Hot Bus powered
   • #1 and #2 Batteries “ON”. Ensure #1 and #2 Battery lights are on
   • DC Ess Bus powered
   • Note: Shed OVRD switch will recover DC non-essential bus
2. Normal Operation – AC Power
   • #1 and #2 Batteries “ON”. Ensure #1 and #2 Battery lights are on
   • #1 and #2 Generators “ON”. Ensure #1 and #2 GEN lights are on
   • #1 Generator powers the #1 AC Bus, #1 AC Ess Bus, #1 AC Non Ess Bus, #1 TR
   • #2 Generator powers the #2 AC Bus, #2 AC Ess Bus, #2 AC Non Ess Bus
   • #1 TR powers the DC Ess Bus and the DC Non Ess Bus
   • Non Ess Busses are powered as long as both the #1 and #2 generators are operating
3. Auto-Transfer Operation - #1 Generator fail.
   • K1 and K6 de-energized
   • #1 and #2 AC Non Ess and DC Non Ess Busses de-energized through NO K1 and K6 relay
       contacts
   • #1 GEN light OFF, #2 GEN light ON
   • #2 Generator powers the #2 AC Bus, #1 and #2 AC Ess Busses
   • #2 Generator powers the #2 TR through the NC contacts of K1. #2 TR powers DC Ess Bus
4. Auto-Transfer Operation - #2 Generator fail.
   • K2 and K7 de-energized
   • #1 and #2 AC Non Ess and DC Non Ess Busses de-energized through NO K2 and K7 relay
       contacts
   • #1 GEN light ON, #2 GEN light OFF
   • #1 Generator powers the #1 AC Bus, #1 and #2 AC Ess Busses, #1 TR
   • #1 TR power the DC Ess Bus
5. Power Recovery of a #1 Failed Generator Using the APU.
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     • #1 Generator switch “OFF”. Ensure #1 GEN light is out.
     • APU switch “ON”. Ensure APU light is on.
     • #1 Bus Tie switch “CONN”.
     • APU generator powers #1 AC Bus, #1 AC Ess Bus
     • #2 Generator powers #2 AC Bus, #2 AC Ess Bus, #2 TR. #2 TR powers DC Ess Bus
     • #1 and #2 AC systems isolated by open contacts of energized K4 and K7 and de-energized K5
     • Note: Shed OVRD switch will recover non-essential busses if required
6.   Power Recovery of a #2 Failed Generator Using the APU.
     • #2 Generator switch “OFF”. Ensure #2 GEN light is out.
     • APU switch “ON”. Ensure APU light is on.
     • #2 Bus Tie switch “CONN”.
     • APU generator powers #2 AC Bus, #2 AC Ess Bus
     • #1 Generator powers #1 AC Bus, #1 AC Ess Bus, #1 TR. #1 TR powers DC Ess Bus
     • #1 and #2 AC systems isolated by open contacts of energized K5 and K6 and de-energized K4
     • Note: Shed OVRD switch will recover non-essential busses if required
7.   APU Ground or Two Engine Out Power.
     • #1 and #2 Batteries “ON”. Ensure #1 and #2 Battery lights are on
     • #1 and #2 Generator switches “OFF”. Ensure #1 and #2 GEN lights are out.
     • APU switch “ON”. Ensure APU light is on.
     • #1 and #2 Bus Tie switch “CONN”.
     • APU generator powers #1 and #2 AC Bus, #1 and #2 AC Ess Bus, #2 TR.
     • #2 TR powers DC Ess Bus.
     • Note: Shed OVRD switch will recover non-essential busses if required
8.   External Power.
     • #1 and #2 Batteries “ON”. Ensure #1 and #2 Battery lights are on
     • #1 and #2 Generator switches “OFF”. Ensure #1 and #2 GEN lights are out.
     • Connect External Power plug. Check that the EXT PWR READY light is on.
     • EXT PWR switch “ON”. EXT PWR READY light goes out, EXT PWR light comes on.
     • #1 and #2 Bus Tie switch “CONN”.
     • External Power provides power to #1 and #2 AC Bus, #1 and #2 AC Ess Bus, #2 TR.
     • #2 TR powers DC Ess Bus.
     • Note: Shed OVRD switch will recover non-essential busses if required
9.   Emergency Generator Power Ground Test.
     • WARNING: Ensure ALL AC power is removed from the system prior to conducting this test.
     • #1 and #2 Generator switches “OFF”. Ensure #1 and #2 GEN lights are out.
     • APU Generator “OFF”. Ensure APU light is out.
     • Bus Tie switches “OFF”
     • Connect the External Power plug. Check that the EXT PWR READY light is on.
     • EXT PWR switch “ON”. EXT PWR READY light goes out, EXT PWR light comes on.
     • Emergency Generator GND TEST switch “ON”.
     • Check for 115 VAC at TP .
     • Emergency Generator provides power to #1 and #2 Ess Bus, Emergency TR.
     • Emergency TR powers DC Ess Bus.
     • Note: The Shed OVRD should not be activated when emergency power is used.


Hydraulic Test Stand
This event will use a training simulator, model number MF101-TSE which is designed and built by The Fluid
Power Training Institute. This event will be divided into six categories.

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    1.   Safety
    2.   Hydraulic schematic reading.
    3.   Hydraulic circuit building from a schematic.
    4.   Hydraulic pump adjustment – flow and pressure.
    5.   Written test – fundamental principles and laws.
    6.   Diagnostic skills.

Criteria:
    1. Safety: AMTs will be judged on their safety practices throughout the competition. This will include
          proper selection and use of personal safety equipment, proper and safe use of diagnostic equipment
          and safe work practices. (Pertaining to working on and around hydraulic systems.)

    2. Hydraulic schematic reading: AMTs will be required to read and understand ISO hydraulic symbols.
       The AMT will, using a hydraulic schematic, construct a working hydraulic system on a hydraulic
       training simulator.
       NOTE: Teams can purchase a ISO symbols, self-learning course from the FPTI training center at a
       discounted price of 40%. We also have an accelerated DVD learning course, which is highly
       animated. A student can learn hydraulic symbols in about two hours with the DVD. The list price,
       with the above referenced text book, is $149.95 less 40%. The title is "How to Interpret Fluid Power
       Symbols." Part number is HC-R015. List price $49.95 plus S & H. The manuals will be on hand
       should they be needed. Contact Rory McLaren at forory@fpti.org or at (801) 908-5456 for further
       information.
    3. Hydraulic system construction/circuit building: The AMT will, using a hydraulic schematic and a
       hydraulic training simulator, construct a hydraulic system safely and accurately.
    4. Flow and pressure settings: The AMT will be required to, using diagnostic instrumentation, make all
       necessary pressure and flow settings as outlined in the system specifications safely and accurately.
       The settings include pump settings (flow and pressure), and pressure control valve settings and flow
       settings.
    5. Written test: AMTs will be required to accurately answer 25 questions about fundamental laws and
       principles of hydraulics.
    6. Diagnostic skills: The AMT will solve two problems based on a given set of symptoms. The
       problems will be actual and not hypothetical. The simulators being used are designed to automatically
       fault to a given situation. The AMT will be judged on their ability to:
            A. Obtain all necessary information about the problem from the machine operator i.e. history,
                 duration, noise, variation from normal operation with regard to operating parameters, etc.
            B. Use the symptom to determine the type of failure, which has most likely occurred i.e.
                 degradation, intermittent, obstruction or catastrophic.
            C. Using the symptom correctly assign the potential problem to a given component(s).
            D. Safely, accurately and efficiently systematically test (using the correct test procedure) suspect
                 component(s) until defective component(s) is located.


Southwest Airlines APU Event

This event will consist of a GTCP85-129 Auxillary Power Unit (APU) and the burner can and fuel control
will be removed and replaced. The APU burner can and surrounding area should be inspected for defects and
if any are noted identified to the judge. Twenty minutes will be given to accomplish this event and Southwest
Airlines will provide the judges.

49-31-11_Installation.pdf
49-31-11_Removal.pdf
49-31-42_Installation.pdf
49-31-42_Removal.pdf

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GTCP 85-129 APU on stand                   Detail of safety wiring of burner can clamp




Burner can removed                          Looking into the plenum / combustion torus area
                                           for inspection once burner can is removed.




Fuel control installed on gearbox of APU




                                           Fuel control removed


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Gearbox once fuel control is removed


FedEx Engine Event

FedEx PDU Install
FedEx PDU Removal


JT9D MAINTENANCE PROCEDURE FOR INSTALLATION OF
THRUST REVERSER PDU

A. Procedure
       See Figure 401.
       (1)     Position PDU (1) on brackets, align flexible duct with PDU and install bolts (2) and (5) in
               upper forward and lower aft brackets (if necessary tap bolts with soft faced mallet).
       (2)     Install bolts (8) and (11), washers (9) and (1), and nut (10) in upper aft and lower forward
               brackets and torque nut to 170-190 lb-in (verify with judge of torque values before torque is
               applied).
       (3)     Install washers (3) and (6) and nuts (4) and (7) on bolts in upper forward and lower aft
               brackets and torque nuts to 170-190 lb-in (verify with judge of torque values before torque is
               applied).
       (4)     Align flexible duct and PDU. Install coupling (15) and flexible duct on PDU and torque
               coupling to value marked on coupling (verify with judge of torque values before torque is
               applied).
       (5)     Connect electrical connector DS304 to PDU (1) finger-tight plus one-eighth turn.
       (6)     Install flexible shaft on PDU with screws (13) and washers (14). Torque screws to 20-25 lb-
               in (verify with judge of torque values before torque is applied) and install lockwire.
       (7)     Connect hose to reducer on PDU and torque coupling to 100-110 lb-in (verify with judge of
               torque values before torque is applied).
       (8)     Connect hose (17) to forward union on PDU and torque coupling to 140-150 lb-in (verify
               with judge of torque values before torque is applied).
       (9)     Connect hose (18) to aft union and torque coupling to 190-200 lb-in (verify with judge of
               torque values before torque is applied).
       (10)    Place all tools on table and clean work area.
       (11)    Announce completion of work task to judge.




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JT9D MAINTENANCE PROCEDURE FOR REMOVAL OF
THRUST REVERSER PDU

A. General
       (1) This procedure provides removal information necessary for removal of pneumatic drive unit
                (PDU).
B. Procedure
       See Figure 301.
       (1) Disconnect electrical connector DS304 from PDU.
       (2) Remove lockwire, screws, and washers attaching flexible drive shaft to PDU and remove shaft.
       (3) Disconnect hoses from PDU.
       (4) Remove coupling connecting flexible ducting to PDU.
       (5) Remove bolts, nuts, and washers attaching PDU to brackets.
       (6) Remove PDU from fan case and place on table.
       (7) Inform judge that unions and o-rings have been swapped and that PDU has inspected and
                approved for installation.
       (8) Apply lubricant to threads of all 3 union fittings on PDU.




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Description: General Release Form Competition document sample