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Question 1Safety precautions - aircraft and workshop
During maintenance on an aircraft with the engine cowlings open, which action gives the best protection against foreign object debris entering the engine?
- Placing a warning notice on the engine controls
- Sweeping the hangar floor at the end of the shift
- Fitting intake and exhaust blanks before work begins Correct answer.
- Keeping the cowlings fully open at all times
Explanation
FOD prevention relies on a physical barrier that closes the openings for the whole period the aircraft is open. Blanks or covers fitted before work starts stop tools, fasteners and debris from entering. Housekeeping and notices support the programme but do not seal the engine.
Question 2Safety precautions - aircraft and workshop
Why must an aircraft be bonded to the refuelling vehicle before fuel transfer begins?
- To prevent the aircraft battery from discharging
- To indicate that the refuelling nozzle is correctly seated
- To provide a return path for the fuel pump motor
- To equalise electrostatic potential and prevent sparking Correct answer.
Explanation
Static charge builds up as fuel flows through pipes and hoses. A bonding lead keeps the aircraft and the bowser at the same potential so that no spark can jump between them near fuel vapour. The bond is connected before caps are opened and removed last.
Question 3Safety precautions - aircraft and workshop
A technician is degreasing parts with a chlorinated solvent. Which personal protection is essential in addition to eye protection?
- Electrically insulating over-shoes
- A bump cap and a dust mask
- Anti-static overalls and an earth wrist strap
- Solvent-resistant gloves and ventilation Correct answer.
Explanation
Chlorinated solvents remove the natural oils from skin and give off vapours that are harmful if inhaled. Gloves that resist the solvent protect the skin, and good ventilation keeps vapour concentrations low. Eye protection alone leaves both skin and lungs exposed.
Question 4Safety precautions - aircraft and workshop
A small fire breaks out in a workshop. What is the correct sequence of actions for a technician who has not been trained in firefighting?
- Raise the alarm, then fight the fire only if trained Correct answer.
- Tackle the fire first and raise the alarm afterwards
- Open all doors and windows to let the smoke out
- Wait for the fire brigade before doing anything
Explanation
Life safety comes first: the alarm must be raised and people moved away before any attempt at extinguishing. Only personnel who have been trained and have a clear escape route should tackle a fire. Untrained staff should evacuate and assemble at the muster point.
Question 5Safety precautions - aircraft and workshop
How should full oxygen cylinders be stored in a workshop?
- With the valve caps removed for quick access
- Near a heat source to prevent condensation
- Upright and secured, away from oil and grease Correct answer.
- Laid flat under a bench to save space
Explanation
Oxygen cylinders must stand upright and be restrained so they cannot fall and shear the valve. They are kept clear of oil, grease and heat because pressurised oxygen reacts violently with hydrocarbons. Valve caps remain fitted until the cylinder is in use.
Question 6Safety precautions - aircraft and workshop
The main purpose of wearing hearing protection in an engine test area is to:
- prevent ear infections from fuel vapour
- reduce the risk of permanent hearing damage Correct answer.
- improve communication between ground crew
- allow the wearer to work for longer shifts
Explanation
High noise levels from running engines cause gradual, irreversible damage to hearing that may only become apparent years later. Hearing protection lowers the sound energy reaching the ear. It does not make speech clearer and is not a working-time control.
Question 7Safety precautions - aircraft and workshop
Before a hydraulic pump is removed from an aircraft, which safety action is required for the system?
- Leave the circuit live and post a notice in the cockpit
- Ask a colleague to hold the system switch off throughout
- Open all bleed valves and leave them open to drain
- Isolate and lock off the supply, then release pressure Correct answer.
Explanation
Breaking into a hydraulic system requires positive isolation with a personal lock and warning tag, followed by release of stored pressure. This prevents a remote or accidental start from pressurising the system while a line is open. A second person holding a switch is not a positive isolation.
Question 8Safety precautions - aircraft and workshop
Mineral hydraulic fluid is splashed into a technician's eye. What is the correct immediate action?
- Apply an eye ointment from the first aid kit
- Shut the eye and report to the supervisor at the end of the shift
- Rub the eye gently until the stinging stops
- Irrigate the eye with clean water or eye wash for several minutes Correct answer.
Explanation
Chemical contamination of the eye is treated by immediate, prolonged irrigation with clean water or an eye wash station. Irrigation dilutes and flushes the fluid out before it can damage tissue, and the casualty is then referred for medical assessment.
Question 9Safety precautions - aircraft and workshop
When preparing battery electrolyte from concentrated sulphuric acid, the correct procedure is to:
- add the water slowly to the concentrated acid while stirring
- pour acid and water together in equal amounts at once
- add the acid slowly to the water while stirring Correct answer.
- add the acid to the water only after the water is warmed
Explanation
Diluting concentrated sulphuric acid releases a large amount of heat. Adding acid slowly to a larger body of water lets the water absorb that heat; the reverse order can make the mixture boil and spatter acid. Warming the water only makes the reaction more violent.
Question 10Safety precautions - aircraft and workshop
Why is nitrogen preferred to compressed air for inflating aircraft tyres?
- It is dry and will not support combustion Correct answer.
- It gives a higher tyre pressure for the same mass
- It leaks more slowly through the tyre valve
- It costs less than compressed air from the shop line
Explanation
Nitrogen is supplied dry and is inert, so it removes both moisture and the oxygen that could feed a fire in the wheel bay. Moisture in ordinary compressed air can also freeze at altitude and affect pressure readings. Cost is not the deciding factor.
Question 11Safety precautions - aircraft and workshop
An oxygen system component has been contaminated with ordinary lubricating oil. Why is this a serious hazard?
- Pressurised oxygen can react violently with oil and ignite it Correct answer.
- The oil freezes at altitude and blocks the regulator passages
- The oil prevents the system being leak-tested with nitrogen
- The oil attacks the aluminium alloy and causes leaks
Explanation
Oxygen systems are cleaned to oxygen-clean standards because oxygen supports combustion and, at pressure, can cause hydrocarbons to ignite or detonate on contact. Even a fingerprint of grease is enough to start a fire in a regulator or valve. Only approved oxygen-compatible cleaners and lubricants may be used.
Question 12Safety precautions - aircraft and workshop
A technician must reach a component three metres above the hangar floor. Which is an acceptable means of access?
- Standing on an upturned parts crate
- A suitably rated mobile access platform or scaffold Correct answer.
- Standing on the top step of a domestic step ladder
- Climbing on the aircraft structure through open panels
Explanation
Work at height must be done from equipment designed and rated for it, such as a mobile elevating platform, a tower scaffold or a properly used industrial ladder. The equipment must be inspected and the user trained. Improvised access is a common cause of falls in hangars.
Question 13Safety precautions - aircraft and workshop
A technician is to work on a 115 V AC aircraft supply. Compared with 115 V 50 Hz mains, why is this supply treated as especially dangerous?
- It can be blocked by wearing thin cotton gloves
- It makes shock and burns far more severe Correct answer.
- It is below the level that affects the body
- It flows only on the skin, so the shock is mild
Explanation
Aircraft AC supplies run at 400 Hz. At the same voltage the higher frequency produces a much stronger physiological effect, with severe muscle contraction, deep tissue heating and burns, so the supply must be isolated and locked off before work. It is never to be treated as low-risk.
Question 14Safety precautions - aircraft and workshop
When drilling a carbon-fibre reinforced plastic component, why must dust extraction or a suitable respirator be used?
- The dust attracts moisture and corrodes the drill bit
- The fine dust harms the lungs and can short electrical gear Correct answer.
- The dust dissolves in cutting fluid and forms an acid
- The dust is highly flammable and can explode in the shop
Explanation
Drilling composite produces very fine respirable dust that irritates and damages the lungs, and carbon fibres are electrically conductive so they can bridge and damage avionics and electrical equipment. Local extraction at the drill point, backed up by a suitable mask, controls both risks.
Question 15Safety precautions - aircraft and workshop
A heavy aircraft component is to be lifted with a workshop crane. Which practice is correct?
- Use a rope sling secured with a single reef knot
- Exceed the SWL briefly if the lift is short and slow
- Check the SWL and lift points, and stand clear Correct answer.
- Stand under the load to guide it onto its mount
Explanation
The safe working load of the crane and sling must cover the lift, the sling must be attached to the designated lifting points, and nobody may stand or pass beneath a suspended load. Guide ropes are used to control the load from a safe distance.
Question 16Safety precautions - aircraft and workshop
A CO2 extinguisher has been discharged in a small, unventilated fuel-tank bay. Why must the space be ventilated and tested before entry?
- It displaces oxygen and can cause rapid asphyxiation Correct answer.
- Carbon dioxide is flammable when it mixes with air
- Carbon dioxide leaves a corrosive residue on the structure
- Carbon dioxide reacts with fuel vapour to form a toxic gas
Explanation
Carbon dioxide extinguishes fire by smothering, which means it replaces the oxygen in a confined space. In an enclosed bay the remaining atmosphere can be unable to support life, so the space is ventilated and tested with an oxygen meter before anyone enters, and entry is controlled as a confined-space task.
Question 17Safety precautions - aircraft and workshop
Hydraulic fluid has spilled across the hangar floor. What is the first priority in dealing with the spill?
- Wash the fluid into the surface water drain with water
- Mop up with paper towels and place them in an open bin
- Make the area safe, then contain and absorb the spill Correct answer.
- Cover the spill with dry cement and continue working
Explanation
The initial response is to remove ignition sources, warn others and prevent slipping before containing the fluid with absorbent material and an earth bund. Only then is the waste collected into a labelled container for disposal. Fluid must never be washed to a drain.
Question 18Safety precautions - aircraft and workshop
A technician must use an unfamiliar cleaning agent. Where is the authoritative information on its hazards, handling and first aid measures found?
- On the label of the bulk storage drum only
- On the supplier's advertising literature
- In the safety data sheet held at the workplace Correct answer.
- In the aircraft maintenance manual chapter 12
Explanation
The safety data sheet is the controlled document that gives the hazard classification, exposure limits, personal protection, spill measures and first aid for the product. It must be available to the user at the point of work, and a risk assessment is based on it.
Question 19Safety precautions - aircraft and workshop
Before entering a drained fuel tank, why does the technician wear conductive footwear and avoid synthetic clothing?
- To keep the technician warm inside the cold tank
- To stop tools falling out of pockets into the tank
- To prevent hydraulic fluid soaking into the clothes
- To prevent a static spark igniting fuel vapour Correct answer.
Explanation
Even a drained tank contains residual fuel and vapour. Movement of clothing and footwear generates static, and a small discharge in a flammable atmosphere can ignite it. Conductive footwear and cotton clothing allow charge to bleed away to the bonded structure, and synthetic garments are avoided.
Question 20Safety precautions - aircraft and workshop
Welding and grinding are to be carried out on a component inside the hangar. Which requirement applies before work starts?
- Only the local fire service can authorise the work
- A fire watch is needed only for one hour after the work
- A hot work permit, cleared area and a fire watch Correct answer.
- Work may begin if a colleague watches with a hose
Explanation
Hot work is controlled by a permit that confirms the area has been cleared of flammable materials, that firefighting equipment and a trained fire watch are in place, and that the work is authorised for a defined period. The fire watch continues during and after the work, typically for at least an hour, to catch smouldering material.
Question 21Workshop practices
When hacksawing a thin-walled metal tube, the blade that should be selected is one with:
- a wavy set with widely spaced teeth
- a fine pitch of about 32 teeth per inch Correct answer.
- a blade with no set to the teeth
- a coarse pitch of about 14 teeth per inch
Explanation
A fine pitch keeps at least two or three teeth in contact with the thin wall at all times, so each tooth takes a small chip and cannot snag on the section. Coarse blades straddle thin material and the teeth catch and strip. The set is needed to keep the blade body clear of the kerf.
Question 22Workshop practices
The thimble of a standard metric outside micrometer is divided into 50 equal divisions. One complete revolution of the thimble advances the spindle by:
- 0.01 mm
- 1.00 mm
- 0.50 mm Correct answer.
- 0.05 mm
Explanation
The micrometer screw has a pitch of 0.5 mm, so one full turn of the thimble moves the spindle 0.5 mm along the barrel. Dividing that movement into 50 thimble divisions gives a reading resolution of 0.01 mm.
Question 23Workshop practices
Engineer's blue is applied to a metal surface before marking out in order to:
- prevent the surface from corroding during machining
- lubricate the scriber so that it moves freely
- make the scribed lines easier to see Correct answer.
- show up any cracks in the material
Explanation
A thin coat of marking blue gives a contrasting background against which the fine bright line cut by the scriber stands out clearly. This reduces the chance of misreading a setting or losing a line during machining.
Question 24Workshop practices
On a pedestal grinding machine, the workrest must be set close to the wheel face (gap about 1.5 mm) in order to:
- avoid trapping the work in the nip Correct answer.
- reduce the load on the grinding motor
- prevent the wheel from becoming glazed
- improve the finish produced on the work
Explanation
A small gap stops thin work from being dragged down between the wheel and the rest, which can jam the wheel, burst it, or pull the operator's hands into the machine. The gap is checked and adjusted as the wheel wears down.
Question 25Workshop practices
When cutting a through thread by hand with a set of three taps, the tap used first is the:
- spiral flute tap
- second tap
- taper tap Correct answer.
- plug tap
Explanation
The taper tap has the longest chamfer lead and starts the thread squarely with the least cutting effort. The second and plug taps then follow the started thread to cut the full thread form to the bottom.
Question 26Workshop practices
A torque wrench is designed to:
- extend the leverage of a breaker bar
- slacken seized or corroded nuts and bolts
- tighten a fastener to a set torque Correct answer.
- measure the angle through which a bolt turns
Explanation
A torque wrench indicates when the fastener has reached a set tightening torque, so that clamping load is controlled. It is a precision measuring instrument and must not be used for loosening or as a lever extension.
Question 27Workshop practices
A centre drill is used before drilling a full-size hole mainly to:
- allow a much higher spindle speed to be used
- remove the work-hardened skin of the material
- produce a chamfer to seat a screw head
- give the drill an accurate start Correct answer.
Explanation
The short, stiff pilot of a centre drill deflects far less than a long twist drill, so it produces a small true hole that guides the larger drill and stops it wandering. The countersink portion also leaves a chamfer that helps the drill enter.
Question 28Workshop practices
A hole specified as H7 mated with a shaft specified as g6 produces a fit that is:
- a clearance fit Correct answer.
- a transition fit
- an interference fit
- a force fit
Explanation
The letter H for the hole fixes the lower deviation at zero, with all tolerance inside the hole, while the lower-case g places the whole shaft tolerance below the nominal size. The shaft is therefore always smaller than the hole, which defines a clearance fit.
Question 29Workshop practices
The correct tapping drill size for an M10 x 1.5 thread is:
- 7.5 mm
- 9.5 mm
- 10.0 mm
- 8.5 mm Correct answer.
Explanation
For a metric thread, the tapping drill is found by subtracting the pitch from the major diameter, giving 10 - 1.5 = 8.5 mm. This leaves enough material for the tap to form a full thread without overload.
Question 30Workshop practices
Reaming a drilled hole produces:
- a hole that must afterwards be finish bored
- a hole with a tapered entry for easier assembly
- a hole of more accurate size and finish Correct answer.
- a hole larger than the drill by the reamer set
Explanation
A reamer removes only a small amount of stock (typically 0.1 to 0.2 mm) from a drilled hole. Because it has many cutting edges and is guided by the hole itself, it corrects size, roundness and surface roughness.
Question 31Workshop practices
When a fastener is safetied with lockwire, the wire must be routed so that:
- the wire can be removed without cutting
- the wire is twisted clockwise only
- loosening of the fastener tightens the wire Correct answer.
- the pigtail is left unsecured at the end
Explanation
The wire is run in the direction that puts tension on it if the fastener tries to undo, so the fastener is pulled back towards the tightened position. This is why the direction of the twist and the side of the fastener the wire leaves from both matter.
Question 32Workshop practices
The purpose of flux when soft soldering is to:
- remove and exclude oxide from the joint Correct answer.
- raise the melting point of the solder
- conduct heat from the iron into the joint
- fill the gap in the joint with filler metal
Explanation
Oxide on the metal prevents solder from wetting the surface, so the flux dissolves existing oxide and shields the joint from air while it is hot. Solder will not adhere to an oxidised surface no matter how much heat is applied.
Question 33Workshop practices
A ball bearing whose inner ring rotates with the shaft should be fitted by applying force to the:
- seal or shield
- inner ring only Correct answer.
- inner and outer rings together
- outer ring only
Explanation
Pressing on the ring that has the interference fit transmits the load directly through the rolling elements' path without forcing it through the balls. If force is applied to the wrong ring, the balls are pressed hard into the races and leave brinelling marks.
Question 34Workshop practices
When calculating the developed length of a sheet metal bend, the bend allowance is based on the:
- inside radius of the bend only
- neutral axis of the material Correct answer.
- material thickness multiplied by two
- outside dimensions of the bend
Explanation
During bending the inner fibres compress and the outer fibres stretch, but the neutral axis keeps its original length. The bend allowance is therefore the arc length measured along that neutral axis.
Question 35Workshop practices
For a snap-head rivet, the shank length required is the total thickness of the sheets plus:
- 1.5 times the rivet diameter Correct answer.
- half of the rivet diameter
- an amount equal to the rivet diameter
- twice the rivet diameter
Explanation
The shank must protrude by about 1.5 times the rivet diameter so there is enough material to form a properly proportioned snap head. Too little protrusion gives an undersized head; too much gives a loose, malformed head.
Question 36Workshop practices
Before an abrasive wheel is mounted on a machine, the ring test is carried out to:
- measure the wheel diameter accurately
- confirm the wheel's maximum speed rating
- detect cracks or internal damage Correct answer.
- check the wheel for correct balance
Explanation
A sound wheel gives a clear ring when tapped lightly, whereas a cracked wheel gives a dull thud. A damaged wheel can burst at working speed, so it must never be mounted.
Question 37Workshop practices
A metric micrometer has a 0.5 mm pitch screw, a thimble divided into 50 divisions and a sleeve vernier of 10 divisions covering 9 thimble divisions. The vernier allows readings to be taken to:
- 0.001 mm Correct answer.
- 0.005 mm
- 0.002 mm
- 0.01 mm
Explanation
Nine thimble divisions represent 0.09 mm, and dividing this into 10 vernier divisions gives 0.009 mm per vernier division. The difference between one thimble division (0.01 mm) and one vernier division (0.009 mm) is 0.001 mm, which is the resolution gained.
Question 38Workshop practices
A hole is specified as 25.000/25.021 mm and the mating shaft as 25.035/25.048 mm. The minimum interference of the fit is:
- 0.014 mm Correct answer.
- 0.048 mm
- 0.035 mm
- 0.027 mm
Explanation
Minimum interference occurs with the largest permissible hole and the smallest permissible shaft, that is 25.035 - 25.021 = 0.014 mm. Maximum interference would be found from the smallest hole and largest shaft.
Question 39Workshop practices
A compression spring has a rate of 15 N/mm and a free length of 60 mm. When it is compressed to a length of 48 mm, the force it exerts is:
- 90 N
- 180 N Correct answer.
- 900 N
- 270 N
Explanation
The deflection is 60 - 48 = 12 mm, and force equals rate multiplied by deflection, so 15 N/mm x 12 mm = 180 N. The rate stays constant within the working range of the spring.
Question 40Workshop practices
A cutting speed of 30 m/min is recommended for a material. The spindle speed for a 10 mm diameter drill, to the nearest 10 rev/min, is:
- 3000 rev/min
- 1900 rev/min
- 300 rev/min
- 950 rev/min Correct answer.
Explanation
Spindle speed is found from N = 1000V/(pi x D), giving 1000 x 30/(3.142 x 10) = 955 rev/min, which rounds to 950 rev/min. The drill diameter must be used in millimetres and the cutting speed in metres per minute.
Question 41Tools
Which type of torque wrench signals that the set torque has been reached by releasing a distinct mechanical 'click' through the handle?
- A deflecting beam wrench
- A click-type wrench Correct answer.
- A slip-clutch screwdriver
- A dial-indicating wrench
Explanation
Click-type (break-back) wrenches contain a spring-loaded mechanism that trips and produces an audible and tactile click when the preset torque is attained. The operator stops pulling at that moment. Beam and dial types instead show the torque continuously on a scale.
Question 42Tools
On a standard metric micrometer, one complete revolution of the thimble advances the spindle by:
- 0.01 mm
- 0.50 mm Correct answer.
- 1.00 mm
- 0.05 mm
Explanation
The spindle thread has a pitch of 0.5 mm, so one full turn of the thimble moves the spindle 0.50 mm. The thimble normally carries 50 divisions, each therefore representing 0.01 mm.
Question 43Tools
The vernier scale on a vernier caliper is provided to:
- Compensate for thermal expansion
- Measure the depth of blind holes only
- Read fractions of a main-scale division Correct answer.
- Magnify the main scale for rough work
Explanation
The vernier is a short auxiliary scale whose graduations are slightly closer together than those of the main scale. The line that aligns best with a main-scale line indicates the fraction of a division to be added, giving a finer reading than the main scale alone.
Question 44Tools
Tool control during an aircraft maintenance task is primarily intended to:
- Prevent tools being left in the aircraft Correct answer.
- Speed up the issue of tools from stores
- Reduce the purchase cost of tooling
- Record the calibration of precision tools
Explanation
Tool control systems such as shadow boards, tool tags and signed issue/return records exist so that any missing item is identified immediately. A tool left inside an aircraft or engine can cause serious damage or loss of control. Calibration records are a separate system.
Question 45Tools
A file should never be used without a handle fitted because:
- The teeth will clog more quickly
- The file will lose its hardness
- The tang can injure the user's hand Correct answer.
- The file will cut more slowly
Explanation
The tang is a sharp, narrow spike formed at the end of the file for mounting in a handle. Without a handle it can pierce the palm or wrist if the file jams or slips. A handle also improves control of the cut.
Question 46Tools
High-speed steel twist drills are widely used for general aircraft work because they:
- Produce reamed-size holes
- Cut only aluminium alloys
- Need no cutting fluid
- Retain hardness when hot Correct answer.
Explanation
High-speed steel keeps its hardness at the elevated temperatures generated at the cutting edge, so it can run faster than plain carbon steel without softening. It is suitable for a wide range of materials, not one alloy only.
Question 47Tools
For tapping an M8 × 1.25 thread, the tapping drill diameter should be approximately:
- 7.25 mm
- 6.75 mm Correct answer.
- 6.25 mm
- 8.00 mm
Explanation
The tapping drill size is obtained by subtracting the thread pitch from the nominal major diameter. For M8 × 1.25 this gives 8.00 − 1.25 = 6.75 mm, which leaves about 75 per cent thread engagement.
Question 48Tools
When tightening a fastener with a click-type torque wrench, the correct technique is to:
- Pull steadily until the click is felt Correct answer.
- Apply load in short jerky strokes
- Use it to slacken seized fasteners
- Set it to maximum after use
Explanation
A smooth, steady pull applied in line with the wrench gives the most accurate result and avoids over-shooting the set value. The wrench is stopped as soon as the click occurs. Jerking or using the wrench to undo fasteners damages the mechanism.
Question 49Tools
A straight extension fitted in line with the square drive of a torque wrench:
- Does not change the torque at the fastener Correct answer.
- Requires a recalibration of the wrench
- Halves the torque at the fastener
- Increases the torque at the fastener
Explanation
An extension placed directly on the drive axis merely moves the wrench away from the fastener. Since the lever arm length and the line of action are unchanged, no correction to the set torque is needed. Only offset adapters such as crow feet alter the effective length.
Question 50Tools
After use, a click-type torque wrench should be stored:
- At maximum setting to pre-load the spring
- With a socket fitted to protect the drive
- Coated in penetrating oil inside the case
- At its lowest setting to avoid spring fatigue Correct answer.
Explanation
Leaving a click-type wrench set at a working value keeps the internal spring compressed, which can cause it to take a set and shift the calibration. Winding it back to the lowest scale value relieves the load. The wrench should be kept clean and dry, not oiled internally.