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Total Training Support's Integrated Training System. We are sure you will
need no other reference material to pass your EASA Part-66 exam in this Module.
These notes have been written by instructors of EASA Part-66 courses,
specifically for practitioners of varying experience within the aircraft
maintenance industry, and especially those who are self-studying to pass the
EASA Part-66 exams.
They are specifically designed to meet the EASA Part-66 syllabus and to answer
the questions being asked by the UK CAA in their examinations.
The EASA Part-66 syllabus for each sub-section is printed at the beginning of
each of the chapters in these course notes and is used as the “Learning
Objectives”.
We
suggest that you take each chapter in-turn, read the text of the chapter a
couple of times, if only to familiarise yourself with the location of the
information contained within. Then, using your club66pro.co.uk
membership, attempt the questions within the respective sub-section, and
continually refer back to these notes to read-up on the underpinning knowledge
required to answer the respective question, and any similar question that you
may encounter on your real Part-66 examination. Studying this way, with the help
of the question practice and their explanations, you will be able to master the
subject piece-by-piece, and become proficient in the subject matter, as well as
proficient in answering the CAA style EASA part-66 multiple choice questions.
The course
notes are written to suit Licence category 'B1' and 'B2', but are also suitable
for Licence category 'A'.
Special note to students of Modules 6 and 7: The syllabus for these two
modules has some sections which are very close in content. Indeed, the CAA
exams include questions in Module 6 which would be more strictly suited to
Module 7, and vice versa. To avoid duplication, these course notes stick rigidly
to the syllabus. Therefore, if you will be sitting the CAA exam, we strongly
recommend that you study both modules simultaneously, and take both exams on the
same sitting. A
Module 6 and 7
course notes package is available at a discounted price.
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membership (Module 7) voucher. This allows you unlimited EASA Part-66 question
practice and feedback within the membership period.
The
Tutorial Support service allows you to ask any question you wish, regarding
any of the multiple-choice questions on the question practice website, or about
any subject within these course notes that you may need additional assistance
with. A Subject Specialist will respond to your query within hours
- often within minutes.
With the
Tutorial Support service, you are also provided with links to additional
online source material for full explanations to most of the multiple-choice
questions, thus giving you access to an unrivalled and fully Integrated
Training System.
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ready to start practicing questions. The offer is not redeemable for cash, and
is not transferable. Keyaccount members can have 1-month extension on their
keyaccount membership, or additional respective module opened, whichever is
preferred.
CONTENTS
Module 7.1 - Safety Precautions-Aircraft and
Workshop
- Safety Precautions - General
- Material Safety Data Sheets
- Container Labelling
- Fire Regulations
- First Aid
- Electricity
- High-Pressure Gases
- Aviation Oils and Fuels
- Chemical and Physiological Hazards
- General Flight-Line Safety
- Weather Radar
Module 7.2 - Workshop Practices
- Care of Tools
- Control of Tools
- Use of Workshop Materials
- Tool Calibration
- Standards of Workmanship
- Dimensions, Allowances, Tolerances
Module 7.3 Tools
Common Hand Tools
- Engineer’s Rule
- Scriber
- Key-Seat Rule
- Fitter’s Square
- Combination Set
- Surface Plates
- Angle Plates
- Marking-Out Tables
- V-Blocks
- Surface Gauge (Scribing Block)
- Spring Dividers
- Callipers
- Trammels
- Hammers
- Punches
- Metal-Cutting Chisels
- Vices
- Hacksaws
- Hacksaws
- Sheet Metal Shears and Snips
- Files
- Hand Brace (Hand Drill)
- Twist Drills
- Stop and Press (Dimpling), Countersinking Tools
- Reamers
- Internal Screw Thread Cutting Taps
- External Screw Thread Cutting Dies
- Screwdrivers
- Pliers
- Wire Snips (Nippers)
- Scrapers
- Spanners, Sockets and Wrenches
- Sockets
- Impact Driver
- Torque Wrenches
Common Power Tools
- Electrically Powered Pillar Drills
- Electrically Powered Hand Drills
- Pneumatically Powered Hand Drills
- Pneumatically Powered Riveting Guns
- Pneumatic Miller (Microshaver)
- Nibblers
- Power Saws
- Abrasive Wheels
Precision Measuring Instruments
- External Micrometers
- Internal Micrometers
- Micrometer Depth Gauge
- Vernier Callipers
- Vernier Height Gauge
- Vernier Protractor
- Miscellaneous Measuring Tools
- Dial Test Indicator (DTI)
- Feeler Gauges
- Screw Pitch and Radius Gauges
- Go/No-Go Gauges
- Straight Edges
Lubrication Equipment and Methods
- Lubrication Methods
- Lubrication Equipment
Electrical General Test Equipment
- The Moving Coil Meter
- Meter Ratings and Terms
- Ammeters, Milliammeters and Micro-ammeters
- Ohmmeter
- Potentiometer-Type Ohmmeter
- Shunt-Type Ohmmeter
- Megohmmeter
- Multimeters
- Electrodynamometer Wattmeter
- Electrodynamometer Voltmeters and Ammeters
- Electrical Troubleshooting
Module 7.4 - Avionic General Test Equipment
- Pitot-Static Leak Testing
- Insulation Testing
- Bonding Testing
- Bonding Testing
- Resistance Values
Module 7.5 Engineering Drawings, Diagrams and
Standards
- The Purpose of the Drawing
- The Authority of the Drawing
- Types of Drawing
- Methods of Drawing Solid Objects
- Pictorial Projections
- Orthographic Projections
- Sectional Views
- Exploded Views
- Drawing Lines, Symbols and Abbreviations
- Dimensioning
- Machining and Surface Finish
- Abbreviations and Symbols
- Validation of Modification/Repair Drawings
- Auxiliary Diagrams and Charts
Microfilm, Microfiche and Computerised
Presentations
- Microfilm
- Microfiche
- Computer CD-ROM
- Supplementary Information
Air Transport Association Specification - ATA
No. 100
Common Aeronautical and Other Standards
- International Organisation for Standardisation
(ISO)
- British Standards (BS)
- Military Standard (MS)
- Air Force and Navy (AN)
- National Aerospace Standard (NAS)
Module 7.6 - Fits and Clearances
Dimensions, Allowances and Tolerances
- Interchangeability
- Dimensions
- Allowances
- Tolerances
Drill Sizes for Holes
Classes and Standards of Fits and Clearances
- Classes of Fit
- Standards of Fits and Clearances
- Newall System
- British Standards BS 4500 System
Ovality, Bow and Twist
- Schedule of Fits and Clearances
- Limits for Wear
- Limits for Ovality
- Limits for Bow
- Limits for Twist
Module 7.7 - Electrical Cables and Connectors
Continuity and Insulation Testing
- Continuity Testing
- Insulation Testing
- Bonding Testing
Use of Crimping Tools
- PIDG Thin Wall Wire Terminals
- Sealed In-Line Crimping
- BICC/Burndy
- Daniels Crimping Tools
- Heavy Duty Terminals
- Hellermann Deutsch Terminals & Splices
- ERMA and AMP Terminals
Testing of Crimped Joints
- Tensile Test
- Voltage Drop Test
Connector Pin Removal and Insertion
- Types of Removal/Insertion Tool
- Plastic Tools
- Tweezer type insert/extract tools
- Soldering
Coaxial Cables
- Description
- Coaxial Stripping Procedures
- Coaxial Cable Testing
Wiring Protection Techniques
- Made Up Cabling
- Installation of Electrical Wiring
- Cable clamps
- Conduit (Metallic and PVC)
- Interference
- Protection of Cabling
- Support of Cabling
- Spiral Binding
- Tywraps
- Cable Conduits (Superflexit)
- Heat Shrink Tubing
- Heat Shrinkable Sleeves
- Cable Performance
- Cable Construction
- Dielectric Materials/Cable Types
- Cable Failures
Module 7.8 - Riveting
Solid Riveting
- Introduction
- Solid Rivet Dimensions and Head Types
- Countersinking
- Solid Riveting Tools
- Solid Riveting Procedure (Snap Head)
- Solid Riveting Procedure (Reaction)
- Formed Rivet Dimensions
- Rivet Faults
- Removal of Rivets
- Riveted Joints
Blind and Special Fasteners
- Tucker Pop Rivets
- Avdel Rivets
- Chobert Rivets
- Hi-Shear Fasteners
- Jo-Bolts
- Hi-Lok Fasteners
- Cherry-Max Rivet
- Imex Rivets
- Cherrylock Rivets
- Huck Blind Rivets
- Huckbolts
Module 7.9 - Pipes and Hoses
Bending and Flaring Aircraft Pipes
- Pipe Bending
- Pipe Flaring
- Inspection and Testing of Pipes and Hoses
Inspection Points
- Bore Testing of Pipes
- Hydraulic Pressure Testing of Pipes
- Pneumatic and Oxygen Pressure Testing of Pipes
- Testing Flexible Hoses
Installation and Clamping of Pipes
- Pipe Supports
- Connection of Pipes
- Maintenance of Pipes and Hoses
- Pipe Identification Labels
Module 7.10 – Springs
- Inspection and Testing of Springs
Module 7.11 - Bearings
Handling and Cleaning of Bearings
- Handling
- Cleaning
- Removal, Lubrication and Fitting
- Effects of Bad Maintenance Practice or Adverse
Working Conditions
Bearing Lubrication Requirements
- Lubricant Selection
- Grease Considerations
- Oil Considerations
- Solid Soft Film Lubricants.
Inspection of Bearings
- Safety Precautions
- Points for inspection
- Feel Test
- Run Test
- Bearing Defects
Storage
Module 7.12 - Transmissions
- Gears
- Belts and Pulleys
- Chains and Sprockets
- Screw Jacks
- Levers
- Push-Pull Rod Systems
Module 7.13 – Control Cables
- Swaging of End Fittings
- Swaging Procedure
- Swaged Splices
Handling, Inspection and Testing of Control
Cables and Associated Hardware
- Handling of Cable
- Cutting Cable
- Corrosion of Cables
- Cable Wear
- Checking the Tension of Installed Cables
- Inspection of Control Cable Pulleys
- Fairleads
- Turnbuckles
Bowden and Teleflex Cable Systems
- Bowden Cable Systems
- Teleflex Cable Systems
Module 7.14 – Material Handling
Sheet Metal
- Marking Out
- Cutting and Bending of Sheet Metal Parts
- Making Layouts
- Relief Holes
- Inspection of Sheet Metal Work
Composites
- Types of Composites
- Fabrication Techniques for Composites
- Trimming and Drilling of Composites
- Composite Inspection
Module 7.15 – Welding, Brazing, Soldering and
Bonding
Welding
- Methods of Welding
- Oxy-Acetylene Welding
- Manual Metal Arc Welding
- Metal Inert Gas Welding (MIG)
- Tungsten Inert Gas Welding (TIG)
- Flash Butt Welding
- Resistance Spot Welding
- Resistance Seam Welding
- Inspection and Testing of Welds
Soldering
- Methods of Soldering
- Hard Soldering (Brazing and Silver Soldering)
- Soft Soldering
- Using Indirectly Heated (Electric) Soldering
Irons
- Active and Passive Fluxes
- Inspection and Testing of Soldered Joints
Bonding
- The Mechanics of Bonding
- Stresses on a Bonded Joint
- Procedure for Bonding
Module 7.16 – Aircraft Weight and Balance
- Definitions
- Mass and Balance Requirements
- Mass and Balance Documentation
- Frequency of Weighing
- Fleet Mass and CG Position
- Weighing Requirements
- Centre of Gravity Limits (CG Envelope)
- Records
- Calculation of Mass and CG of any System
- Principles of Weight and Balance of Aircraft
- Calculation of Mass and CG of Aircraft
- Aircraft Weighing Methods
- Preparation for Weighing
- Weighing on Aircraft Jacks
- Calculation of Aircraft’s CG
- CG as Percentage Standard Mean Chord (SMC)
- Changes in Basic Weight
- Load Sheet
- Effects of Incorrect Loading
Module 7.17 – Aircraft Handling and Storage
- Aircraft Towing and Taxiing
- Aircraft Jacking, Chocking, Hoisting and
Securing
- Aircraft Storage
- Refuelling / Defuelling Procedures
- De-icing / Anticing Procedures
- Aircraft Ground Servicing Equipment
- Effects of Environmental Conditions on Handling
Module 7.18 – Disassembly, Inspection, Repair and
Assembly Techniques
- Types of Defect
- Visual Inspections
- Corrosion Removal, Assessment and Reprotection
- General Repair Methods
- Non-Destructive Inspection (NDI) Techniques
- Direct Visual Inspections
- Borescopes
- Penetrant Flaw Detection (PFD)
- Eddy Current Flaw Detection (ECFD)
- Magnetic Particle Flaw Detection (MPFD)
- Radiographic Flaw Detection (RFD)
- Disassembly and Re-assembly Techniques
- Trouble Shooting Techniques
Module 7.19 – Abnormal Events
Types of Abnormal Occurrences
Inspections Following Lightning and High
Intensity Radiated Fields (HIRF)
- Lightning Strike
- High Intensity Radiated Fields (HIRF)
Penetration
Inspections After Heavy Landings and Flight
Through Turbulence
- Heavy or Overweight Landing
- Flight through Severe Turbulence
Module 7.20 – Maintenance Procedures
Maintenance Planning
- Owner’s and Operator’s Responsibilities
(Aircraft and Helicopters not exceeding 2730 kgs).
- Large Aircraft and Commercial Air Transport
- Reliability Programmes
Modification Procedures
- Major Modifications
- Minor Modifications
- EASA Modification Regulations
Stores Procedures
- The Approved Stores
- Stores Procedures
- Component Release
- The Acceptance of New Aircraft Components
- Certification / Release Procedures
- Components and Parts (EASA Form 1)
- Certification of Maintenance
- Certification and Release Procedures (Light
Aircraft)
- The Role of the Licensed Aircraft Maintenance
Engineer
- Interface With Aircraft Operation
- JAR OPS
- Technical Log and Log Books
- Production Planning
Maintenance Inspection / Quality Control and
Assurance
- Definitions
- EASA 145 Quality System
Additional Maintenance Procedures
- Part-145 - Approval of Maintenance
Organisations
- Part M – Continued Airworthiness
- Control of Life-Limited Components
All notes provided by Total Training Support come with the following
feedback service:
If you
encounter any question either within the respective module on the club66
professional website (www.club66pro.co.uk)
or in your actual Part-66 exam, which cannot be answered anywhere within these
notes, please email us the question. One of our subject specialists will review
the question, and if necessary, add an additional explanation into these notes.
We will email you back the answer they provide.