Aerospace Maintenance Council - Event Manual · 2020. 4. 5. · The AMC provides an opportunity for current and future maintenance professionals to showcase their abilities and see

Event Manual

The Aerospace Maintenance Council, a non-profit organization, promotes and supports the aerospace maintenance community. The council’s flagstone event, the Aerospace Maintenance Competition (AMC), recognizes and celebrates the aviation maintenance technician, and raises awareness of the knowledge and skill required to maintain safe, airworthy aircraft, worldwide. The competition is held annually in conjunction with Aviation Week’s MRO Americas.

The event, originally scheduled for April 28-30, was postponed amidst the coronavirus pandemic. The event is rescheduled for Sept. 1-4, 2020 in conjunction with Aviation Week Network’s MRO Americas at—

Kay Bailey Hutchison Convention Center 650 S. Griffin St., Dallas, Texas

The purpose of this manual is to provide participants information about the competition and its competitive events. It will be revised periodically while events are added and modified, please check back often to ensure you’re referencing the most current version.

Send comments and suggested revisions to [email protected].

http://mroamericas.aviationweek.com/am18/Public/Enter.aspx

http://www.dallasconventioncenter.com/

mailto:[email protected]

Aerospace Maintenance Competition Event Manual

Page 2 of 82

This document is the property of the Aerospace Maintenance Council, it may not be reproduced without express written consent. Uncontrolled printed versions of this document are for reference only, users are responsible for verifying its currency against the master electronic version available on the AMC website.

Revision Number: 03

Original Issue Date: 12/20/2019

Revision Date: 04/06/2020

Table of Contents

About............................................................................................................................................................. 4

MRO Americas .............................................................................................................................................. 4

Hotel Accommodation .................................................................................................................................. 4

Floor Access .................................................................................................................................................. 4

Registration Hours ........................................................................................................................................ 5

Exhibit Hall Hours .......................................................................................................................................... 5

Schedule of Events ........................................................................................................................................ 5

Competition Rules ......................................................................................................................................... 5

Use of Alternates .......................................................................................................................................... 6

Scoring........................................................................................................................................................... 7

Sponsor and Event Setup .............................................................................................................................. 7

Shipping Information .................................................................................................................................... 8

Competition Layout ...................................................................................................................................... 9

Competitor Orientation ................................................................................................................................ 9

Teams .......................................................................................................................................................... 10

Events .......................................................................................................................................................... 14

Event Schedule ............................................................................................................................................ 14

#1 UPS Safety Wiring ............................................................................................................................... 17

#2 Abaris Training Composite Repair ...................................................................................................... 19

#3 Federal Aviation Administration Human Factors Exam ..................................................................... 21

#4 Alaska Airlines External Power Receptacle Event .............................................................................. 22

#5 Nida Corporation Power Troubleshooting ......................................................................................... 24

#6 U.S. Air Force Flex Fluid Lines ............................................................................................................. 26

#7 Eastern Florida State Space Vehicle - Vacuum Loading Operation .................................................... 30

#8 ULTRAX Aerospace Condition-Based Intelligence (CBITM) .................................................................. 35

#9 JetBlue University ADS-B Troubleshooting ........................................................................................ 36

#10 NBAA & Dallas Airmotive Honeywell TFE731-2 Engine Fan Blade Removal .................................. 37

#11 Daniels Manufacturing Corporation Electrical Troubleshooting ................................................... 39

#12 Daniels Manufacturing Corporation Safe-T-Cable ......................................................................... 41

http://www.aerospacecompetition.com/


Page 3 of 82


Revision Number: 03



#13 FedEx Express Turbine Engine PDU Removal and Installation....................................................... 43

#14 Perfect Point E-Drill Fastener Removal .......................................................................................... 45

#15 Barfield Air Data Testing ................................................................................................................ 47

#16 AAR Non-Destructive Testing—CANCELLED .................................................................................. 48

#17 Barfield Rf Antenna Testing ........................................................................................................... 49

#18 8Tree and Alaska Airlines Airframe Damage Inspection ................................................................ 50

#19 American Airlines Pedestal ............................................................................................................ 51

#20 PPG Transparencies, Paint and Wing Sealant ................................................................................ 52

#21 W.L. Gore & Associates, Inc. Leading Edge & Panel Sealing .......................................................... 54

#22 American Airlines APU Burner Can ................................................................................................ 57

#23 United Fuel Tank Entry Precautions............................................................................................... 59

#24 Michelin Aircraft Tires Inspection .................................................................................................. 60

#25 Click Bond Adhesive-Bonded Fastener Installations ...................................................................... 62

#26 Boeing Cable Rigging ...................................................................................................................... 64

#27 (A) Pratt & Whitney PW1100G-JM Engine ACC Valve R/R ............................................................. 67

#27 (B) Pratt & Whitney V2500 HPC 7th Stage Bleed Valve Solenoid Test ........................................... 74

Record of Revisions ..................................................................................................................................... 80



Page 4 of 82


Revision Number: 03



About

The AMC provides an opportunity for current and future maintenance professionals to showcase their abilities and see how they stack up against peers across the country and the world. Five-member teams compete in maintenance events intended to test skill and knowledge required of an aviation maintenance technician. Teams may enter one of the following categories:

• Commercial Aviation • General Aviation • Space • Education • Military • MRO/OEM

The competition is managed by the Aerospace Maintenance Council’s AMC committee. It is supported through the generous contributions of the aerospace community. Sponsors host events, provide prizes, and make monetary contributions.

MRO Americas

The competition is held on the exhibit floor of MRO Americas, an annual gathering of aviation maintenance professionals that incorporates informative conference sessions and a showcase of new and innovative products, technologies, offerings and services. More information about the location and logistics can be found on that event’s website.

The AMC will take place at MRO Americas Booth Number 8000. The exhibit hall layout is available at https://exhibitor.mroamericas.aviationweek.com/am20/Public/eventmap.aspx?shavailable=1&shexhlist=1.

Hotel Accommodation

Aviation Week has reserved room blocks at a discounted rate for all MRO Americas participants. Reserve accommodation at https://mroamericas.aviationweek.com/en/plan-your-visit/hotel.html.

Floor Access

To access the competition area, all AMC competitors, instructors/coaches, sponsors, visitors and volunteers must register for a floor pass at https://na.eventscloud.com/ereg/index.php?eventid=537604&categoryid=3665410.

If completed in advance, registration is free. Individuals must be 16 years and older to register.

Only AMC competitors, instructors/coaches, sponsors, and volunteers will have early access to the show floor. AMC visitors and guests will only have access when the show floor is open to the public.


http://mroamericas.aviationweek.com/am18/Public/Enter.aspx

https://exhibitor.mroamericas.aviationweek.com/am20/Public/eventmap.aspx?shavailable=1&shexhlist=1

https://exhibitor.mroamericas.aviationweek.com/am20/Public/eventmap.aspx?shavailable=1&shexhlist=1

https://mroamericas.aviationweek.com/en/plan-your-visit/hotel.html

https://na.eventscloud.com/ereg/index.php?eventid=537604&categoryid=3665410


Page 5 of 82


Revision Number: 03



Registration Hours

Badges may be picked up on site at the MRO Americas Registration Area. Participants are highly encouraged to pick up badges on Monday or Tuesday to avoid line delays the day of the competition.

• Monday, August 31 — 8:00 am - 5:00 pm • Tuesday, September 1 — 7:30 am - 5:30 pm • Wednesday, September 2 — 7:30 am - 6:30 pm • Thursday, September 3 — 8:00 am - 4:00 pm

Exhibit Hall Hours

• Wednesday, September 2 — 9:30 am- 6:30 pm • Thursday, September 3 — 9:00 am - 4:00 pm

Schedule of Events

Tuesday, September 1

• 8:00 AM – 2:30 PM: American Airlines and Pratt & Whitney Tours (students and military only), register here

• 8:00 AM – 5:00 PM: Registration (badge collection) for MRO Americas (all participants/visitors must register in advance)

• 8:00 AM – 12:00 PM: Event Setup (sponsors and judges only), Expo floor, (see competition layout) • 2:00 PM – 3:00 PM: Judge Briefing (judges only) • 3:00 PM – 4:30 PM: Competitor Orientation (competitors, coaches and judges only)

Wednesday, September 2 (doors open for competitors at 8:00 AM)

• 8:00 AM - 8:30 AM: Event Setup (judges only, please no competitors) • 8:30 AM – 9:30 AM: Competitor Walk-Through, Expo floor • 9:30 AM – 5:30 PM: Competition, Expo floor

Thursday, September 3 (doors open for competitors at 8:00 AM)

• 9:00 AM – 5:30 PM: Competition, Expo floor

Friday, September 4 (Expo floor open to the public 9:30 AM - 1:00 PM)

• 9:00 AM – 12:00 PM: Award Ceremony (open to the public)

Competition Rules

1) Each team consists of five team members. 2) Each team is allowed, but not required, to designate alternate(s) in the event a competitor is not

able to participate the day of the competition. Alternates may not compete until approved by the chairman.


https://www.aerospacecompetition.com/tour.html

https://na.eventscloud.com/ereg/index.php?eventid=537604&categoryid=3665410


Page 6 of 82


Revision Number: 03



3) Competitors must be either certificated by a national aviation authority (e.g., hold an FAA mechanic certificate), enrolled in a certificated aviation maintenance technician school, employed by a certificated repair station or manufacturing facility, or a member of the armed forces.

4) School category teams may be comprised of a combination of— a) Currently-enrolled students; b) Individuals that graduated the institution in the six months previous to the competition that are

not currently employed by an aviation-related company; and/or c) Individuals that are currently employed by an aviation-related company but were enrolled at the

school as of April 1, 2020. 5) Each team member must sign a release of liability form to participate. Hard copies will be provided

for signature at orientation. 6) Teams have 15 minutes to complete their assigned competitive event. All teams compete in all

events. 7) Each event has a designated number of team member(s) required to complete the task. For events

that require less than five team members, the team will assign member(s) of their choice to compete.

8) There is a five-minute break between the end of one event and the beginning of the next event. Competitors present in the five minutes preceding the event start time may review task cards, materials, or prepare for the event, as permitted by the event judge. Time will not be credited for competitors arriving after the designated start time.

9) Scores are calculated based on the standard score sheet. 10) Event sponsors provide judges for each event. Judges may stop the clock to remedy problems or

answer a question at their discretion. 11) Scores provided verbally at the completion of an event are not official until properly recorded. 12) Score grievances may be brought to the sergeant at arms during the competition and up to one half

hour after its conclusion. The AMC chairman reserves the right to modify final scores up until the awards ceremony.

13) The three teams with the lowest score in each category will be recognized at the awards ceremony. The team with the lowest score across all categories will be awarded the William F. “Bill” O’Brien Award for Excellence in Aircraft Maintenance.

14) The AMC chairman reserves the right to remove any team member(s) from the competition for, but not limited to, unprofessional behavior, cheating, etc.

15) The AMC committee reserves the right to alter events and/or rules prior to or during the competition and will make best efforts to notify all team members of the change.

16) Participants are expected to observe personal protection equipment requirements throughout the competition. Failure to observe safety practices will result in penalties.

17) All required tooling and protection equipment are provided by event sponsors. Personal tools are not allowed.

Use of Alternates

Each team will consist of five team members. Each team is allowed, but not required, to designate alternate(s) in the event a member is not able to compete the day of the competition.


https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amc-releaseofliability-2020.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amc-scoresheet-2020304.pdf


Page 7 of 82


Revision Number: 03



The five competing team members will receive identifying wristbands at orientation and are expected to wear them at all times during the competition. In the event a team member is not able to compete during the event, the alternate must obtain a wristband from the AMC chairman before taking the place of a competing member.

Goodie bags provided at orientation for competing team members only. Only five bags per team will be distributed. Materials contained in goodie bags may be offered to alternates upon availability.

Scoring

Judges will utilize the standard AMC score sheet to calculate team scores for each event. Event scores are calculated by adding the total amount of time expended to complete the event, plus penalties assessed and bonus points awarded. Standard penalties are assessed for—

• Failure to follow procedures • Improper use of tools • Unprofessionalism • Failure to properly store tools and/or equipment • Improper use of safety equipment • Incomplete or incorrect recordkeeping • Other, and provided for by the specific event or at the judge’s discretion

Any additional penalties and optional bonus opportunities specific to a particular event are detailed in that event’s criteria.

Sponsor and Event Setup

Sponsors will setup event and exhibit tables on Tuesday, September 1 from 8:00 AM to noon.

Event breakdown will take place when the exhibit floor closes, Thursday, September 3 from 5:00 PM to 10:00 PM and Friday, September 4 from 7:00 AM to 6:00 PM.

All event spaces with electric needs will be pre-set with a 120V 5 Amp (500w) Single Outlet, two standard six-foot tables and two chairs. Sponsors are responsible for costs associated with any additional freight or facility needs (i.e., furniture, wireless internet, carpet, etc.). Contact [email protected] to coordinate these additional requirements.

Information regarding shipments and exhibit hall access is in the MRO Americas Exhibitor Manual available at https://mroamericas.aviationweek.com/en/exhibitor-resources1/exhibitor-resources2020.html.


https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amc-scoresheet-2020304.pdf


https://mroamericas.aviationweek.com/en/exhibitor-resources1/exhibitor-resources2020.html

https://mroamericas.aviationweek.com/en/exhibitor-resources1/exhibitor-resources2020.html


Page 8 of 82


Revision Number: 03



Shipping Information

You have two options for shipping your event and tabletop materials — either to the warehouse or directly to show site.

1. Warehouse Shipping Address (for materials arriving between July 31 and August 25):

Aerospace Maintenance Competition / Booth #8000-[Enter Event/Sponsor Table Number] MRO AMERICAS 2020 C/O Freeman 5130 Cash Rd. Dallas, TX 75247 T: (214) 634-1463

Freeman will accept crated, boxed or skidded material beginning Friday, July 31, 2020 at the above address. Material arriving after Tuesday, August 25, 2020 will be received at the warehouse with an additional after deadline charge. Please note that the Freeman Warehouse does not accept uncrated freight (loose, pad-wrapped material and/or unskidded machinery), COD shipments, hazardous materials, freight requiring refrigerated or frozen storage, a single piece of freight weighing more than 5,000 pounds or a single piece of freight beyond the dimensions of 108” H x 93” W. Warehouse materials are accepted at the warehouse Monday through Friday between the hours of 8:00 AM - 3:30 PM. Certified weight tickets must accompany all shipments. If required, provide your carrier with this phone number: (214) 634-1463.

2. Show Site Shipping Address (for materials arriving after August 30 at 12:00 PM):

Aerospace Maintenance Competition / Booth #8000-[Enter Event/Sponsor Table Number] MRO AMERICAS 2020 Kay Bailey Hutchison Convention Center C/O Freeman 650 South Griffin Dallas, TX 75202 T: (214) 634-1463

Freeman will receive shipments at the exhibit facility beginning at 12:00 PM on Sunday, August 30, 2020. Shipments arriving before this date may be refused by the facility. Any charges incurred for early freight accepted by the facility will be the responsibility of the exhibitor. Certified weight tickets must accompany all shipments. If required, provide your carrier with this phone number: (214) 634-1463.

Shipping Labels

To ensure proper delivery, shipments should identify the AMC Booth #8000, and the AMC-designated event or sponsor number (for example, 8000-01, 8000-02, etc.), as provided for in this manual.



Page 9 of 82


Revision Number: 03



Competition Layout

Team and Sponsor Recognition

Sponsor and team logos will be displayed on event signage and in the event program. Signage will be created and displayed at the AMC committee’s discretion. Event sponsors and those in the exhibit areas may bring company-branded table skirts and any floor and/or table signage that will fit within their designated space. Banners or flags that require hanging or rigging are prohibited.

Competitor Orientation

Orientation takes place the day before the competition begins, Tuesday September 1 at 3:00 PM, and is mandatory for all team members and judges. Guests are not permitted.

One hour before the competition begins on Wednesday, September 2, competitors will have the opportunity to walk around the competition floor to get a close-up look at each event and ask further questions. If practical and as time allows, that event’s judge may offer tutorials to ensure all competitors understand the event criteria and requirements.



Page 10 of 82


Revision Number: 03



Teams

The AMC is able to accommodate 90 teams. Spots are available on a first come, first served basis.

Each team is assigned a team number that will be used as an identifier on the team schedule and to facilitate scoring. The following team rosters, provided in numerical order by team number, and alphabetically by team name, include all teams confirmed as of the revision date of this manual.

Team Roster (Numerical)

No. Team Name Category 1 Aviation Institute of Maintenance - Fremont School 2 Marine Helicopter Squadron One HMX - Nightriders Military 3 Australian Licenced Aircraft Engineers Association MRO/OEM 4 United States Army National Guard - CTARNG Military 5 Del Mar College School 6 United States Air Force - McChord Military 7 Pratt & Whitney - WiseMen MRO/OEM 8 United States Air Force - Tinker AFB Military 9 Spokane Community College Aviation Club School

10 United Airlines - Chix Fix Commercial 11 Pratt & Whitney - WiseWomen MRO/OEM 12 Embry-Riddle University - Team 2 School 13 United States Air Force - 86 MXG Ramstein AB Military 14 Qatar Airways Commercial 15 American Airlines - TUL MRO/OEM 16 United States Marine Corp - MAG 16 Military 17 Airbus – Team 1 MRO/OEM 18 Embry-Riddle University - Team 1 School 19 Tarrant County College - Team 1 School 20 Mohawk Valley Community College School 21 Royal Canadian Air Force - 12 Wing Military 22 Horizon Air Commercial 23 Pittsburgh Institute of Aeronautics - Myrtle Beach School 24 United States Coast Guard - Air Station Miami Military 25 Aviation High School School 26 WSU Tech School 27 American Airlines - DWH MRO/OEM 28 Spirit Airlines Commercial 29 Airbus – Team 2 MRO/OEM 30 United States Air Force - WR-ALC 562nd AMXS Military 31 Pittsburgh Institute of Aeronautics - Pittsburgh School 32 United States Air Force - 58 AMXS Military 33 WestJet Airlines Team 1 Commercial 34 United States Air Force Reserves - 446 Aircraft Maintenance Squadron Military 35 Western Michigan University School



Page 11 of 82


Revision Number: 03



No. Team Name Category 36 United Airlines - East Team Commercial 37 United States Air Force - 1 SOMXG - Team 2 Military 38 Alaska Airlines - ANC Commercial 39 Broward College - Team 2 School 40 Indian Hills Community College School 41 WestJet Airlines Team 2 Commercial 42 United Airlines - Base Maintenance MRO/OEM 43 OPEN 44 OPEN 45 Alaska Airlines - SEA Commercial 46 Pittsburgh Institute of Aeronautics - Youngstown School 47 United States Coast Guard - Air Station Clearwater Military 48 American Airlines - MOC Commercial 49 United States Air Force - 309 AMXG/EDMX Military 50 Tulsa Tech - Team 2 School 51 United States Army - 128th Aviation Brigade Military 52 Alitalia - Team 2 Commercial 53 Royal Canadian Air Force - Air Mobility Group Military 54 Liberty University School 55 American Airlines - All Female Commercial 56 Boeing MRO/OEM 57 Eastern Florida State College School 58 Royal Canadian Air Force - 3 Wing Bagotville Military 59 Canadian Forces School of Aerospace Technology and Engineering Military 60 Alitalia - Team 1 Commercial 61 Royal Canadian Air Force - CP 140 Long Range Patrol Team Military 62 JetBlue Commercial 63 West Los Angeles College- Flying Wildcats School 64 Salt Lake Community College School 65 Middle Tennessee State University School 66 United States Coast Guard - C-27J APO Military 67 OPEN 68 Utah State University School 69 Royal Canadian Air Force - 1 Wing Military 70 The Technical School of Aircraft Maintenance School 71 Lewis University School 72 Qantas Commercial 73 UPS Commercial 74 Broward College - Team 1 School 75 Royal Canadian Air Force - SAR Aircraft Maintenance Military 76 Portland Community College School 77 United States Air Force - McConnell 22 MXG/931 MXG Military



Page 12 of 82


Revision Number: 03



No. Team Name Category 78 United Airlines - West Team Commercial 79 United States Air Force - 1 SOMXG - Team 1 Military 80 Vaughn College of Aeronautics and Technology School 81 American Airlines - DFW Commercial 82 United States Air Force - OKC Air Logistics Complex Military 83 Republic Airline Commercial 84 United States Air Force - Edwards AFB/412 Maintenance Group Military 85 TulsaTech - Team 1 School 86 Flybe MRO/OEM 87 FedEx Express - LAX MRO/OEM 88 HAECO Americas MRO/OEM 89 Pittsburgh Institute of Aeronautics - Hagerstown School 90 FedEx Express - INDY Commercial

Team Roster (Alphabetically)

No. Team Name Category 17 Airbus – Team 1 MRO/OEM 29 Airbus – Team 2 MRO/OEM 38 Alaska Airlines - ANC Commercial 45 Alaska Airlines - SEA Commercial 60 Alitalia - Team 1 Commercial 52 Alitalia - Team 2 Commercial 55 American Airlines - All Female Commercial 81 American Airlines - DFW Commercial 27 American Airlines - DWH MRO/OEM 48 American Airlines - MOC Commercial 15 American Airlines - TUL MRO/OEM

3 Australian Licenced Aircraft Engineers Association MRO/OEM 25 Aviation High School School

1 Aviation Institute of Maintenance - Fremont School 44 OPEN 56 Boeing MRO/OEM 74 Broward College - Team 1 School 39 Broward College - Team 2 School 59 Canadian Forces School of Aerospace Technology and Engineering Military

5 Del Mar College School 57 Eastern Florida State College School 18 Embry-Riddle University - Team 1 School 12 Embry-Riddle University - Team 2 School 90 FedEx Express - INDY Commercial 87 FedEx Express - LAX MRO/OEM 86 Flybe MRO/OEM



Page 13 of 82


Revision Number: 03



No. Team Name Category 88 HAECO Americas MRO/OEM 43 OPEN 22 Horizon Air Commercial 40 Indian Hills Community College School 62 JetBlue Commercial 67 OPEN 71 Lewis University School 54 Liberty University School

2 Marine Helicopter Squadron One HMX - Nightriders Military 65 Middle Tennessee State University School 20 Mohawk Valley Community College School 89 Pittsburgh Institute of Aeronautics - Hagerstown School 23 Pittsburgh Institute of Aeronautics - Myrtle Beach School 31 Pittsburgh Institute of Aeronautics - Pittsburgh School 46 Pittsburgh Institute of Aeronautics - Youngstown School 76 Portland Community College School

7 Pratt & Whitney - WiseMen MRO/OEM 11 Pratt & Whitney - WiseWomen MRO/OEM 72 Qantas Commercial 14 Qatar Airways Commercial 83 Republic Airline Commercial 69 Royal Canadian Air Force - 1 Wing Military 21 Royal Canadian Air Force - 12 Wing Military 58 Royal Canadian Air Force - 3 Wing Bagotville Military 53 Royal Canadian Air Force - Air Mobility Group Military 61 Royal Canadian Air Force - CP 140 Long Range Patrol Team Military 75 Royal Canadian Air Force - SAR Aircraft Maintenance Military 64 Salt Lake Community College School 28 Spirit Airlines Commercial

9 Spokane Community College Aviation Club School 19 Tarrant County College - Team 1 School 70 The Technical School of Aircraft Maintenance School 50 Tulsa Tech - Team 2 School 85 TulsaTech - Team 1 School 42 United Airlines - Base Maintenance MRO/OEM 10 United Airlines - Chix Fix Commercial 36 United Airlines - East Team Commercial 78 United Airlines - West Team Commercial 79 United States Air Force - 1 SOMXG - Team 1 Military 37 United States Air Force - 1 SOMXG - Team 2 Military 49 United States Air Force - 309 AMXG/EDMX Military 32 United States Air Force - 58 AMXS Military



Page 14 of 82


Revision Number: 03



No. Team Name Category 13 United States Air Force - 86 MXG Ramstein AB Military 84 United States Air Force - Edwards AFB/412 Maintenance Group Military

6 United States Air Force - McChord Military 77 United States Air Force - McConnell 22 MXG/931 MXG Military 82 United States Air Force - OKC Air Logistics Complex Military

8 United States Air Force - Tinker AFB Military 30 United States Air Force - WR-ALC 562nd AMXS Military 34 United States Air Force Reserves - 446 Aircraft Maintenance Squadron Military 51 United States Army - 128th Aviation Brigade Military

4 United States Army National Guard - CTARNG Military 47 United States Coast Guard - Air Station Clearwater Military 24 United States Coast Guard - Air Station Miami Military 66 United States Coast Guard - C-27J APO Military 16 United States Marine Corp - MAG 16 Military 73 UPS Commercial 68 Utah State University School 80 Vaughn College of Aeronautics and Technology School 63 West Los Angeles College - Flying Wildcats School 35 Western Michigan University School 33 WestJet Airlines Team 1 Commercial 41 WestJet Airlines Team 2 Commercial 26 WSU Tech School

Events

Teams are responsible for assigning individual competitors to each event. The number of competitors required to complete each event is provided in the event criteria. Description, instructions, and judging criteria for each event are provided in subsequent pages of this manual. Competitors may contact judges directly with questions on a specific event.

Event Schedule

The competition consists of 15-minute stages. Each team is responsible for assigning the number of individual competitors required for each event, as provided for in the event criteria.

The event schedule provides the start and end time for each stage, and the team numbers assigned to each event for each stage.

PLEASE NOTE: WHILE IN PREVIOUS YEARS, JUDGES HAD START TIME DISCRETION, THIS YEAR’S SCHEDULE WILL NOT ALLOW FOR ANY DELAYED STARTS. EVENT STAGES WILL BEGIN PROMPTLY AT THE DESIGNATED START TIME, AND END AT THE DESIGNATED END TIME. TEAMS ARRIVING LATE WILL NOT RECEIVE DISPENSATION.



Page 15 of 82


Revision Number: 03



Wednesday, September 2, 2020 NOTE: Numbers within the table indicate team number

Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6 Stage 7 Stage 8 Stage 9 Start Time 9:30 AM 9:50 AM 10:10 AM 10:30 AM 10:50 AM 11:10 AM 11:30 AM 11:50 AM 12:10 PM 12:25 PM End Time 9:45 AM 10:05 AM 10:25 AM 10:45 AM 11:05 AM 11:25 AM 11:45 AM 12:05 PM 12:25 PM 1:00 PM Events 1, 2 & 3 1 & 46 12 & 57 23 & 68 34 & 79 45 & 90 11 & 56 22 & 67 33 & 78 44 & 89

LUN

CH B

REAK

Events 4, 5 & 12 2 & 47 13 & 58 24 & 69 35 & 80 1 & 46 12 & 57 23 & 68 34 & 79 45 & 90 Events 6, 7 & 14 3 & 48 14 & 59 25 & 70 36 & 81 2 & 47 13 & 58 24 & 69 35 & 80 1 & 46 Events 8, 9 & 19 4 & 49 15 & 60 26 & 71 37 & 82 3 & 48 14 & 59 25 & 70 36 & 81 2 & 47 Events 10, 11 & 24 5 & 50 16 & 61 27 & 72 38 & 83 4 & 49 15 & 60 26 & 71 37 & 82 3 & 48 Events 13 & 15 6 & 51 17 & 62 28 & 73 39 & 84 5 & 50 16 & 61 27 & 72 38 & 83 4 & 49 Events 16 & 21 7 & 52 18 & 63 29 & 74 40 & 85 6 & 51 17 & 62 28 & 73 39 & 84 5 & 50 Event 20 8 & 53 19 & 64 30 & 75 41 & 86 7 & 52 18 & 63 29 & 74 40 & 85 6 & 51 Events 17 & 18 9 & 54 20 & 65 31 & 76 42 & 87 8 & 53 19 & 64 30 & 75 41 & 86 7 & 52 Events 22 & 23 10 & 55 21 & 66 32 & 77 43 & 88 9 & 54 20 & 65 31 & 76 42 & 87 8 & 53 Events 25, 26 & 27 11 & 56 22 & 67 33 & 78 44 & 89 10 & 55 21 & 66 32 & 77 43 & 88 9 & 54

Stage 10 Stage 11 Stage 12 Stage 13 Stage 14 Stage 15 Stage 16 Stage 17 Stage 18 Stage 19 Stage 20 Stage 21 Stage 22 Start Time 1:00 PM 1:20 PM 1:40 PM 2:00 PM 2:20 PM 2:40 PM 3:00 PM 3:20 PM 3:40 PM 4:00 PM 4:20 PM 4:40 PM 5:00 PM

End Time 1:15 PM 1:35 PM 1:55 PM 2:15 PM 2:35 PM 2:55 PM 3:15 PM 3:35 PM 3:55 PM 4:15 PM 4:35 PM 4:55 PM 5:15 PM Events 1, 2 & 3 10 & 55 21 & 66 32 & 77 43 & 88 9 & 54 20 & 65 31 & 76 42 & 87 8 & 53 19 & 64 30 & 75 41 & 86 7 & 52 Events 4, 5 & 12 11 & 56 22 & 67 33 & 78 44 & 89 10 & 55 21 & 66 32 & 77 43 & 88 9 & 54 20 & 65 31 & 76 42 & 87 8 & 53 Events 6, 7 & 14 12 & 57 23 & 68 34 & 79 45 & 90 11 & 56 22 & 67 33 & 78 44 & 89 10 & 55 21 & 66 32 & 77 43 & 88 9 & 54 Events 8, 9 & 19 13 & 58 24 & 69 35 & 80 1 & 46 12 & 57 23 & 68 34 & 79 45 & 90 11 & 56 22 & 67 33 & 78 44 & 89 10 & 55 Events 10, 11 & 24 14 & 59 25 & 70 36 & 81 2 & 47 13 & 58 24 & 69 35 & 80 1 & 46 12 & 57 23 & 68 34 & 79 45 & 90 11 & 56 Events 13 & 15 15 & 60 26 & 71 37 & 82 3 & 48 14 & 59 25 & 70 36 & 81 2 & 47 13 & 58 24 & 69 35 & 80 1 & 46 12 & 57 Events 16 & 21 16 & 61 27 & 72 38 & 83 4 & 49 15 & 60 26 & 71 37 & 82 3 & 48 14 & 59 25 & 70 36 & 81 2 & 47 13 & 58 Event 20 17 & 62 28 & 73 39 & 84 5 & 50 16 & 61 27 & 72 38 & 83 4 & 49 15 & 60 26 & 71 37 & 82 3 & 48 14 & 59 Events 17 & 18 18 & 63 29 & 74 40 & 85 6 & 51 17 & 62 28 & 73 39 & 84 5 & 50 16 & 61 27 & 72 38 & 83 4 & 49 15 & 60 Events 22 & 23 19 & 64 30 & 75 41 & 86 7 & 52 18 & 63 29 & 74 40 & 85 6 & 51 17 & 62 28 & 73 39 & 84 5 & 50 16 & 61 Events 25, 26 & 27 20 & 65 31 & 76 42 & 87 8 & 53 19 & 64 30 & 75 41 & 86 7 & 52 18 & 63 29 & 74 40 & 85 6 & 51 17 & 62



Page 16 of 82


Revision Number: 03



Thursday, September 3, 2020 NOTE: Numbers within the table indicate team number

Stage 23 Stage 24 Stage 25 Stage 26 Stage 27 Stage 28 Stage 29 Stage 30 Stage 31 Stage 32 Lunch Start Time 9:00 AM 9:20 AM 9:40 AM 10:00 AM 10:20 AM 10:40 AM 11:00 AM 11:20 AM 11:40 AM 12:00 PM 12:15 PM

End Time 9:15 AM 9:35 AM 9:55 AM 10:15 AM 10:35 AM 10:55 AM 11:15 AM 11:35 AM 11:55 AM 12:15 PM 1:00 PM Events 1, 2 & 3 18 & 63 29 & 74 40 & 85 6 & 51 17 & 62 28 & 73 39 & 84 5 & 50 16 & 61 27 & 72

LUN

CH B

REAK

Events 4, 5 & 12 19 & 64 30 & 75 41 & 86 7 & 52 18 & 63 29 & 74 40 & 85 6 & 51 17 & 62 28 & 73 Events 6, 7 & 14 20 & 65 31 & 76 42 & 87 8 & 53 19 & 64 30 & 75 41 & 86 7 & 52 18 & 63 29 & 74 Events 8, 9 & 19 21 & 66 32 & 77 43 & 88 9 & 54 20 & 65 31 & 76 42 & 87 8 & 53 19 & 64 30 & 75 Events 10, 11 & 24 22 & 67 33 & 78 44 & 89 10 & 55 21 & 66 32 & 77 43 & 88 9 & 54 20 & 65 31 & 76 Events 13 & 15 23 & 68 34 & 79 45 & 90 11 & 56 22 & 67 33 & 78 44 & 89 10 & 55 21 & 66 32 & 77 Events 16 & 21 24 & 69 35 & 80 1 & 46 12 & 57 23 & 68 34 & 79 45 & 90 11 & 56 22 & 67 33 & 78 Event 20 25 & 70 36 & 81 2 & 47 13 & 58 24 & 69 35 & 80 1 & 46 12 & 57 23 & 68 34 & 79 Events 17 & 18 26 & 71 37 & 82 3 & 48 14 & 59 25 & 70 36 & 81 2 & 47 13 & 58 24 & 69 35 & 80 Events 22 & 23 27 & 72 38 & 83 4 & 49 15 & 60 26 & 71 37 & 82 3 & 48 14 & 59 25 & 70 36 & 81 Events 25, 26 & 27 28 & 73 39 & 84 5 & 50 16 & 61 27 & 72 38 & 83 4 & 49 15 & 60 26 & 71 37 & 82

Stage 33 Stage 34 Stage 35 Stage 36 Stage 37 Stage 38 Stage 39 Stage 40 Stage 41 Stage 42 Stage 43 Stage 44 Stage 45 Start Time 1:00 PM 1:20 PM 1:40 PM 2:00 PM 2:20 PM 2:40 PM 3:00 PM 3:20 PM 3:40 PM 4:00 PM 4:20 PM 4:40 PM 5:00 PM

End Time 1:15 PM 1:35 PM 1:55 PM 2:15 PM 2:35 PM 2:55 PM 3:15 PM 3:35 PM 3:55 PM 4:15 PM 4:35 PM 4:55 PM 5:15 PM Events 1, 2 & 3 38 & 83 4 & 49 15 & 60 26 & 71 37 & 82 3 & 48 14 & 59 25 & 70 36 & 81 2 & 47 13 & 58 24 & 69 35 & 80 Events 4, 5 & 12 39 & 84 5 & 50 16 & 61 27 & 72 38 & 83 4 & 49 15 & 60 26 & 71 37 & 82 3 & 48 14 & 59 25 & 70 36 & 81 Events 6, 7 & 14 40 & 85 6 & 51 17 & 62 28 & 73 39 & 84 5 & 50 16 & 61 27 & 72 38 & 83 4 & 49 15 & 60 26 & 71 37 & 82 Events 8, 9 & 19 41 & 86 7 & 52 18 & 63 29 & 74 40 & 85 6 & 51 17 & 62 28 & 73 39 & 84 5 & 50 16 & 61 27 & 72 38 & 83 Events 10, 11 & 24 42 & 87 8 & 53 19 & 64 30 & 75 41 & 86 7 & 52 18 & 63 29 & 74 40 & 85 6 & 51 17 & 62 28 & 73 39 & 84 Events 13 & 15 43 & 88 9 & 54 20 & 65 31 & 76 42 & 87 8 & 53 19 & 64 30 & 75 41 & 86 7 & 52 18 & 63 29 & 74 40 & 85 Events 16 & 21 44 & 89 10 & 55 21 & 66 32 & 77 43 & 88 9 & 54 20 & 65 31 & 76 42 & 87 8 & 53 19 & 64 30 & 75 41 & 86 Event 20 45 & 90 11 & 56 22 & 67 33 & 78 44 & 89 10 & 55 21 & 66 32 & 77 43 & 88 9 & 54 20 & 65 31 & 76 42 & 87 Events 17 & 18 1 & 46 12 & 57 23 & 68 34 & 79 45 & 90 11 & 56 22 & 67 33 & 78 44 & 89 10 & 55 21 & 66 32 & 77 43 & 88 Events 22 & 23 2 & 47 13 & 58 24 & 69 35 & 80 1 & 46 12 & 57 23 & 68 34 & 79 45 & 90 11 & 56 22 & 67 33 & 78 44 & 89 Events 25, 26 & 27 3 & 48 14 & 59 25 & 70 36 & 81 2 & 47 13 & 58 24 & 69 35 & 80 1 & 46 12 & 57 23 & 68 34 & 79 45 & 90



Page 17 of 82


Revision Number: 03



Event #1 UPS Safety Wiring

Provided by

Team members required One

Contact(s)/Judge(s) Lornna Ruble, 502-396-4062 or 305-869-8218, [email protected]

Candice McHargue, 502-494-2657, [email protected]

Description This event will test each participant's skill and speed while accomplishing a series of safety wire patterns and safeties.

References AC 43.13-1B - Acceptable Methods, Techniques, and Practices - Aircraft Inspection and Repair

Tools and equipment list Safety wire pliers, wire cutters, needle nose, and 32/1000 safety wire

Instructions Competitors will have eleven minutes to complete safety wiring in two sections (see illustration, below). (Note, this is different than in years past when competitors had 15 minutes to complete as many patterns as possible.)




https://www.faa.gov/regulations_policies/advisory_circulars/index.cfm/go/document.information/documentid/99861

https://www.faa.gov/regulations_policies/advisory_circulars/index.cfm/go/document.information/documentid/99861


Page 18 of 82


Revision Number: 03



Event #1 UPS Safety Wiring

Scoring Scores will be calculated according to the AMC score sheet. A thirty second penalty will be assessed for each incorrect safety wire pattern (which may include but is not limited to inadequate tautness of the safety wire, loose pigtail to the securing hardware, and negative safety).

There are two aircraft parts on the board that provide bonus opportunities. The competitor must tell the judge in advance whether they will attempt completion of the bonus section:

• After completing Section 1, competitors have the option of safety wiring one of two aircraft parts in the bonus area for a one-minute deduction off the final time.

• After completing Section 2, competitors will have the option of safety wiring the second aircraft part in the bonus area for a two-minute deduction off the final time.

Bonus point will not be provided for incorrect or inadequate safety wiring in the bonus area. Penalties will not be assessed for incorrect or inadequate safety wiring in the bonus area.



Page 19 of 82


Revision Number: 03



Event #2 Abaris Training Composite Repair

Provided by

Team members required Two

Contact(s)/Judge(s) Corrie Volinkaty, Technical Instructor, [email protected]

Description This skills event is based on an elevated high temperature, vacuum bagged, composite repair scenario.

References Textbook titled “Essentials of Advance Composite Fabrication & Repair,” available thru Aviation Supplies & Academics, Inc.’s website www.asa2fly.com.

Tools and equipment list Each team will be provided a work packet which includes the Job Card, Repair Ply Material and vacuum bag. All tools & equipment needed to perform this skills event will be provided and reused by all teams including the following items; Vacuum source/hoses/ports, Heatcon Single Zone Bonder/heat blanket/thermocouples, scissors, Stanley Knife, sharpie marker, volt ohm meter, 12-inch scale, circle template, tape dispenser and calculator.

Instructions A) Competitors may review the job card in the five minutes preceding the event’s official start time. Arriving at the Composite Skills Event early allows for more time to review Job Card & derive a plan of attack.

B) The Job Card can be accomplished in any order that is decided by the team, but all sign off blocks must be completed. Non-completed job cards are a frequently-cited penalty for this event so take care to sign off all blocks.



http://www.asa2fly.com/


Page 20 of 82


Revision Number: 03



Event #2 Abaris Training Composite Repair

C) Repair ply material, a rectangle piece of paper, will be used for the repair plies. After drawing a 3”, 4” and 5” circle with the circle template provided, mark the warp direction by drawing a line within each circle. The short side of the repair material is the warp direction. Once cut out, follow Job Card for proper orientation of each repair ply…a cause of many deductions in the past, the Judge will be watching closely!!

D) Teams should be familiar with Ohm’s Law when given Voltage, Wattage & solving for Resistance (R = V² ÷ W). This will be used to calculate, measure & document both results on the Job Card. They also need to solve & calculate a resin mix ratio word problem…Example; Based on a given amount of total mixed epoxy resin needed, say 50 grams with a mix ratio 100:35, how many grams of Part A? How many grams of Part B? Teams will clearly write their answers on the Job Card.

E) Teams should also be familiar with vacuum bag processing. Peel ply, Bleeder, solid film, Breather materials needed for this skills challenge will be pre-cut, clearly marked and reused for all other teams. Once their repair area is vacuumed down they can start the bonder.

F) After you are done, the judge will give your time to write on the Job Card. Take a breath… & please help clean up and put the table back the way you found it. All cleanup efforts are greatly appreciated.

G) All teams must understand that these instructions are a general overview of this skills challenge & that there is a lot of detail on the Job Card, that if not followed, can lead to problems and/or unexpected deductions.

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for items missed or a block not signed off on a job card.



Page 21 of 82


Revision Number: 03



Event #3 Federal Aviation Administration Human Factors Exam

Provided by


Contact(s)/Judge(s) Dr. Bill Johnson [email protected]

Description This event will consist of multiple-choice questions relating to human factors.

NOTE: Special thanks to the FAA’s Dr. Bill Johnson and the Northrop Rice Aviation Training Solution’s Cathy Landry for creating the text questions for this year’s revised exam.

References FAA Aviation Maintenance Technician General Handbook

Tools and equipment list Tablet

Instructions Each designated team member will sit for a timed exam, proctored on a tablet.

Scoring Scores will be calculated based on the number of incorrect answers and unanswered questions, and the time it takes to complete the test.



https://www.faa.gov/regulations_policies/handbooks_manuals/aircraft/media/amt_general_handbook.pdf


Page 22 of 82


Revision Number: 03



Event #4 Alaska Airlines External Power Receptacle Event

Provided by


Contact(s)/Judge(s) Robert A. Long, Shop Aircraft Technician, [email protected]

Ken Pitt, Powerplant Engineer, [email protected]

Gregory McDonald, Senior Inspector

Roger Bailey, AOG Engineer

Description Competitors will evaluate a discrepancy provided on a logbook sheet and determine steps for corrective action. Competitors will utilize tools to complete the task the complete appropriate paperwork.

References Task Summary

Simulator Aircraft Maintenance Manual (Rev. i)

Tools and equipment list Inspection flashlight, screwdriver, wrench – hex 1/8 inch and 3/16 inch, wear gage, safety tags

Instructions A) Identify the aircraft and aircraft type you are tasked to work on B) Understand the discrepancy provided on the logbook sheet and

determine planned action for corrective action C) Identify the appropriate sections of the Simulated Aircraft

Structure (SAS) Maintenance Manual to accomplish corrective maintenance action and associated Task Cards




https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amc_task_summary_2020.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amc_2020_-_master_manual_rev._i.pdf


Page 23 of 82


Revision Number: 03



Event #4 Alaska Airlines External Power Receptacle Event

D) Identify components, determine effectivities, utilize tools, hardware, technical data and standard aircraft maintenance practices to complete tasks

E) Complete logbook entry filling in required areas with appropriate information

F) Consider completed task on SAS Simulator same as completed task on live aircraft

G) Tool collection and accountability H) Foreign object debris (FOD) survey within work location I) Document completion and task card completion

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed as provided for in the Alaska Skills Time Sheet.


https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/time_sheet__-___rev_d_-_2018.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/time_sheet__-___rev_d_-_2018.pdf


Page 24 of 82


Revision Number: 03



Event #5 Nida Corporation Power Troubleshooting

Provided by


Contact(s)/Judge(s) Robin Asplund, [email protected]

Description This event challenges the aircraft maintenance technician’s ability to troubleshoot basic aircraft power distribution systems. Contestants will be provided schematics, system descriptions and operational procedures to troubleshoot generic single engine and multi-engine power distribution systems. Scores will be based on the speed and accuracy of finding the system faults.

References Detailed contest material available at www.nida.com/amc

Tools and equipment list Multi-meters

Instructions A) Single Engine Power Distribution System Troubleshooting 1) System will be operationally ready with no faults. 2) Review the pilot “write up” on the discrepancy sheet. 3) Request the first fault insertion from the judge. 4) Determine the most probable cause of the fault and the

recommended repair. 5) Sign off the pilot “write up” with your conclusion. 6) Repeat Steps 2 through 5 until all single engine aircraft faults

are completed. Only one fault will be inserted at a time. B) Multi-Engine Aircraft Power Distribution System Troubleshooting

1) Move to the multi-engine training panel



http://www.nida.com/amc


Page 25 of 82


Revision Number: 03



Event #5 Nida Corporation Power Troubleshooting

2) Repeat Steps 2 – 6 above until all multi-engine aircraft faults are completed

3) Finish your paperwork and tell the judge to stop the clock.

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for incorrect answers or unfinished scenarios.



Page 26 of 82


Revision Number: 03



Event #6 U.S. Air Force Flex Fluid Lines

Provided by


Contact(s)/Judge(s) MSgt Warren Hessler, [email protected]

SSgt Travis Wilkin, [email protected]

Description Hose assembly length is 11.5 inches (“A”). Assembly length is measured from middle of b-nut flat to middle of b-nut flat. Cutoff factor for each hose end fitting is .75 inches (“C”). (See figure 6)

References None

Tools and equipment list Qty 2, 11/16 combination wrench

Qty 1, 13/16 combination wrench

Qty 1, tape measure

Qty 1, feeler gauge (0.23 - .046)

Qty 1, 3/8" dr torque wrench able to torque 190-215 in lbs.

Qty 1, 3/8" dr 11/16" crow foot.

Qty 1, hacksaw.

Qty 1, 10 pack replacement hacksaw blades. (32 TPI)

Qty, 1 diagonal cutters

Qty 1, brass pick

Qty 2, leather gloves

Instructions A) Medium pressure PTFE hose buildup 1) Measure hose to required length





Page 27 of 82


Revision Number: 03




2) Wrap circumference of hose with masking tape at cutoff to prevent flare out of braid **CAUTION** Do not overwrap tape

3) Cut off hose square using hack saw 4) Clamp sockets in vise.

**CAUTION** Do not overtighten vice on thin walled fittings 5) Insert neck-down end of hose into sockets using a twisting,

pushing motion until hose is through the sockets, ensuring the ends are skirt to skirt. (Figure 1). Remove tape from hose and assembly from vise

6) Separate wire braid from tube. Seal pick is provided to aide in

separation. 7) Insert sleeve between braid and outer diameter of the inner

tube **CAUTION** Do not allow wire braid to be caught between sleeve and inner tube. Do not pinch inner tube with sleeve

8) Complete positioning of sleeve by pushing sleeve against a flat surface until tube bottoms against inside sleeve diameter (Figure 3).



Page 28 of 82


Revision Number: 03




9) Check tube end to make sure it is bottomed against sleeve and

wires are not trapped under sleeve. Trim excess wires as needed.

10) Clamp Nipple in vise (Note: Do not lubricate hose or nipple before insertion. Fitting components are dryfilm lubricated at time of manufacture.)

11) Size tube to sleeve by pushing hose over nipple until sleeve bottoms against nipple chamfer.

12) Check end to make sure sleeve is positioned properly. 13) Slide socket forward and thread onto nipple by hand

14) Reposition assembly by placing socket flats in vise.



Page 29 of 82


Revision Number: 03




15) Tighten assembly by using a wrench on the nipple hex until

gap between socket hex and nipple hex is 1/32 inch. Gap may vary from .023 to .046 inch.

16) Repeat steps 6 through 15 for fitting on the other end. 17) Inspect hose.

B) Medium pressure PTFE hose install 1) Place hose into fixture assembly, threading coupling nuts on

by hand. 2) Torque coupling nuts 190-215 in lbs. utilizing a backup

wrench.

Figure 6.

Scoring Scores will be calculated according to the AMC score sheet.



Page 30 of 82


Revision Number: 03



Event #7 Eastern Florida State Space Vehicle - Vacuum Loading Operation

Provided by


Contact(s)/Judge(s) Bill Fletcher, [email protected]

Description This event simulates the loading of a small quantity of a hazardous commodity from a holding tank into a space vehicle flight tank. The individual performing the procedure will be required to don the proper PPE, assemble a mobile fluid transfer station per a detailed procedure and a schematic and transfer 200 grams of a commodity (colored water) from a holding tank to a flight tank using a vacuum loading operation. A command/response protocol (see definition below) must be followed when completing the operation. Upon completion of the fluid transfer all system lines will be evacuated using compressed air (60 seconds) and disassembled from the station. (Note: The Flight Tank does not drain during line evacuation).

The QDs we are using are a push/pull type connector (explain inserting and pushing until it bottoms out and then how they have to push on the collar to get it to release the tubing). One will be available at the event table prior to the event for the technician to look at and operate to familiarize themselves on how it works.

All steps must be completed. There are no provisions for NOT PERFORMING a step or series of steps.

Definition of Command/Response Protocol- a method of communication in such a manner that the command or work instruction is read by one individual (command) and then it is repeated (response) by the person performing that work step as they complete the instruction.




Page 31 of 82


Revision Number: 03




References None

Tools and equipment list • PE provided for the individual performing the procedure o Tyvek suit (simulates SCAPE Suit) – one per team – Sara

Gloves (Disposable Polypropylene Coveralls wit Hood and Booties) 2X #13-PPW-CHB-2X-C2, X Large #13-PPW-CHB-XL-C2, Large #13-PPW-CHB-2X-LG-C2

o Neoprene gloves – 1 pair per team – Home Depot (Large #202188317, X-Large #202288319 Large and XL Nitrile Gloves I Box each

o Face shields - 4 o Disposable Respirator- one per team o Painters Tape – 3 rolls

• Equipment provided o Control Box - 2 (plus 3 AC to DC adapters) o Vacuum Pump w/gauge -2 plus a spare o Power Cords for Vacuum Pumps – 2 (with switches label

Vacuum pump) o Air compressor (shared between two stations) plus one 3 way

adapter and 2 hoses o Power cord and 3 way plug o Multiple electrical strip - 2 o Air Compressor cover o Compressed air-pressure regulator - Spare o Supply tank -2 o Flight tank -4 plus one spare o Vacuum & Fluid Lines (6 Tygon tubes cut to 4 foot lengths

each) 3 sets plus spare tubing o Digital Scale - 2 o Timer – 2 o Stop Watches - 2 o Clip Boards – 4 o Pens and Markers – Multiple o Alcohol Wipes (For cleaning face shields) o Banner Stand (To hold banners between competition tables)

plus banners o SpaceTEC Banner for bleacher area (Needs to be shipped to

AMC early so it can be placed on the bleachers).



Page 32 of 82


Revision Number: 03




o Large and Small Tie Wraps o SpaceTEC tablecloths with clear plastic to cover them for

water spots -2 o Shop Towel Rolls - 4 o Poly-Temp PTFE Thread Tape o Spare Seal Kit for Vacuum Pump o Large Trash Bags o Green Food Coloring o Batteries (AA and AAA) o Mounting Tape o Double Stick Tape o Duct Tape o Sealer (for possible leaks in tanks) o Spare air gauge o Spare Water Separator o Spare Desiccant Dryer/filter o Electrical tape o Rubber bands (Medium and Large) o Velcro

• Tool Bag and Tools o Vehicle Processing Kit Tube Bender Tube Cutter 37 Degree Flaring Tool Fitting Box Spare Tubing

o Box Cutter o Needle Nose Pliers o Tape Measure o Phillips and Flathead Screwdrivers o 2 Adjustable Wrenches o Wire Cutters o Slip Joint Pliers o Scissors

Instructions A) Preparation and protocol 1) The operator (team member 1) will dress out in appropriate

PPE to simulate the protective equipment used during such an operation.



Page 33 of 82


Revision Number: 03




2) Team member 2 will read out the procedure while team member 1 performs the operation. The “call and response” protocol referenced above must be used. That is, team member 2 will read out the step, and team member 1 gives an appropriate response to verify the step is complete. For example, if team member 2 reads off “close valve 1”, team member 1 would respond with “valve 1 closed” after completing the step.

B) Setup 1) Turn on power to Control Box 2) Cycle electrical valves to ensure operation (red light indicator) 3) Verify all valves (manual and electrical) are closed 4) Turn off power to the Control Box 5) Connect Vacuum and Fluid lines as shown in schematic. Note:

all fittings are push lock type. Ensure lines are pushed in all the way. The compressed air line to pressure valve will already be connected.

6) Verify all Vacuum and Fluid lines are connected as shown in schematic.

7) Verify Flight Tank is on digital scale. C) Evacuate Tank

1) Turn on power to Control Box 2) Open MV 4 3) Start Vacuum Pump 4) Open Vacuum Valve 5) Open Flight Valve 6) Open MV2 7) Evacuate system until vacuum gage reads at least 22 Hg +/- 5 8) Close Vacuum Valve 9) Close Flight Valve 10) Close MV 4 11) Turn off Vacuum pump

D) Flight Tank Load-Vacuum 1) Turn on digital scale and tare 2) Open Atmospheric Vent Valve 3) Open Supply Valve 4) Open Flight Valve and cycle valve as necessary to meter 150

grams of fluid into Flight Tank – NOTIFY JUDGE WHEN COMPLETE

5) Close all valves (manual and electric)



Page 34 of 82


Revision Number: 03




Note: If Vacuum load was unsuccessful, Step 4-system drain must be completed before restarting step 2- evacuate tank

E) System Drain 1) Verify all valves closed (manual and electric) 2) Verify compressed air regulator set at 20 +/-5 psi 3) Open MV3 4) Open MV1 5) Open Atmospheric Vent Valve 6) Open Flight Valve 7) Open Supply Valve 8) Open Pressure Valve 9) Purge all water from system for 60 seconds (use timer

provided) Note: FLIGHT TANK DOES NOT DRAIN 10) Close Pressure Valve 11) Close Supply Valve 12) Close Flight Valve 13) Close Atmospheric Vent Valve 14) Close MV1 15) Reduce compressed air regulator to zero 16) Close MV3 17) Open MV2 to vent Flight Tank 18) Open MV1 to vent Supply Tank 19) Close all valves (manual and electric) 20) Turn off power to Control Box

F) System Clean up 1) Verify power to Vacuum pump and control box is turned off 2) Verify all valves closed 3) Disconnect all hoses between control panel and tanks (both

ends of all 5 hoses must be disconnected)

END OF EVENT

Participants should remove PPE and return it to the PPE staging table

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for each step not completed and for each gram over/under flight tank load target



Page 35 of 82


Revision Number: 03



Event #8 ULTRAX Aerospace Condition-Based Intelligence (CBITM)

Provided by


Contact(s)/Judge(s) Travis Fisher [email protected]

Matt Nimmo [email protected]

Scott Carlson [email protected]

Description Competitors will complete a standard inspection check on an aircraft, which consists of 1) a Garmin cockpit and 2) a T700 turboshaft engine. They will use CBITM to capture observable facts and document the condition of the aircraft, generating accurate, actionable intelligence to distribute within their community.

References https://ultraxinc.com/amc2020/

A detailed instructional video will be available no later than April 1, 2020.

Tools and equipment list All required equipment and tools will be provided by ULTRAX and available in the competition booth.

1. Garmin glass cockpits 2. GE T700 Turboshaft Turbine Engines 3. Computing devices with CBI™ Web Application 4. Baselining Sensor Kit to capture electrical properties 5. Engine Indication Simulator 6. Torque wrench and crow’s foot 7. DMM

Instructions Service Inspection Instructions

Scoring Scores will be calculated according to the AMC score sheet. Penalties will be assessed and bonus points available as provided for in the event instructions.





https://ultraxinc.com/amc2020/

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/2020_ultrax_amc_event_summary___instructions_final_3.3.20.pdf


Page 36 of 82


Revision Number: 03



Event #9 JetBlue University ADS-B Troubleshooting

Provided by


Contact(s)/Judge(s) Andy Kozak, [email protected]

Description Technicians will use modern test equipment, AeroflexIFR 6000 to validate proper operation and reporting to comply with the upcoming 2020 regulations for all aircraft operating in regulated airspace. The technicians will set-up the mock aircraft to be tested and demonstrate proper testing procedures and document results for completion.

References Event overview

Tools and equipment list Electronic Flight Instrument panel set-up with GPS and Encoder simulators to represent a working modern flightdeck.

Instructions The technician will fill out a task card with reported information from the IFR 6000. See linked event overview, above, for more information.




https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/ads-b_amc_event_overview_rev_1_2019_adk.pdf


Page 37 of 82


Revision Number: 03



Event #10 NBAA & Dallas Airmotive Honeywell TFE731-2 Engine Fan Blade Removal

Provided by


Contact(s)/Judge(s)

Darrell Capra, Program Director

Joe Capra, Program Director

Jim Huntoon [email protected]

Scott Mcpherson [email protected]

Nathan Winkle

Description

This event will test the technician’s ability and speed when installing the fan blades, spinner support and spinner on a Honeywell TFE731 Turbofan engine. This will require technicians to install the fan blades in a uniform manner to prevent shingling of the mid span dampeners utilizing specialized tooling and the OEM maintenance manuals.

References Event Detailed Instructions

Engine Light Maintenance Manual Sections for fan assembly

Tools and equipment list OEM specialized fan installation tooling, ¼” drive speed handle and torque wrench





Page 38 of 82


Revision Number: 03



Event #10 NBAA & Dallas Airmotive Honeywell TFE731-2 Engine Fan Blade Removal

Instructions

Within the allocated time, complete tasks in order:

A) Locate alignment mark on fan disk for blade #1 B) Install fan blade retainer C) Install fan blades #1 through #30 in fan disk D) Assemble specialized tooling on fan assembly and slide fan blades

into disk until fully seated. E) Install spinner support F) Install spinner




Page 39 of 82


Revision Number: 03



Event #11 Daniels Manufacturing Corporation Electrical Troubleshooting

Provided by


Contact(s)/Judge(s) Matthew Bohannon, Product Manager, [email protected]

Description Competitors will be required to find the multiple faults in a MIL-DTL-26482 and MIL-DTL-38999 Series 3 connector consisting of 21 size 16 contacts using a Snap-on multi-meter. Competitors will remove the faulty wires, properly terminate contacts to a new wire, insert the new wire into both sides of the connector, check contact retention using a retention tester and continuity using a multi-meter.

References DMC Instructional Video Electrical Troubleshooting

DMC wiring diagram

Tools and equipment list AF8 Crimp Tool

TH1A: Turret Head

TH163: Turret Head

DAK16B: Insertion Tool

DRK16B: Removal Tool

DAK95-16B or M81969/14-03: Insertion Tool

DRK95-16B or M81969/14-03: Removal Tool

HT250-2: Retention Tester

67-016-01: Retention Tester Tip (socket)

68-016-01: Retention Tester Tip (pin)



https://drive.google.com/drive/folders/139gVeQEBYtiHu2HyqmRufscYYjuJCQg9?usp=sharing

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/2020_connector_challenge.pdf


Page 40 of 82


Revision Number: 03



Event #11 Daniels Manufacturing Corporation Electrical Troubleshooting

Digital Multimeter: Snap-on, part number EEDM504D

22” pre-stripped wire

Contacts: M39029/32-248 (SOCKET), M39029/58-364 (PIN)

26482 (Front Release) Connector: PT07SE22-21S-ND (Amphenol PN)

D38999 (Rear Release) Connector: D38999/24FH21PN

Multiple wires improperly terminated to simulate a faulty wire

Note: Competitors will be provided with a multi-meter and leads. They may NOT use their own equipment for this competition

Instructions A) Competitors will be presented with mounted 26500 and D38999 receptacles on a mock panel

B) The connector will have 21 contact cavities with size 16 contacts C) Competitors must check continuity of ALL contact cavities and find

the faulty wires using a multi-meter D) Remove the faulty wires using the proper tooling E) Competitors must assemble the crimp tools provided with the

corresponding accessory (turret head or positioner). Different turret heads may be required for different connectors/contacts

F) The competitors must set the crimp tools to the proper crimp settings based upon the contact part number and wire gauge. This may be different for different contacts

G) Once properly set, the competitors will crimp a pin and socket on the opposite ends of a 22” piece of pre-stripped wire (provided)

H) Completed wire must then be inserted into the proper cavities of the connector

I) Once the new wire is inserted, the competitors must test contact retention using a 5lb or less retention test tool

J) Finally, competitors MUST test the continuity of the new wires using a multi-meter

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for incorrect repair of faulty wire.



Page 41 of 82


Revision Number: 03



Event #12 Daniels Manufacturing Corporation Safe-T-Cable

Provided by


Contact(s)/Judge(s) Bill Randall, Strategic Accounts Manager, [email protected]

Description This event will test each participant’s skill and speed while accomplishing a series of patterns using Safe-T-Cable. The application of the safe-t-cable must maintain positive tension on the fasteners and meet the criteria for flex limits.

References Installation Instructions

Verification Equipment

Elongated Ferrules

Tools and equipment list Safety (Safe-T-Cable) Cable Gun SCTR327 (7 inch nose for .32 cable)

C10-218 Cable qty 100 .032” x 18” safety cables

F10-04 Elongated Ferrules (use where low profile bolts are present)

SCT-TB1 Torque Verification Block

3/8” drive torque wrench

Instructions Competitors must first verify proper function and tensioning settings of the tool by using the SCT-TB1 and a 3/8 inch drive torque wrench. Safe-T-Cable should remain in place on SCT-TB1 test block during application of the measured force.

Once verification is complete, competitors will complete as many 2 or 3 bolt patterns as they can in the allotted time. Competitors must properly thread the Safe-T-Cable through the fasteners in a manner



https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/sct_instructions.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/sct_verification_equipment.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/sct_elongated_ferrules.pdf


Page 42 of 82


Revision Number: 03



Event #12 Daniels Manufacturing Corporation Safe-T-Cable

that maintains positive tension. Competitors will properly tension the Safe-T-Cable and crimp a ferrule on the end of the cable using the DMC SCTR327 rotary tool. Any excess cable/FOD must be properly disposed of after application is complete.

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed related to tautness of the safety cable and negative safety.



Page 43 of 82


Revision Number: 03



Event #13 FedEx Express Turbine Engine PDU Removal and Installation

Provided by

Team members required Three

Contact(s)/Judge(s) Larry Bradbury, [email protected]

Description This event will test the technician’s ability to remove and install the Thrust Reverser, Pneumatic Drive Unit (PDU) on a Pratt and Whitney JT9D-7R4 turbofan engine.

References None

Tools and equipment list 1/4" Drive 40-200 in lb torque wrench (PN QD1R200)

1/4" Drive 12-Point 1/4" semi-deep socket (PN TMDS8)




1/4" Drive 6" extension (PN TMXK60)

1/4" Drive 14" extension (PN TMXK140)

1/4" Drive ratchet (PN T72)

1/4" Drive 9/16" crowfoot (PN TMCO18)

3/8" Drive 200 - 1000 in lb torque wrench (PN QD2R1000A)

3/8" Drive 12-Point 1/4" shallow socket (PN F081)





Page 44 of 82


Revision Number: 03



Event #13 FedEx Express Turbine Engine PDU Removal and Installation



3/8" Drive 6" extension (PN FXK6)

3/8" Drive 11" extension (PN FXK11)

3/8" Drive ratchet (PN F80)

3/8" Drive 5/8" crowfoot (PN FC020A)

3/8" Drive 11/16" crowfoot (PN FC022A)

1/4 combination wrench (PN OEX8B)





8-3/4" Snap-On ratcheting screwdriver (PN SSDMR4B)

Jaw cannon plug pliers (PN PWC52A)

Instructions JT9D Pneumatic Drive Unit – Removal/Installation Instructions

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for failure to place PDU on table and simulate packing change, failure to show judge torque on wrench before proceeding, failure to install or secure mount bolts, failure to install, secure or torque Lines and B Nuts.


https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/jt9d_pdu_event__002-1_.pdf


Page 45 of 82


Revision Number: 03



Event #14 Perfect Point E-Drill Fastener Removal

Provided by

Team Members Required One

Contact(s)/Judge(s) Jim Becker, Director-Business Development

Nils Besvold, Sales and Marketing Associate, [email protected]

Description This event will test the technician’s ability and speed when removing titanium fasteners from an aircraft structure. This will require technicians to remove 5 fasteners using an E-drill from a wing flap. The Fasteners will be of a blind-bolt configuration and exact part numbers will be presented at the competition.

References Event Detailed Instructions

Test article photos

E-drill Training Videos

Full E-drill User Guide

Tools and equipment list Eye protection required. The E-drill hand tool, locating devices, punches, hammers, and consumables will be provided.

Instructions A) Using supplied reference data, remove the Qty. (5) fasteners identified on the flap. The fasteners to be removed will be marked. See references for detailed instructions and videos on using the E-drill with blind-bolt.

B) Using the Air Punch, sever the stem of the fastener from the head. C) Locate and remove all FOD and check the structure for damage to

the structure.



https://ppedm.com/about-us/events/amc/

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/pptestarticlephotos.zip

https://ppedm.com/support/training-videos/

https://ppedm.com/wp-content/uploads/2018/12/PPEDM-2018-EDRILL-INSTRUCTION.pdf

https://ppedm.com/about-us/events/amc/


Page 46 of 82


Revision Number: 03



Event #14 Perfect Point E-Drill Fastener Removal

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for mis-aligning the E-drill over the fastener which results in damage to the structure, mis-handling the tool or locators, and excessive water leakage or sparking.



Page 47 of 82


Revision Number: 03



Event #15 Barfield Air Data Testing

Provided by


Contact(s)/Judge(s) Victor Bontorno, Director Distribution & GSTE, 305-894-5408, [email protected]

Description This competition is designed to test the skills of each participating team in their understanding of and ability to troubleshoot an aircraft Pitot-Static system. Barfield recommends participants fully understand a basic aircraft Pitot-Static system and potential issues that could be found. The faults found during this procedure will test this knowledge.

References None

Tools and equipment list See procedure, linked below

Instructions Test procedure 84-611-00052-150412-5 (Rev. 3-25-19)

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for damaging indicators, not following cautions outlined in the procedure, replacing hose with incorrect parts, unnecessarily replacing a good hose, incorrectly identifying a broken indicator, or loitering in the Pitot-Static event area prior to competing.



https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/airdata-2019.pdf


Page 48 of 82


Revision Number: 03



Event #16 AAR Non-Destructive Testing—CANCELLED



Page 49 of 82


Revision Number: 03



Event #17 Barfield Rf Antenna Testing

Provided by


Contact(s)/Judge(s) Victor Bontorno, Director Distribution & GSTE, 305-894-5408, [email protected]

Description Coaxial Cable & Antenna System Inspection with a Frequency Domain Reflectometer

References SiteHawk RF Antenna & Cable Analyzer – Aviation Test Kit 7003A001-4

Tools and equipment list P/N 7003A001-4 SiteHawk RF Aviation & Cable Analyzer – Aviation Test Kit

Instructions TECHNICAL TIP Procedure (Rev. 03/25/2019)




https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/bird_sitehawk_av_brochure.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/rev_4_draft_competition_tech_tip_procedure.pdf


Page 50 of 82


Revision Number: 03



Event #18 8Tree and Alaska Airlines Airframe Damage Inspection

Provided by


Contact(s)/Judge(s) Howard Chung, [email protected]

Lamar Legrone, [email protected]

Description Competitors will measure dent damages on an airframe panel using traditional methods and with the dentCHECK inspection tool. Competitors will be evaluated on the ability to follow the prescribed steps outlined in the manual.

References Task Instructions

Tools and equipment list Depth gauge, six-inch ruler, marker, flashlight, calculator, calibration block, camera dentCHECK inspection tool

Instructions Within the allocated 15 minutes, complete tasks in order:

1. Evaluate dent as per Task #1 Manual (Dent Evaluation using Traditional Method)

2. Repeat dent evaluation as per Task #2 Manual (Dent Evaluation using dentCHECK)



https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amc2020_event18_event_summary___manuals_-_v2.pdf


Page 51 of 82


Revision Number: 03



Event #19 American Airlines Pedestal

Provided by

Equipment sponsor


Contact(s)/Judge(s) Aaron Klippel [email protected]

Ed Kempa [email protected]

Description Execute removal/replacement of MD-80 pedestal floor light.

References Removal and Replacement Instructions

Tools and equipment list See removal and replacement instructions, linked above.

Instructions See removal and replacement instructions, linked above.





https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/aa-pedestalevent-20190131.pdf


Page 52 of 82


Revision Number: 03



Event #20 PPG Transparencies, Paint and Wing Sealant

Provided by

Team members required Five

Contact(s)/Judge(s) Jason Richburg, Product Support Engineering Manager, [email protected]

Description This is a five-part event with three separate sessions. The transparencies section will require a framing assembly repair and a Surface Seal application. The paint section will require competitors to use a Virtual Reality (VR) paint booth to simulate painting. The sealant section will require operators to perform sealing on hi-lok fasteners, dome caps and fillet sealing, both by hand and by seal caps/ use of nozzles, as well as proper mixing of semkits and manual removal of cured sealant.

References Technical data sheet for Semco® 1088 Mixer, FlexPak cartridge, Semco® 1250 Battery Gun (available on http://www.ppgaerospace.com)

Tools and equipment list See procedures, linked below

Instructions Glass Plug Replacement Procedure

Surface Seal® Procedure

Virtual Reality Procedure

Sealants Procedure (provided on site)



http://www.ppgaerospace.com/

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amc_glass_plug_replacement_procedure_2019.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amc_surface_seal_instructions_2019.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amc_virtual_reality_procedure_2019.pdf


Page 53 of 82


Revision Number: 03



Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for any process errors and /or quality concerns.



Page 54 of 82


Revision Number: 03



Event #21 W.L. Gore & Associates, Inc. Leading Edge & Panel Sealing

Provided by

Team members required Three

Contact(s)/Judge(s) GORE™ SKYFLEX™ Aerospace Materials Team:

Jack Penick, Application Engineer [email protected]

Jon Jacobs, Application Engineer [email protected]

Gerhard Burmann, Application Engineer [email protected]

Description D-Nose Leading Edge and Access Panel installation using GORE™ SKYFLEX™ Aerospace Materials

References Installation Guide and Link to video for Installing Flat Tapes on D-Nose:

Installation Guide Tapes

Video Surface Protection – D-Nose

Installation Guide and video for Installing Gaskets on Access Panel:

Installation Guide Gaskets

Video Environmental Sealant – Gasket

Tools and equipment list Scissors

Nylon and Wood Awl for punching holes

Torque Wrench – One per team

Speed Handle – Two per team

Screwdriver and bits – Two per team

Alignment Fixture for Gasket Installation

Rags

Instructions A) D-Nose LEADING EDGE: 1) Find 700 Series GORETM SKYFLEXTM Aerospace Tapes- Part

Number GSC-21-95159-024 and ensure within shelf life.





https://www.gore.com/resources/installation-guide-tapes-gore-tm-skyflex-tm-aerospace-materials

https://www.gore.com/resources/video-gore-tm-skyflex-tm-surface-protection?from=%5B%22product%3A1596%22%2C%22content_type%3A386%22%2C%22language%3Aen%22%5D

https://www.gore.com/resources/installation-guide-gaskets-gore-tm-skyflex-tm-aerospace-materials

https://www.gore.com/resources/video-gore-tm-skyflex-tm-environmental-sealants-gaskets?from=%5B%22product%3A1596%22%2C%22content_type%3A386%22%2C%22language%3Aen%22%5D


Page 55 of 82


Revision Number: 03



2) Ensure Spar and D-Nose clean and free of debris – use provided rags to wipe faying surfaces down.

3) Apply GORETM SKYFLEXTM Aerospace Tapes on Leading Edge Spar using 4 pieces of tape cut to length with scissors. The First piece should be applied along the top and the second along the bottom. Finally apply two shorter pieces to the radius and ensure 3-5mm overlap on top and bottom pieces – Figure 1.

4) See Installation Guide for Tapes and watch video in References.

5) Poke holes for each fastener in tape material with Nylon or Wood Hole Awl

6) Install Leading Edge Profile over Spar 7) Use provided speed handle / screwdriver to seat each of the

18 fasteners using a staggered pattern. 8) Use provided torque wrench to tighten each fastener to 30

in·lbs using a staggered pattern.

Figure 1: Rig – D-Nose Installation Areas in Blue

B) ACCESS PANEL 1) Find 720 Series GORETM SKYFLEXTM Aerospace Gaskets Part

Number GSC-21-96704-027 and ensure within shelf life. 2) Ensure Access Panel and Frame clean and free of debris – use

provided rag to wipe faying surfaces. 3) Apply GORETM SKYFLEXTM Aerospace Gasket on Polycarbonate

Panel shown in Figure 2 and Figure 3. Carefully Align fastener holes in gasket with those on the panel. Ensure gasket is placed on the correct side of the access panel. It should be applied to bottom of the panel. The fastener countersink is considered the top of the panel.



Page 56 of 82


Revision Number: 03



4) See Installation Guide for Gaskets and watch video link in References.

5) Install Panel in Opening – Gasket between frame and panel. 6) Use provided speed handle / screwdriver to seat each of the

20 fasteners using a staggered pattern. 7) Use provided torque wrench to tighten each fastener to 30

in·lbs using a staggered pattern

Figure 2 – Proper alignment of gasket on bottom of Access Panel

Figure 3 - Top of Access Panel – Gasket installed on bottom

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for:

• Not following work instructions – example – faying surfaces are clean, using correct part number, checking expiration date, tightening all fasteners in staggered pattern.

• Incorrect application of tapes and overlaps at D-Nose and misalignment of gasket to access panel

• Using incorrect tools



Page 57 of 82


Revision Number: 03



Event #22 American Airlines APU Burner Can

Provided by


Contact(s)/Judge(s) Jim Gentry, B-737 Supervisor Aircraft Maintenance, American Airlines, [email protected]

Glen Phillips, Supervisor, APU and Wiring Center, [email protected]

Description Remove and Replace MD80 APU Combustion Chamber O-ring Packing per instructions. Competitors will show inspector torques and return to zero after usage. Know how to safety 3 B-nuts not in a line. Know how to attach and safety a V-style cooupling clamp. Wear safety glasses.

References IPC of APU: MD80 AMM 49-20-01-201

Tools and equipment list 1 - diagonal cutter plier

1 - 8" wire twist plier

1 - 10" wire twist plier

1 -spool of .032" safety wire

1 - 3/8" dr 7/16" deep 12pt socket

1 - 3/8" dr 9/16" crows foot

1 - 5/8 x 9/16 open end wrench

1 - 3/4 x 7/8 open end wrench

1 - 3/8" dr ratchet




https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/ipc_revised_3sep19_for_2020.pdf


Page 58 of 82


Revision Number: 03



1 - 3/8" dr torque wrench 40-200in lbs

1 - 48oz dead blow hammer

1 - 6" blade flat tip screwdriver

Instructions Remove and Replace MD80 APU Combustion Chamber Instructions



https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amc_rev_for_2020.docx


Page 59 of 82


Revision Number: 03



Event #23 United Fuel Tank Entry Precautions

Provided by


Contact(s)/Judge(s) Fred Glau, Supervisor, [email protected]

Paul Davis, Lead Technician

Scotty Cole, Avionics Technician

John Vasquez, Avionics Technician

Description Competitors will defuel and refuel a 747-400 fuel tank.

References Fuel Tank Diagram

Fuel Tank SIM Photos

Grounding lug photo

Tools and equipment list Speed Handle with no 3 apex bit

Screw Driver with no 3 apex bit

0-200 in/lb torque wrench

Grease pencil

Instructions Fuel tank procedures




https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/fuel_tank_competition_diagrams_2019.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/unitedphotos.zip

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/ground_lug_fuel_tank_sim.jpeg

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/fuel_tank_procedures_2019_revised._3-4-19.pdf


Page 60 of 82


Revision Number: 03



Event #24 Michelin Aircraft Tires Inspection

Provided by


Contact(s)/Judge(s) Jim Boyle, Aviation Technical Director – Americas, [email protected]

Description Competitors will answer inspection requirement questions and perform an airworthiness inspection of an aircraft tire including visual inspection, tire pressure reading, inspection record, and required maintenance actions.

References CYGNUS X1 Aircraft Maintenance Manual, Task 32-0000001

CYGNUS X1 Aircraft Maintenance Manual, Task 32-0000002

Michelin Aircraft Tire Care & Service Manual

Tire Inspection Form

Tools and equipment list Proper Tire Pressure Gauge

Tread Depth Gauge

Tire Inspection Form

Appropriate PSE

Flashlight

Instructions Competitors will be presented with a mounted and inflated aircraft tire with visible worn conditions and damages. Tire is assumed to be on-wing and stationary for 4 hours.

A) Answer the following questions: 1) How often should on-wing aircraft tires be inspected? 2) How often should on-wing aircraft tire pressures be verified? 3) How much is the pressure of an aircraft wheel/tire assembly

allowed to decrease in 24 hours? 4) What is the cause of Chevron Cutting? 5) What is the purpose of the Sidewall Vents?



https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amm_tire_inspections_master.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/amm._tire_pressure_servicing_master.pdf

https://aircraft.michelin.com/michelin-aircraft-tyre

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/tire_inspection_form.pdf


Page 61 of 82


Revision Number: 03



Event #24 Michelin Aircraft Tires Inspection

B) Perform visual inspection of wheel/tire assembly per job card including tread depth.

C) Record the following: 1) Tire Part Number and Size including Ply, Load and Speed Rating 2) Tire Serial Number 3) Retread Level 4) Remaining Tire Skid Depth

D) Record any noted conditions and damages on inspection form. Determine tire disposition and required actions.

E) Perform Tire Pressure Check and record readings. Determine tire disposition and required actions.

Determine what corrective actions may be required and make appropriate maintenance log entries.

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for incorrect answers/log entries.



Page 62 of 82


Revision Number: 03



Event #25 Click Bond Adhesive-Bonded Fastener Installations

Provided by


Contact(s)/Judge(s) Amy Arnold, Director Marketing & Communications, 775-885-8000 x1141, [email protected]

Rick Angell, Technical Training Manager

Barry Madson, Head Mechanical Engineer

Courtney Brown, Applications Engineer

Tim Anderson, Customer Support Engineer

Description This is a skills event using adhesive-bonded fasteners to install surface mounts for securing wire harnesses, conical inserts for a doubler patch, and to repair oversized bolt holes.

References Installation videos are posted to the Click Bond YouTube channel:

Surface Prep: https://www.youtube.com/watch?v=M_4b2mgMcDo

Adhesive Prep: https://www.youtube.com/watch?v=B3VjfKV0ero

Nutplate Installation: https://www.youtube.com/watch?v=Xl_zYF7l-1g

Externally Fixtured Fastener Installation:

https://www.youtube.com/watch?v=mTKAsNgogNw

Internally Fixtured Fastener Installation: https://www.youtube.com/watch?v=BtQQxUfnYHg



https://www.youtube.com/watch?v=M_4b2mgMcDo

https://www.youtube.com/watch?v=B3VjfKV0ero

https://www.youtube.com/watch?v=Xl_zYF7l-1g

https://www.youtube.com/watch?v=mTKAsNgogNw

https://www.youtube.com/watch?v=BtQQxUfnYHg


Page 63 of 82


Revision Number: 03



Event #25 Click Bond Adhesive-Bonded Fastener Installations

Printed instructions will be provided at the competition.

Tools and equipment list Gloves

Scotch Brite abrasive pads

Solvent wipes

Adhesive

Adhesive dispensers

Mixing tips

Fasteners (surface mounts, conical inserts, sleeves)

Instructions Team members will complete adhesive-bonded fastener installations:

A) Read all instructions provided before starting B) Use provided personal protection equipment C) Install adhesive-bonded fasteners as detailed in provided

instructions

Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for application of too little or too much adhesive, and/or adequate adhesive squeeze-out around fastener base.



Page 64 of 82


Revision Number: 03



Event #26 Boeing Cable Rigging

Provided by


Contact(s)/Judge(s) George Thompson, Boeing Seattle Flight Test, [email protected]

Todd Warnstadt, [email protected]

Description After first flight the aileron cable rig was found to be out of tolerance. Team members will re-rig cables AA & AB.

References Table 1-3 Cable Rigging Tension (lbs)

Tensitron ACX-1 Series Digital Aircraft Cable Tension Meter Operating Instructions

Safety Turnbuckle Diagram

Tools and equipment list Tensitron Cable Tension Meter

Cable diameter gauge

Instructions Warning: Check and clear aircraft and flight controls before turning on hydraulics.

A) Turn on both A&B system hydraulic switches, cycle ailerons check and install the rig pins in the captain’s wheel and the aileron control quadrant.

B) Turn off and deactivate both A&B systems hydraulics by pulling the circuit breaker for A&B system and installing the lock out collars.

Warning: Hydraulics systems must be deactivated prior to the start of any rigging operations.

C) Use the Cable diameter gauge included to easily and accurately measure cable size.

D) Record the size cable being rigged E) Set up Tensitron Meter




https://43107113-970418485411930239.preview.editmysite.com/uploads/4/3/1/0/43107113/cablerigging-table1-3.pdf

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/tensitron-manual.docx

https://www.aerospacecompetition.com/uploads/4/3/1/0/43107113/tensitron-manual.docx

https://43107113-970418485411930239.preview.editmysite.com/uploads/4/3/1/0/43107113/safety_turnbuckle_diagram.pdf


Page 65 of 82


Revision Number: 03




1) Power unit on by pressing ON button. Main display will indicate tension, material, five stored tension readings and their average, and other information.

2) Select a screen a) Move between screens by using the up (↑) and down (↓)

buttons b) Make or enter a selection by pressing the Enter/Zero

button c) Exit a setting by pressing the Escape (ESC) button.

3) Select Tension Units a) Using the up or down arrows, scroll to TENSION UNITS,

then press ENTER b) Next, select from Kilograms, DecaNewtons, or LBS, and

then press ENTER 4) Select Material

a) Using either the up or down arrows, scroll to SELECT MATERIAL, then press ENTER

b) Next scroll through the cable descriptions until the correct cable size is highlighted, then press ENTER. Your main display will indicate the cable size selected.

F) Use the tension values in Table 1-3 Cable Rigging Tension for cables AA&AB, the Tensitron meter and cable clamps adjust the cable tension to the correct value +5 / -15 lbs. for 64 F outside ambient temperature.

G) Record the required tension in lbs. per Table 1-3 H) Remove rig pins and cable clamps I) Reset Circuit breakers for the A&B system hydraulics

Warning: Check and clear aircraft and flight controls before turning on hydraulics.

J) Turn on A&B system hydraulic switches cycle the captain’s wheel, 5 times.

Note: Operate captain’s wheel gently and smoothly when cycling and returning to neutral.

K) Install Rig pins, Recheck rig load (table 1-3) of each cable and free movement of appropriate rig pins.

L) If good turn off hydraulics go to next step, if not return to step B M) Using the push/pull rod adjust the aileron to align with the mark,

after adjustments are complete, hand tighten jam nuts remove rig pins.

N) Safety turnbuckles per Safety Turnbuckle Diagram



Page 66 of 82


Revision Number: 03




O) Return all tools

Notes:

No more than 3 threads may show beyond turnbuckle body. Align the slit in the barrel with the slot in the cable terminal, insert the straight end of the lock clip into the aperture formed by the aligned slots. Bring hook end of the lock clip over the hole in the center of the turnbuckle barrel and seat the hook loop into the hole by applying pressure to the hook shoulder. Repeat these steps to lock the opposite end of the turnbuckle. Both locking clips may be inserted in the same turnbuckle barrel hole, or they may be inserted in the opposite holes.

Examine both locking clips for proper engagement of the hook lip by a slight pull in the disengaging direction without the use of any tools and by visual examination to make certain that the hook lip has engaged the interior of the turnbuckle body.

Lock clips shall not be reused. The paint on the clips provides a means for determining that the clips have not been previously used.




Page 67 of 82


Revision Number: 03



Event #27 (A) Pratt & Whitney PW1100G-JM Engine ACC Valve R/R

Provided by


Contact(s)/Judge(s) Hank Norton [email protected]

Description The task involves the removal, inspection, and replacement of an Active Clearance Control (ACC) valve installed on the PW1100G-JM engine.

Note: This event is made up of two separate tasks. Odd-numbered teams will complete Task #27(A), even-numbered teams will complete Task #27(B) (provided in subsequent pages of this manual).

References 43.13-1B – Acceptable Methods, Techniques, and Practices – Aircraft Inspection and Repair

Tools and equipment list Electrical Connector Pliers

3/8” drive ratchet

3/8” drive 6” extension

3/8” drive, 3/8” 12 point deep well socket

11/16” open end wrench

½” open end wrench

7/8” open end wrench

Dead blow plastic hammer

6” flathead screwdriver

3/8” drive torque wrench (click type – 200-1000 in/lb)




Page 68 of 82


Revision Number: 03




3/8” drive torque wrench (click type – 40-200 in/lb)

3/8” drive, 7/8” crows-foot

3/8” drive, 11/16” crows-foot

Lint-Free cotton cloth

Instructions “This document has been publicly released.”



Page 69 of 82


Revision Number: 03






Page 70 of 82


Revision Number: 03






Page 71 of 82


Revision Number: 03






Page 72 of 82


Revision Number: 03






Page 73 of 82


Revision Number: 03




Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for failure to place cloth under fuel lines, failure to validate torque wrench settings with the judge before use, failure to use back-up wrenches properly to apply counter-torque, or failure to visually examine the ACC valve and report findings to the judge.



Page 74 of 82


Revision Number: 03



Event #27 (B) Pratt & Whitney V2500 HPC 7th Stage Bleed Valve Solenoid Test

Provided by


Contact(s)/Judge(s) Steve Lewis [email protected]

Description This is a skill event that requires utilization of engine test equipment to determine proper function of engine components.

Note: This event is made up of two separate tasks. Odd-numbered teams will complete Task #27(A), even-numbered teams will complete Task #27(B).

References V2500 HPC STAGE 7 SOLENOID VALVE 4020KS2, REMOVAL – FUNCTIONAL – TEST INSTRUCTIONS

BASIC SOLENOID TEST PROCEDURES LISTED ON TEST SET FACE PLATE

Tools and equipment list IAE 2R19437 TEST SET

11/16 COMBINATION WRENCH

¾ COMBINATION WRENCH



¼ INCH DRIVE RATCHET

¼ – 12 POINT SOCKET




Page 75 of 82


Revision Number: 03




¼ INCH DRIVE EXTENSION 6 INCH

PLIERS SOFT-JAW

11/16 CROWS FOOT ¼ DRIVE (OPEN END)

13/16 CROWS FOOT ¼ DRIVE (OPEN END)

TORQUE WRENCH 0-250 INCH POUNDS

STRAP WRENCH FOR ELECTRICAL CONNECTOR

PROTECTIVE CAPS/COVERS

Instructions “This document has been publicly released.”

REMOVAL STAGE 7 SOLENOID VALVE 4020KSE

1. DISCONNECT THE HP3 AIR TUBES:

A) HP3 SUPPLY INPUT.

B) HP3 SERVO OUTPUT.

2. DISCONNECT THE ELECTRICAL CONNECTOR.

3. REMOVE HPC STAGE 7 SOLENOID VALVE:

A) REMOVE THE BOLTS & WASHERS WHICH ATTACH SOLENOID VALVE TO ENGINE BRACKET.

B) REMOVE SOLENOID VALVE.

4. INSTALL PROTECTIVE COVERS.

FUNCTIONAL TEST OF SOLENOID VALVE 4020KSE WITH TEST SET IAE2RI9437

1. INSTALLATION OF TEST SET:

A) CONNECT RED LINE TO SOLENOID VALVE SUPPLY INPUT CONNECTOR.

TORQUE TO 210 IN LBS.

B) CONNECT GREEN LINE TO SOLENOID VALVE SERVO OUTPUT CONNECTOR.



Page 76 of 82


Revision Number: 03





2. CONNECT SOLENOID VALVE ELECTRICAL CONNECTOR WITH CABLE PROVIDED TO TEST SET.

3. PREFORM BASIC SOLENOID TEST PROCEDURES LISTED ON TEST SET FACE PLATE.

(NOTE: SOLENOID VALVE IS ALREADY CONNECTED TO TEST SET)

4. REMOVAL OF SOLENOID VALVE FROM TEST SET:

A) TURN TEST SET ELECTRICAL POWER OFF AND REMOVE ELECTRICAL CABLE.

B) REMOVE RED LINE FROM SOLENOID VALVE SUPPLY INPUT CONNECTOR.

C) REMOVE GREEN LINE FROM SOLENOID VALVE SERVO OUTPUT CONNECTOR.

INSTALLATION OF STAGE 7 SOLENOID VALVE 4020KSE

1. REMOVE PROTECTIVE COVERS FROM LINES AND ELECTRICAL CONNECTOR.

2. ATTACH THE SOLENOID VALVE TO ENGINE BRACKET WITH WASHERS AND BOLTS.


4. INSTALL THE ELECTRICAL CONNECTOR TO THE SOLENOID VALVE

TIGHTEN CONNECTOR FULLY UNTIL RED LINE IS NO LONGER VISABLE

1. CONNECT THE HP3 AIR TUBES:

5. CONNECT THE HP3 SUPPLY LINE TO SOLENOID VALVE.


B) CONNECT THE HP3 SERVO LINE TO SOLENOID VALVE.


5. CLEAN UP AND REPLACE TOOLS.

6. INFORM JUDGE THAT EVENT IS COMPLETED.



Page 77 of 82


Revision Number: 03






Page 78 of 82


Revision Number: 03






Page 79 of 82


Revision Number: 03




Scoring Scores will be calculated according to the AMC score sheet. Additional penalties may be assessed for each step not completed, or incorrect test results.



Page 80 of 82


Revision Number: 03



Record of Revisions

REVISION NUMBER

REVISION DATE

PAGE(S) AFFECTED REVISION DESCRIPTION

00 12/18/2019 ALL Initial Release 01 03/05/2020 N/A Cancelled Boeing Fiber Optics Event (previously event #27).

There is no replacement for this event. 01 03/05/2020 N/A Removed reference to event groups in Events section (will no

longer refer to event groups, instead the event schedule will just reference the individual events).

01 03/05/2020 5 Changed competition start time on Tuesday, April 28 from 10:00 AM to 9:30 AM. Changed end time on Tuesday, April 28 and Wednesday, April 29 to 5:30 PM, added location information.

01 03/05/2020 6 Added link to 2020 release of liability form. 01 03/05/2020 6 & 7 Added link to standard score sheet, revised for 2020 event.

01 03/05/2020 9 Updated competition layout. 01 03/05/2020 10 Updated confirmed team list, added team numbers, added two

rosters, one listed numerically, by team number, and one alphabetical by team name.

01 03/05/2020 14-16 Added event schedule, included notes to clarify team number assignments in the schedule, added additional explanation in event description. Added note that start and end times will be strictly enforced for 2020, teams arriving late will not be provided a delayed start time.

01 03/05/2020 17 Revised instructions, description, and judge information for UPS Safety Wiring Event (Event #1).

01 03/05/2020 21 Moved FAA Exam Event from Event #29 to Event #3. 01 03/05/2020 22 Added new judge information to Alaska Airlines External Power

Receptacle Event (Event #4), uploaded new 2020 files for the task summary and maintenance manual (there were no substantive changes to the content in these documents).

01 03/05/2020 35 Update description and instructions for ULTRAX Aerospace Condition-Based Intelligence (CBITM) (Event #8)

01 03/05/2020 37 Revise description, tooling list, and instructions for NBAA & Dallas Airmotive Engine Fan Blade Removal (Event #10).

01 03/05/2020 39 Added wiring diagram and link to new video and photos to Daniels Manufacturing Corporation Electric Troubleshooting (Event #11).



Page 81 of 82


Revision Number: 03



REVISION NUMBER

REVISION DATE


01 03/05/2020 43 Updated tooling list, removed judging criteria from linked instructions, and changed from two- to three-person event for FedEx Express Turbine Engine PDU Removal and Installation, (Event #13).

01 03/05/2020 45 Update judges, description, and instructions for Perfect Point E-Drill Fastener Removal (Event #14)

01 03/05/2020 50 Moved 8Tree and Alaska Airlines Airframe Damage Inspection Event from Event #3 to Event #18, added co-sponsor recognition, revised event description and added reference to linked instructions.

01 03/05/2020 51 Added American Airlines Pedestal Event equipment sponsor recognition: Gemba Systems.

01 03/05/2020 57 Changed safety wire gauge for American Airlines APU Event (Event #22).

01 03/05/2020 62 Updated description, judges, and tooling list for Click Bond Adhesive-Bonded Fastener Installations Event (Event #25)

01 03/05/2020 67 Changed event number for Pratt & Whitney Event from Event #29 to Event #27 (for both A and B tasks), changed from two competitors to one competitor, replaced judge contacts.

02 03/08/2020 67 & 74 Fixed incorrect reference to event #30(A) and 30(B) in Pratt & Whitney Event (Event #27), changed incorrect event number for Event #27(B) (was previously, incorrectly labeled as Event #28(B)).

03 04/05/2020 30 Revise instructions for Eastern Florida State Space Vehicle – Vacuum Loading Op (Event #7).

03 04/05/2020 6 Given the postponement of the AMC, and the likely graduation of students that were scheduled to compete in the upcoming event, incorporated deviation to the rulebook to allow individuals to compete on a school team even if they have graduated and been employed during the time period between the originally scheduled dates (last week of April) and the rescheduled dates (last week of August).

03 04/05/2020 4 Revise MRO Americas floor pass registration link, new link for new September dates.



Page 82 of 82


Revision Number: 03



REVISION NUMBER

REVISION DATE


03 04/05/2020 All Review with new dates and details throughout (schedule of events, liability form, sponsor and event setup, shipping information.

03 04/05/2020 48 Cancelled AAR Nondestructive Testing Event


Documents

Aerospace Maintenance Council - Event Manual · 2020. 4. 5. · The AMC provides an opportunity for current and future maintenance professionals to showcase their abilities and see