Syllabus.pdf

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COURSE SYLLABUS

AFGHANISTAN AIR FORCE

C-208 Aircraft Maintenance Technician

Effective Date:

1 August 2014

Afghanistan Air Force

Contract number FA8617-14-C-6195

1 Aug 2014

AFSAT/AETC Approved for Release

AFSAT Disclosure Case Number 14-014, dated 26 AUG 2014 applies

UNCLASSIFIED

FA8617-14-C-6195

CDRL Data Item No. A010

Course Syllabus

Afghanistan BT/LL Program

FORWARD

1. PURPOSE: This publication is the syllabus for the Afghan Air Force (AAF) T-182T / C-

208B aircraft maintenance training program. This syllabus contains qualitative data for instructors in terms of criterion objectives for each unit of instruction and shows time, training standard correlation, support materials and guidance. It is broken into three major courses: levels 3, 2 and 1.

2. COURSE DESIGN DESCRIPTION: The instructional design is group paced. Courses will train AAF personnel to apply skills gained during training with limited instructor assistance.

Instructors should incorporate student-centered instructional techniques and materials into the course in an effort to enhance the learning environment.

3. TRAINING EQUIPMENT: All courses requires a computer with projector for viewing

PowerPoint presentations. Practical lessons require a mission aircraft dedicated for training use.

4. REFERENCES: All Original Equipment Manufacturer (OEM) maintenance manuals including aircraft, engine, propeller, avionics, structural and wiring diagrams.

5. INSTRUCTION SEQUENCE: Variations in instructional sequence are authorized.

Opportune training events or situations that allow for cross-utilization of equipment should be maximized. Classroom instruction will be conducted using computer presentation systems.

Practical instruction will be task specific using actual mission aircraft.

SYLLABUS

CESSNA 208 AIRCRAFT MAINTENANCE TECHNICIAN COURSE

LEVEL III

Course Description

This course prepares Afghan Air Force (AAF) fixed wing aircraft maintenance personnel to participate in a maintenance team conducting routine aircraft inspection, servicing, launch and recovery operations. It provides the necessary skills, knowledge and abilities enabling successful graduates to enter the level II maintenance technician course building on knowledge gained from level III training. Topics include: aircraft systems, danger areas, marshaling and ground handling, servicing, minor inspection and repair and theory of operation. This course is intended fill a gap between generic technical training and level II aircraft maintenance technician task qualification training allowing graduates to participate meaningfully within a flightline maintenance team. In cases where no technical training was received prior to arrival at unit, instructors will deliver instruction on fundamental topics including: FOD control, tool and equipment usage, fasteners, and corrosion control.

Course Objectives

Students will demonstrate knowledge in component identification, aircraft danger areas and theory of operation of major aircraft systems

Students will demonstrate the ability to independently conduct routine aircraft marshalling, servicing and ground handling operations without instructor assistance given the applicable tools and technical manual(s)

Students will demonstrate the ability to conduct pre/post flight inspections and aircraft configurations with limited instructor assistance given the applicable tools and technical manual(s)

Students will demonstrate the ability to independently conduct all tasks contained in the applicable Master Task List with limited instructor assistance given the applicable tools and technical manual(s)

Student Evaluation and Standards

Course events include classroom lecture/discussion, practical exercises and participation in a maintenance team conducting hands-on tasks involving actual mission aircraft under the direction of an instructor. Evaluation includes block progress checks, a comprehensive progress check and task proficiency demonstrations. Events will be evaluated as pass/fail and students will receive remedial instruction until task proficiency is achieved. Instruction will be delivered in the English language supported by Dari interpreter-translators. A comprehensive written end-of-course examination will be administered. Students must achieve at least a 70% passing score.

Course Attendance Policy

Training is very valuable and significant resources are expended to deliver quality instruction. As each lesson builds upon the knowledge and skills previously learned it is essential that students attend every lesson. Commanders and supervisors should ensure that students are able to commit to the entire course duration with no leaves or extended absences.

Attendance is mandatory six days per week, 6 hours per day. Students will be expected to make every effort attend each training event. Students absent for less than 12 consecutive instructional hours may receive remedial training at their Instructor’s discretion outside of normal class hours. Students absent for 12 or more consecutive training hours will be recommended for removal from training.

Students will be expected to be on time for each training event. If a student is more than 15 min late for any event he will be excused from that event and have to receive remedial training outside of normal class hours. If a student is more than 15 min late three times during the course he will be recommended for removal from training.

General Course Outline

Lesson No. Topic Time Allotted*

Course intro Administrative, Safety, Danger areas, Expectations 1 Day

Lesson 1 Aircraft Fundamentals 2 Days

Lesson 2 Theory of Operation 2 Days

Lesson 3 Flight Controls and Landing Gear 1 Day

Lesson 4 Engine and Propeller 3 Days

Lesson 5 Fuel System 1 Day

Lesson 6 Electrical System 1 Day

Lesson 7 Aircraft Lighting 1 Day

Lesson 8 Pneumatic and Environmental 1 Day

Lesson 9 Pitot Static 1 Day

Lesson 10 Communication and Navigation 1 Day

Lesson 11 Ground Support Equipment 2 Days

Lesson 12 Aircraft Movement & Ground Handling 8 Days

Lesson 13 Aircraft Servicing/Inspection 8 Days

Lesson 14 Maintenance Forms & Publications 3 Days

TOTAL: 36 Days

*Varies with class size, figure shown for class of 5. Time allotted may vary widely due to student attendance, proficiency and other factors e.g. Afghan seasonal holidays

Additional Information

Projected Course Length: 6 weeks (36 training days)

Class Size: Min: none Max: 5

Target Audience: Newly assigned AAF aircraft maintenance technicians assigned to fixed-wing aircraft maintenance units. Typically in the NCO or junior officer grades

Lesson Outline

Course Intro

Title: Administrative, Safety, Danger areas, Expectations

Lesson Objective: The objective of this lesson is to welcome and motivate students while making clear expectations for student attendance and individual performance, discuss safety and gain knowledge of aircraft danger areas. Instructor will coordinate with the local AAF Maintenance Group and Fixed Wing Maintenance Squadron Commanders to brief student expectations. Instructor will cover the importance of safety and strict adherence to technical manuals to prevent injury and/or damage to equipment.

Instructor will demonstrate appropriate use of personal protective equipment e.g. gloves and eye/ear protection. Students will be taught aircraft danger areas and be expected to correctly identify with an accuracy of 100%.

- Method of evaluation: comprehensive progress check questions

- Course objectives supported: All

Measurable Samples of Behavior:

- Restate definitions of safety, personal protective equipment, warnings, cautions and notes.

- Identify aircraft danger areas

- Restate instructor and AAF leadership expectations and attendance rules

Time Allotted: 1 Day

Methods of Instruction: Briefing, guided discussion.

Instructional Materials: Handout

Audio Visual Aids Required: None.

Instructional Equipment: Personal protective equipment.

Lesson 1

Title: Aircraft Fundamentals

Lesson Objective: The objective of this lesson is to define major aircraft features, components of structure, systems, missions and configurations. Instructor will identify and explain methods to ensure systems are in off, safe or normal mode. Aircraft weights, dimensions and operating parameters will be taught. Students will be introduced to basic aerodynamics and instructors will explain how the aircraft is able to achieve flight. Using actual mission aircraft students will review aircraft danger areas and be expected to correctly identify with an accuracy of 100%.

- Restate major aircraft sections and components with an accuracy of 100%

- Identify aircraft danger areas and restate methods to ensure systems are in off/safe/normal mode with an accuracy of 100%

- Restate aircraft systems nomenclature, features, dimensions and configurations with instructor assistance

Time Allotted: 2 Days

Instructional Materials: Handout, PowerPoint Presentation

Audio Visual Aids Required: PowerPoint presentation.

Instructional Equipment: Computer and computer projector, C-208 aircraft.

Lesson 2

Title: Theory of Operation

Lesson Objective: The objective of this lesson is to introduce students to the major components and theory of operation of aircraft systems. Instructors will broadly describe operation of the electrical system, powerplant, landing gear/brakes, flight controls, environmental/oxygen and fuel systems. Instructor will identify and explain subcomponents and their functions. Students will be taught simple hydraulic/electrical theory, internal operation of aircraft powerplants, flight control actuation, subcomponents of the fuel and environmental systems. Students will be expected to identify main subcomponents of major aircraft systems to an accuracy of 100%. Using actual mission aircraft students will review dangers associated with each system (e.g.

fuel exposure, electrical shock) and be expected to correctly identify with an accuracy of

100%.

- Restate main components of major aircraft systems with an accuracy of 100%

- Identify dangers associated with major aircraft systems with an accuracy of

100%

- Restate electrical, hydraulic, flight control and powerplant theory of operation with instructor assistance

Instructional Materials: Handout, PowerPoint Presentation

Audio Visual Aids Required: PowerPoint presentations.

Lesson 3

Title: Flight Controls and Landing Gear

Lesson Objective: The objective of this lesson is to introduce students to the function, operation, and limitations of the C-182/C-208B primary flight controls, spoilers, trim systems and landing gear. Instructors will describe the mechanical actuation of the flight control system and describe how the various flight control surfaces react. Instructors will identify and explain subcomponents and their functions. Students will be expected to identify safe installation of locking devices and position of circuit breakers to an accuracy of 100%. Instructors will describe the landing gear, tow lugs, brakes, wheels, tires and steering mechanisms. Using actual mission aircraft students will conduct basic inspections of flight controls and landing gear.

- Restate main components of aircraft flight control and landing gear systems and their functions with an accuracy of 100%

- Identify proper installation of locking and safety devices with an accuracy of

100%

- Perform basic pre/post flight inspection of flight control surfaces, tires and brakes with limited instructor assistance given applicable tools and technical manual(s)

Instructional Materials: Handout, PowerPoint Presentation

Lesson 4

Title: Engine and Propeller

Lesson Objective: The objective of this lesson is to identify the major sections of the C-

182/208 powerplant and McCauley propeller along with their supporting systems.

Instructors will identify and explain engine subcomponents, accessories and their functions. Students will learn the theory of operation of turbine and reciprocating engines and be expected to correctly restate given instructor assistance. Engine power terminology, engine controls, G1000 engine indication system and sensing system will be introduced. Supporting systems (ignition, pressure, scavenge and breather systems) function and operation will be discussed. Lubrication system and chip detectors will be discussed in detail. Students will be expected to restate importance of properly operating lubrication system and demonstrate how to check oil level to an accuracy of

100%. Instructors will describe the fire detection system. Using actual mission aircraft students will conduct basic engine inspections.

- Restate theory of operation of C-182/208 engines with instructor assistance

- Identify major engine subcomponents, accessories and their functions with limited instructor assistance

- Restate importance of properly operating lubricating system and failure modes, demonstrate procedure to check engine oil with an accuracy of 100% given applicable tools and technical manual(s)

- Perform basic pre/post flight inspection of engines with limited instructor assistance given applicable tools and technical manual(s)

Time Allotted: 3 Days

Instructional Materials: Handout, PowerPoint Presentation

Lesson 5

Title: Fuel System

Lesson Objective: The objective of this lesson is to identify the main components of the C-

182/208 fuel system and state their relative locations in the system. Instructors will discuss components in approximately the order that they appear in the fuel system as fuel enters the fuel tanks and makes its way through the system to the engine. Students will learn the system theory of operation and dangers of fuel with emphasis on 100 low-lead type fuel. Students will be expected to correctly identify tanks, vents, valves, drains, reservoir, pumps, manifolds and filters given instructor assistance. Students will be expected to restate major components and flow of fuel with limited instructor assistance. Instructors will also describe the fuel quantity transducers and indicators as well as discuss maximum fuel imbalance.

- Restate theory of operation of C-182/208 fuel system with instructor assistance

- Identify major fuel system subcomponents and their functions with limited instructor assistance

- Restate dangers of fuel, especially 100 low-lead, with an accuracy of 100%

Instructional Materials: Handout, PowerPoint Presentation

Lesson 6

Title: Electrical System

Lesson Objective: The objective of this lesson is to identify the main components of the C-

182/208 electrical systems and state component purposes. Students will learn in broad terms electrical theory, how electricity moves throughout the system and common failure modes. Instructors will discuss components and their operation in both in a classroom environment and on actual aircraft. Students learn the system theory of operation and the dangers of electricity. Students will be expected to correctly identify the battery, generator, buses, circuit breakers and starter given instructor assistance.

Students will be expected to restate major components and electrical path with limited instructor assistance. Students will be exposed to procedures to apply external power.

Instructors will also describe switches, lights, wiring and the generator control unit.

Students should be cautioned not to attempt system troubleshooting as that may cause injury or damage to equipment. Students should be trained to recognize faults and alert a qualified mechanic.

- Method of evaluation: direct evaluation, comprehensive progress check questions

- Restate theory of operation of C-182/208 electrical system with instructor

- Identify major electrical system subcomponents and their functions with limited instructor assistance

- Restate dangers of electricity, correctly identify a popped circuit breaker and state reset procedure with an accuracy of 100%

Instructional Materials: Handout, PowerPoint Presentation

Lesson 7

Title: Aircraft Lighting

Lesson Objective: The objective of this lesson is to identify the location of the interior and exterior lighting on the C-182/208 aircraft and their associated controls. Students will learn the various functions, location of switches and circuit breaker. Instructors will discuss components and their operation in both in a classroom environment and on actual aircraft. Students learn the system theory of operation, operational check and light bulb change procedures. Students will be expected to correctly identify the landing, navigation, taxi and strobe lights given instructor assistance. Students will be expected to restate major components and simple/basic electrical path with limited instructor assistance. Students will be exposed to procedures to remove and inspect lens covers.

- Restate functions and locations of C-182/208 lighting system with instructor

- Identify common system failure modes and procedures to quickly correct with instructor assistance

- Perform operational checkout of exterior aircraft lighting as part of a preflight inspection with an accuracy of 100%

Instructional Materials: Handout, PowerPoint Presentation

Lesson 8

Title: Pneumatic and Environmental

Lesson Objective: The objective of this lesson is to identify the function and location of the pneumatic and environmental systems of the C-182/208 aircraft. Students will learn the various functions and component location of the engine bleed air system. Instructors will discuss components and their operation in both cabin heat functions, vacuum, ventilation, air conditioning and fuel control systems. Students will learn the system theory of operation, operational check and common/very basic failure modes. Instructors will describe in broad terms how bleed air is tapped from the engine and routed.

Students will be expected to restate major components with limited instructor assistance. Students will be exposed to procedures to inspect the air conditioner compressor drive belt, hoses and pressure lines.

- Restate functions and locations of C-182/208 pneumatic and environmental systems with instructor assistance

- Identify common system failure modes and inspection procedures with

Instructional Materials: Handout, PowerPoint Presentation

Lesson 9

Title: Pitot Static

Lesson Objective: The objective of this lesson is to identify the function and location of the pitot/static systems of the C-182/208 aircraft. Students will learn the system function and component location. Instructors will discuss components and their operation in instrument systems. Students learn the system theory of operation, and inspection procedures. Students will be expected to restate major components with limited instructor assistance.

- Restate functions and locations of C-182/208 pitot/static systems with

- Identify common system failure modes and inspection procedures with

Instructional Materials: Handout, PowerPoint Presentation

Lesson 10

Title: Communication and Navigation

Lesson Objective: The objective of this lesson is to identify the functions, capabilities and component location of the communication and navigation systems of the C-182/208 aircraft. Students will learn the various system functions, modes and component location. Instructors will discuss components, their operation and the Line Replaceable

Unit (LRU) concept. Students learn the system theory of operation, and common failure modes. Instructors will describe in broad terms how the weather radar operates.

Students will be expected to restate major components with limited instructor assistance.

- Restate functions and locations of C-182/208 communication and navigation systems with instructor assistance

- Identify common system failure modes of operation and restate LRU concept with instructor assistance

Instructional Materials: Handout, PowerPoint Presentation

Lesson 11

Title: Ground Support Equipment

Lesson Objective: The objective of this lesson is to identify the functions and proper use of various Ground Support Equipment (GSE). Students will learn how to perform a prior to use inspection, transport, set-up and safely operate GSE. Students learn equipment-specific safety measures e.g. proper grounding, set parking brake and procedures to service equipment e.g. refill pressure washer water tank. Instructors will demonstrate proper selection and use of appropriate Personal Protective Equipment (PPE). Students will be expected to restate GSE functions, safety precautions and PPE use with limited instructor assistance. This lesson will not teach or qualify students to operate a motor vehicle, instructors will emphasize that students that cannot drive must not tow/transport GSE.

- Restate functions and safety precautions of C-182/208 GSE systems with limited instructor assistance

- Preform GSE prior-to-use inspection, proper set-up and PPE use with limited

Methods of Instruction: Briefing, guided discussion, demonstration

Instructional Materials: Handout, PowerPoint Presentation

Audio Visual Aids Required: PowerPoint presentation.

Instructional Equipment: Computer and computer projector, GSE (Light-All, Ground Power

Cart, Oxygen Servicing Cart, Air Compressor, Rinse Cart, Pressure Washer, Jacks, Ladders, Maintenance Stands, Tow Bar / Tractor, Fuel Pump Cart)

Lesson 12

Title: Aircraft Movement and Ground Handling

Lesson Objective: The objective of this lesson is to teach students proper aircraft marshalling and towing procedures. Students will learn various signals and methods necessary to safely launch, recover and park aircraft. Instructors will cover responsibilities of each member of a launch/recovery crew including fireguard and marshaller. Students will also learn how to operate an aircraft tow vehicle and participate as part of a tow team operation. Instructors will cover the responsibilities each tow team member including tow supervisor, wing walker, brake rider and tractor operator.

Students will learn how to move an aircraft by hand, procedures to safely hangar an aircraft and emergency procedures. This lesson will not teach or qualify students to operate a motor vehicle. Instructors will emphasize to students that cannot drive that they cannot safety operate an aircraft tow vehicle.

- Method of evaluation: direct evaluation using actual mission aircraft, comprehensive progress check questions

- Demonstrate proficiency in all phases of aircraft marshalling as part of a launch or recovery team without instructor assistance

- Demonstrate proficiency in all areas as member of an aircraft tow team without instructor assistance

- Restate conditions where a wing-walker is necessary and demonstrate emergency action procedures without instructor assistance

- Restate inspection and use procedures of flightline fire extinguishers, demonstrate proficiency as fireguard

Time Allotted: 8 Days

Instructional Materials: Handout, PowerPoint Presentation

Audio Visual Aids Required: PowerPoint presentations.

Instructional Equipment: Computer and computer projector, C-208 aircraft, tow tractor and tow bars

Lesson 13

Title: Aircraft Servicing and Inspection

Lesson Objective: The objective of this lesson is to teach students proper aircraft servicing and inspection procedures. Students will learn procedures for servicing fuel, oil, TKS fluid and oxygen. Students will also learn procedures for conducting pre and post-flight inspections as well as C-208 configuration changes. Instructors will cover inspection techniques and common wear points e.g. tires and brakes. Working under the direction of a fully qualified mechanic, students will conduct inspections utilizing locally developed

English/Dari checklists. This lesson builds upon, incorporates and enhances knowledge gained from previous lessons. Instructors should challenge students and train to any knowledge gaps or provide remedial instruction if necessary. Upon successful completion students should be able to operate semi-independently under the general direction of a fully-qualified mechanic.

- Method of evaluation: direct evaluation using actual mission aircraft,

- Demonstrate proficiency in aircraft servicing with limited instructor assistance given applicable checklist(s) and technical manual(s)

- Demonstrate proficiency in the performance of aircraft pre and post-flight inspections with limited instructor assistance given applicable checklist(s) and technical manual(s)

Time Allotted: 8 Days

Instructional Materials: Handout, PowerPoint Presentation, Locally developed checklists

Instructional Equipment: Computer and computer projector, C-208 aircraft

Lesson 14

Title: Maintenance Forms & Publications

Lesson Objective: The objective of this lesson is to familiarize students with aircraft forms entry procedures, AAF supply requisition forms and applicable Afghan Ministry of

Defense (MoD) decrees. Students will learn procedures making entries in aircraft forms, discrepancy sign-off and determining the aircraft status from the forms. Instructors will introduce students to MoD forms 9 and 14. Instructors will also introduce students to

MoD decree 4.9-1, Aviation Maintenance Management Policy. Literacy levels may vary widely and instructors will tailor instruction accordingly. The lesson objective is familiarization only, until students become fully qualified they will most likely not utilize

MoD forms and publications in their day-to-day duties. More in-depth instruction may be offered to senior ranking students.

- Method of evaluation: direct evaluation using actual aircraft forms,

- Demonstrate proficiency in making aircraft forms entries with limited

- Demonstrate proficiency in determining aircraft status using aircraft forms with limited instructor assistance

- Restate purpose of MoD forms 9, 14 and MoD decree 4.9-1

Instructional Materials: Handout, PowerPoint Presentation, MoD forms/decrees

Audio Visual Aids Required: None

Instructional Equipment: C-208 aircraft forms

LEVEL II

This course will prepare students to contribute meaningfully to a maintenance team conducting scheduled inspections, component removals/installations, operational checks and corrosion control. Under the direction of a fully qualified Airframe and Powerplant

(A&P) mechanic students may perform unscheduled maintenance, repairs and troubleshooting. Students will be thoroughly trained in aircraft system theory, design, operation and failure modes. Upon successful completion students will be prepared to independently diagnose/remedy common expected wear-out items. Successful graduates may be expected to lead/train level III students. This course is intended to provide students with the necessary knowledge, skills and ability to operate independently under the general direction of a fully qualified A&P mechanic while gaining experience in preparation for level I training.

Students will demonstrate knowledge of aircraft systems and proficiency in conducting routine scheduled and preventative maintenance tasks including engine, airframe and flight control systems

Students will demonstrate the ability to independently conduct routine component removals, inspections, reinstallations and operational checkouts with limited instructor assistance given the applicable tools and technical manual(s)

Students will demonstrate the ability to diagnose faulty components, state reason for failure and provide corrective actions given the applicable tools and technical manual(s)

Students will demonstrate the ability to independently conduct all level-2 tasks contained in the applicable Master Task List with limited instructor assistance given the applicable tools and technical manual(s)

Course events are primarily hands-on using actual mission aircraft either dedicated for training use or undergoing scheduled maintenance. Classroom lecture/discussion should be utilized to expand upon a subject area or aircraft system, answer questions and create a forum for guided discussion. Instructors are encouraged to utilize illustrated parts breakdowns to show an exploded view of a component in a classroom prior to conducting maintenance actions to enhance student understanding. Evaluation should include practical exercises, direct questions and “over-the-shoulder” task proficiency assessments during maintenance events. Evaluation should also include block progress checks based on major aircraft systems. Events will be evaluated as pass/fail and students will receive remedial instruction until task proficiency is achieved. Instruction will be delivered in the English language supported by Dari interpreter-translators. A comprehensive written end-of-course examination will be administered. Students must achieve at least a 70% passing score.

Same as level-3 course.

Course intro Administrative and expectations 1 Day

Lesson 1 Towing supervisor, fuselage jacking 2 Days

Lesson 2 Servicing and intro to 100hr inspections 6 Days

Lesson 3 Aircraft doors and windows 6 Days

Lesson 4 Brake system and landing gear inspections 3 Days

Lesson 5 Nose wheel steering and shock strut 4 Days

Lesson 6 Lighting system maintenance 4 Days

Lesson 7 Flight control system inspections 6 Days

Lesson 8 Propeller, governor and spinner 5 Days

Lesson 9 Engine scheduled maintenance 6 Days

Lesson 10 Ignition system 3 Days

Lesson 11 Fuel nozzle inspection and maintenance 3 Days

Lesson 12 Fuel system 6 Days

Lesson 13 Anti-icing system 6 Days

Lesson 14 Equipment and furnishings, radio operation 3 Days

Lesson 15 Air conditioning system 5 Days

TOTAL: 69 Days

*varies with class size, figure shown for class of 3; time allotted may vary widely due to student attendance, proficiency and other factors e.g. Afghan seasonal holidays

Additional Information

Projected Course Length: 12 weeks (69 training days)

Class Size: Min: none Max: 3

Target Audience: Students that have completed the level-3 course. Typically in the

NCO or junior to field grade officer ranks

Title: Administrative and expectations making clear the expectations for student attendance and individual performance.

Instructor will coordinate with the local AAF Maintenance Group and Fixed Wing

Maintenance Squadron Commanders to brief student expectations. Instructor will introduce himself and the interpreter and invite students to do the same. This is an opportunity to learn about the student’s background and potential strengths or weaknesses. The senior ranking class member is appointed class leader and instructor will state his role. Instructor will cover the course outline and describe the daily routine that students can expect. Instructor will emphasize safety and state personal protective equipment use policy.

- Restate definitions of safety and personal protective equipment

Instructional Materials: Training schedule handout.

Instructional Equipment: None.

Title: Towing supervisor, fuselage jacking

Lesson Objective: The objective of this lesson is to for students to gain the skills and abilities necessary to perform the duties of aircraft tow team supervisor and fuselage jacking. Instructor will delineate the duties of tow team supervisors and state the hazards of ground movements. Using actual mission aircraft, students will form a tow team and rotate in the role of tow team supervisor. Students will perform an aircraft jacking operation in preparation for leveling and rotate in the supervisor role.

- Method of evaluation: comprehensive progress check questions, direct evaluation

- Restate tow team supervisor duties to an accuracy of 100%

- Perform tow team supervisor duties without instructor assistance

- Restate conditions that indicate fuselage jacking and dangers with 100% accuracy

- Conduct an aircraft fuselage jacking operation with limited instructor

Methods of Instruction: Practical exercise, briefing, guided discussion.

Instructional Materials: PowerPoint Presentation

Audio Visual Aids Required: Print selected slides from PowerPoint presentation (optional).

Instructional Equipment: Computer and projector, C-208 aircraft.

Title: Servicing and intro to 100hr inspections abilities necessary to conduct scheduled maintenance actions on engine oil and air filters, flight control systems including applying lube and strut servicing. Instructors will describe the progressive inspection concept and the magnitude of each 100hr interval.

Using actual mission aircraft students will conduct removal, inspection and reinstallation of engine oil and air filters. Students will perform flight control lubrication as indicated by the applicable maintenance manual and learn procedures for strut servicing.

- Restate progressive inspection concept to an accuracy of 100%

- Remove, inspect and reinstall engine oil and air filters with limited instructor assistance

- Apply lubricant to aircraft flight and engine controls and inspect system for evidence of chaffing or other damage with limited instructor assistance

- Service a nose landing gear shock strut with limited instructor assistance

- State effects of excessive or lack of lubricant to an accuracy of 100%

Time Allotted: 6 Days

Instructional Materials: PowerPoint Presentation

Title: Aircraft doors and windows abilities necessary to remove, inspect, repair, adjust and install aircraft doors and windows. Instructors will describe the functions and failure modes of doors, latching mechanisms, seals, steps and windows. Using actual mission aircraft students may remove one or more of the following: crew, passenger or cargo doors. Students will learn inspection latching mechanism adjustment procedures. Students will learn procedures to remove and install steps, door seals and gas springs. Instructors will cover conditions that indicate temporary windshield repairs. Students may remove one or more of the following: cabin, crew door, cargo door or pilot’s vent window.

- Restate door and window failure modes and corrective actions to an accuracy of 100%

- Restate conditions that indicate and procedures to conduct temporary windshield repairs with limited instructor assistance

- Remove, inspect and reinstall an aircraft door and associated components

- Adjust latching mechanism and hinge points with limited instructor assistance

Instructional Materials: PowerPoint Presentations

Title: Brake system and landing gear inspections abilities necessary to remove, inspect, repair and install brake master cylinders, backplate and pressure plate. Students will also learn wheel balancing, brake bleeding and pad wear check procedures. Instructors will describe the operation and failure modes of brake system. Using actual mission aircraft students may remove brake pads, master cylinder, parking brake valve, axle and/or landing gear. Instructors will cover main wheel alignment check.

- Conduct brake pad wear check, removal and replacement without instructor

- Remove and install brake master cylinder, backplate and pressure plate with

- Balance wheel and tire assembly with limited instructor assistance

Instructional Materials: PowerPoint Presentations

Title: Nose wheel steering and shock strut abilities necessary to remove, install, rig and conduct operational check of the nose wheel steering system. Removal and installation of the shimmy damper will also be taught. Students will also learn procedures for removal, disassembly, inspection and assembly of the nose gear shock strut.

- Conduct nose wheel steering removal, installation and operational checkout

- Demonstrate rigging procedures with limited instructor assistance

- Remove and install shimmy damper assembly with limited instructor

- Remove, disassemble, reassemble and install nose gear shock strut

Time Allotted: 4 Days

Instructional Materials: PowerPoint Presentations

Title: Lighting system maintenance abilities necessary to remove and install interior and exterior components of the aircraft lighting system including strobe light flash tubes and power pack. Procedures for wing tip removal and installation will also be taught. Students will learn common failure modes, system inspection and lens cleaning procedures.

- Correctly identify all interior aircraft lighting system components with an accuracy of 100%

- Demonstrate ability to remove and install interior system components including bulbs, sockets and wiring with limited instructor assistance

- Demonstrate ability to remove and install exterior system components including navigation, beacon and anti-collision lights with limited instructor assistance

- Demonstrate ability to remove and install wing tip with limited instructor

Instructional Materials: PowerPoint Presentation.

Title: Flight control system inspections abilities necessary to remove, inspect and install components of the aircraft flight control system including: control column, control cables, rods and bell cranks. Students will learn procedures for flap motor and transmission removal and installation. Scheduled maintenance procedures will also be taught including checking and adjusting cable tension.

- Perform inspections of flight control system components as part of scheduled maintenance with limited instructor assistance

- Demonstrate ability to remove and install to remove and install control column and column tube assembly bearings with limited instructor assistance

- Correctly identify, state functions of, and restate inspection criteria for control cables, bell cranks and push-pull rods with an accuracy of 100%

- Demonstrate ability to remove and install flap motor and transmission with

Instructional Materials: PowerPoint Presentation.

Title: Propeller, governor and spinner abilities necessary to remove and install the propeller assembly, spinner, propeller governor and propeller overspeed governor.

evaluation of task performance

- Perform removal and installation of aircraft propeller and spinner assemblies

- Diagnose propeller grease or oil leakage and state corrective actions

- Diagnose propeller corrosion and state corrective actions

- Demonstrate ability to remove and install propeller governor and overspeed governor with limited instructor assistance

Time Allotted: 5 Days

Instructional Materials: PowerPoint Presentation.

Title: Engine scheduled maintenance abilities necessary to conducted scheduled maintenance actions related to the engine, engine compartment, engine controls, accessories and exhaust.

- Perform routine scheduled engine inspections including engine compartment zonal inspection and blade wash with limited instructor assistance

- Demonstrate ability to remove and install engine control cables and assemblies with limited instructor assistance

- Remove, inspect and reinstall engine exhaust with limited instructor assistance

- Demonstrate ability to remove and install starter generator assembly with limited instructor assistance

- Correctly state chip detector function and demonstrate inspection/check with

100% accuracy

Instructional Materials: PowerPoint Presentation.

Title: Ignition System abilities necessary to conducted scheduled maintenance actions related to the ignition system including exciter, cables and spark igniters.

- Remove and install ignition exciter and ignition cable with limited instructor

- Remove, inspect, clean and install spark igniters with limited instructor

Instructional Materials: PowerPoint Presentation.

Title: Fuel nozzle inspection and maintenance abilities necessary to conduct scheduled maintenance actions related to the fuel nozzles including removal, inspection, cleaning and installation. Instructors will teach procedures for nozzle and fuel tube replacement, cleaning procedures and nozzle spray pattern analysis.

- Remove and install fuel nozzles and associated components with limited

- Conduct spray pattern analysis of fuel nozzles and identify faulty nozzles with

100% accuracy.

- Demonstrate ability to properly conduct routine fuel nozzle cleaning as part of scheduled inspections with limited instructor assistance

Instructional Materials: None

Audio Visual Aids Required: None

Instructional Equipment: C-208 aircraft.

Title: Fuel system abilities necessary to conduct scheduled maintenance actions and repairs related to the fuel system including valves, drains, lines, filters and reservoirs. Students will learn to mix and apply sealant. Instructors will describe common system failure modes and remedy procedures.

- Remove disassemble, inspect and install fuel filter with limited instructor

- Remove and install fuel drain, vent and associated lines and tubes with limited instructor assistance

- Demonstrate ability to diagnose fuel leaks and ability to properly mix and apply sealant with limited instructor assistance

- Demonstrate ability to remove fuel reservoir, selector controls and low fuel switch with limited instructor assistance

Instructional Materials: PowerPoint Presentation.

Title: Anti-icing system abilities necessary to conduct scheduled actions and repairs related to the anti-icing and de-icing system. Students will learn procedures to drain and remove anti-ice fluid tank and associated pumps, filters, switches and valves. Instructors will describe common system failure modes and remedy procedures.

- De-service, drain remove and install anti-ice fluid tank, filter pack and pump

- Remove and install solenoid valve, low level switch, check valve and drain valve with limited instructor assistance

- Demonstrate ability to remove and install porous panel with limited instructor assistance

- Demonstrate ability to and install windshield spray bar, propeller proportioning unit and slinger ring with limited instructor assistance

Title: Equipment and furnishings, radio operation abilities necessary to conduct removal and installation of seats, harnesses and to operate radios. Students will learn procedures to remove and install armrests, sunvisors seat belts and inertia reels. Instructors will describe common system failure modes and remedy procedures.

- Remove and install crew and passenger seats with limited instructor

- Operate VHF radio and interphone systems with limited instructor assistance

- Demonstrate ability to remove and install seat belts, shoulder harness, inertia reel, armrest and sunvisor with limited instructor assistance

- Demonstrate ability to conduct restraint system operational check with 100% accuracy

Lesson 15

Title: Air conditioning system abilities necessary to conduct maintenance actions related to the air conditioning system including vents, valves, ducts, compressor, condenser and evaporator. Students will learn procedures to remove and install components, plumbing and drive belt. Instructors will describe common system failure modes and remedy procedures.

- Remove and install cabin air ventilation valve, fan and duct with limited

- Remove and install air conditioning compressor, condenser, evaporator and receiver/dryer with limited instructor assistance

- Demonstrate ability to remove and install system controls with limited instructor assistance

- Demonstrate ability to conduct compressor drive belt functional check with

100% accuracy

LEVEL I

This course will prepare students to contribute meaningfully to a maintenance team conducting removals and installations of major/critical assemblies, flight control rigging and removal and installation of flight control surfaces. Students will be taught procedures for conducting complex, critical and/or sensitive adjustments/calibrations.

Students will learn procedures for propeller assembly damage repair, adjustment and functional check. Detailed aircraft inspections e.g. hard/heavy landing, lightning strike, foreign object damage, overspeed and extreme maneuvering will be taught. Engine indicating system functional checks, aircraft leveling and engine run will also be covered.

Successful graduates of the Level I course will have the knowledge, skills and ability to perform in leadership roles within fixed wing aircraft maintenance. This is the final

“capstone” course, graduates that successfully matriculate through all levels of training will have the ability to plan, direct and carry out aircraft maintenance. It is intended for mid-level officers/SNCOs that will supervise subordinate mechanics while working under the general oversight of an A&P mechanic.

Students will demonstrate proficiency in the removal, installation and rigging of major aircraft components such as wing, strut and flight control surfaces

Students will demonstrate the ability to independently conduct conditional inspections

Students will learn procedures for conducting engine and associated component removal, installation and inspections

Students will learn procedures for engine control rigging, functional check and adjustment

Students will learn procedures for propeller assembly damage repair, adjustment, test and functional checks

Students will demonstrate proficiency in aircraft leveling, fuselage jacking supervisor, engine run

Students will learn procedures for conducting sensitive adjustments to the fuel quantity system, low fuel level switch and anti-ice sender unit

Students will demonstrate the ability to diagnose faulty components, state reason for failure and provide corrective actions given the applicable tools and technical manual(s)

Students will demonstrate the ability to independently conduct all level-1 tasks contained in the applicable Master Task List with limited instructor assistance given the applicable tools and technical manual(s)

Course events are primarily hands-on using actual mission aircraft either dedicated for training use or undergoing scheduled maintenance. Classroom lecture/discussion should be utilized to expand upon a subject area or aircraft system, answer questions and create a forum for guided discussion. Instructors are encouraged to utilize illustrated parts breakdowns to show an exploded view of a component in a classroom prior to conducting maintenance actions to enhance student understanding. Evaluation should include practical exercises, direct questions and “over-the-shoulder” task proficiency assessments during maintenance events. Evaluation should also include block progress checks based on major aircraft systems. Events will be evaluated as pass/fail and students will receive remedial instruction until task proficiency is achieved. Instruction will be delivered in the English language supported by Dari interpreter-translators. A comprehensive written end-of-course examination will be administered. Students must achieve at least a 70% passing score.

Same as level-3 course.

Course intro Administrative and expectations 1 Day

Lesson 1 Fuselage jacking supervisor, aircraft leveling 2 Days

Lesson 2 Conditional inspections 18 Days

Lesson 3 Major aircraft structures removal and installation 18 Days

Lesson 4 Fuel quantity system calibration, adjustment and test 4 Days

Lesson 5 Engine vibration analysis and propeller balancing 4 Days

Lesson 6 Engine conditional inspections and borescope 6 Days

Lesson 7 Propeller damage repair, adjustment and test 6 Days

Lesson 8 Engine removal and installation 6 Days

Lesson 9 Engine controls 5 Days

Lesson 10 Engine rigging 4 Days

Lesson 11 Engine indicating systems 6 Days

Lesson 12 Exhaust duct field installation 4 Days

Lesson 13 Starter-generator detailed inspection 4 Days

Lesson 14 Engine run up 12 Days

TOTAL: 100 Days

*varies with class size, figure shown for class of 3; time allotted may vary widely due to student attendance, proficiency and other factors e.g. Afghan seasonal holidays

Additional Information

Projected Course Length: 17 weeks (100 training days)

Class Size: Min: none Max: 2

Target Audience: Students that have completed the level-3 course. Typically in the

NCO or junior to field grade officer ranks

Title: Administrative and expectations making clear the expectations for student attendance and individual performance.

Instructor will coordinate with the local AAF Maintenance Group and Fixed Wing

Maintenance Squadron Commanders to brief student expectations. Instructor will introduce himself and the interpreter and invite students to do the same. This is an opportunity to learn about the student’s background and potential strengths or weaknesses. The senior ranking class member is appointed class leader and instructor will state his role. Instructor will cover the course outline and describe the daily routine that students can expect. Instructor will emphasize safety and state personal protective equipment use policy.

- Restate definitions of safety and personal protective equipment

Instructional Materials: Training schedule handout.

Instructional Equipment: Personal protective equipment.

Title: Fuselage jacking supervisor, aircraft leveling abilities necessary to perform the duties of fuselage jacking team supervisor and perform aircraft leveling. Instructor will delineate the duties of fuselage jacking team supervisors and state the hazards of the operation. Using actual mission aircraft, students will form a jacking team and rotate in the role of team supervisor. Students will learn the conditions when aircraft leveling is indicated and procedures for conducting the task.

Students will perform an aircraft leveling operation and then down-jack the aircraft.

- Restate fuselage jacking team supervisor duties to an accuracy of 100%

- Perform fuselage jacking team supervisor duties without instructor assistance

- Restate conditions that indicate fuselage jacking and dangers with 100%

- Conduct an aircraft leveling operation with limited instructor assistance

Instructional Materials: PowerPoint Presentation

Title: Conditional inspections abilities necessary to independently conduct conditional inspections including:

heavy/hard landing, lightning strike, foreign object damage and overspeed. Students will learn the conditions when conditional inspections are indicated and procedures for conducting the task. Using actual mission aircraft, students will expose aircraft structures and learn the inspection criteria.