Chapter 5 Documentation for Maintenance Manufacturer Documentation Documents

Chapter 5 Documentation for Maintenance

Manufacturer Documentation • Documents provided for maintenance of aircraft • Form/content may vary • Some customized (See Table 5 -1)

Manufacturer Documentation • Airplane Maintenance Manual (AMM) • Formal document (ATA coding system) • Aircraft & on-board equipment • • • Explanation of how each system/sub-system works Basic maintenance described Various tests performed • Functional/Operational/Adjustments • Replenishing of various fluids • Other servicing tasks Normally excludes repairs to: • Structure • Fiberglass paneling Technician signs off logbook/nonroutine work card (NRWC)

Manufacturer Documentation • Component Maintenance Manual (CMM) • Includes Vendor Manuals (VM) • • • Many components made by other vendors Landing gears Flight crew seats • Breakdown of all components • Provides part numbers • Technical data approved by FAA

Manufacturer Documentation • Fault Isolation Manual (FIM) • Set of fault isolation trees • • Block diagram Troubleshooting Isolate fault Identify/pinpoint problems

Manufacturer Documentation • Illustrate Parts Catalog (IPC) • Parts list/location of all parts • Shows • • • Assemblies Subassemblies Alternate part numbers Part inter-changeability Modifications (service bulletin) • Pre and post modification

Manufacturer Documentation • Storage and Recovery Document (SRD) • Information about aircraft • • Out of service/stored for extended time Draining certain fluids Moving aircraft Protecting components from weather Part inter-changeability Old aircraft – separate document New aircraft – part of AMM

Manufacturer Documentation • Structure Repair Manual (SRM) • When should damage be fixed? • Minor or major damage? • Airframe specific • Aircraft skin • • • Structural damage Specific tolerances and procedures Damage beyond SRM tolerances • • Contact manufacturer engineering Engineering Order (OR) • How to repair and sign off

Manufacturer Documentation • Maintenance Planning Data Document (MPD) • List of maintenance/servicing tasks • • All items identified by MRB Tasks listed by groupings • Certification Maintenance Requirements (CMRs) • Required by FAA • Maintain aircraft certification

Manufacturer Documentation • Schematic Diagram Manual (SDM) • Detailed information • • • Wiring harnesses Connectors Interfacing equipment • Schematics of systems • • • Electrical Electronic Hydraulic Logic diagrams for applicable systems Tasks listed by groupings

Manufacturer Documentation • Wiring Diagram Manual (WDM) • Essential for troubleshooting • • Wiring runs for all systems/components Harnesses

Manufacturer Documentation • Master Minimum Equipment List (MMEL) • Developed by manufacturer’s engineers • • All equipment on aircraft model Approved by FAA • Identify equipment that may be • • • Degraded Inoperative May have prescribed fix date • Airline develops own MEL • Tailor to specific equipment

Manufacturer Documentation • Dispatch Deviation Guide (DDG) • MMEL items inoperative/degraded • May required maintenance action prior to dispatch • • • Pull/placard circuit breakers Disconnect power Tie up loose cables for removed equipment

Manufacturer Documentation • Configuration Deviation List (CDL) • Similar to DDG but • • Involves aircraft configuration Does not affect airworthiness/safety • • • May have restrictions Icing conditions Flight speed restrictions Repair cycle customized by aircraft operator Discovered during line checks/pre-post flights • • • Panels Gear doors Flap hinge fairings Cargo doors Warning systems

Manufacturer Documentation • Nonessential Equipment and furnishing Items (NEF) • Do not affect safety/airworthiness • Customized from MMEL • Deferral program • Usually fixed at first available opportunity • Most common deferred items • • Paneling Cup holders Missing paint Cosmetic items

Manufacturer Documentation • Task Cards (TC) • Selected items chosen • Action completed without entire manual • Service Bulletins, Letters, Maintenance Tips • Airframe/Engine manufacturer • • Modifications Suggestions • Bulletins – modification • • Improve safety/operation Detailed description • Service Letter • Improve maintenance actions without modification

Regulatory Documentation • Federal Aviation Regulations (FAR) • All aspects of aviation • • • Private Commercial Airports Navigational aids ATC Controllers

Regulatory Documentation • Advisory Circulars(AC) • Issued by FAA • • Provide assistance meeting FAR requirements Suggestions how to comply “means, but not the only means” FAA not trying to micromanage

Regulatory Documentation • Airworthiness Directive (AD) • Mandatory • • Unsafe condition Service Bulletin could turn into AD • • • Description of unsafe condition Product with AD applies Corrective action required Date of compliance Where to get additional information Alternative methods of compliance • Notice of Proposed Rule Making (NPRM) • Intent to change/amend FARs • Public hearings

Airline Documentation • Operations Specification (Ops Spec) • Required for each aircraft flown • Parent document • Strict FAA requirements • Help from FAA representative

Airline Documentation • Technical Policies and Procedures Manual (TPPM) • Primary document for M&E • FAA requirement for maintenance manual • • • Written by engineering Ensures accuracy Define exact M&E functions/activities carried out Detailed document Several volumes

Airline Documentation • Inspection Manual (IM) • Separate document or part of TPPM • All inspection activities • • • Mechanic inspection tasks QC inspector’s tasks Special inspections (Hard landing, bird strikes) Required inspection items (RII) program Required paperwork, forms, reports

Airline Documentation • Quality Assurance Manual (QA) • Special manual or part of IM • Defines • • Duties/responsibilities Annual QA processes and procedures Forms Follow-up/enforcement procedures of QA write-ups • Reliability Program Manual • Defines reliability program • Chapter 18

Airline Documentation • Minimum Equipment List (MEL) • Airline customizes MMEL to their model • Mandatory for airline’s dispatch • • Cannot be less restrictive than MMEL Discourage operation with inoperative equipment Penalties in passenger/cargo capacity PIC can refuse to fly

Airline Documentation • Task Cards • Produced by airline manufacturer • Airline can amend (avoid duplication) • One action only for each card • Engineering Orders (EO) • Work nor covered in standard maintenance plan • Official • • • Issued by engineering Approved by QA Could be called work order

ATA Document Standards • Uniform coding system • All mode/types of aircraft • Description and Operation (001 - 099) • What system does • Various operational modes • Detailed description of how it works • Fault Isolation (101 – 199) • Fault trees • Specific faults based on flight deck effects

ATA Document Standards • Maintenance Practices (201 - 299) • When 2 or more actions must be used to complete task • Followed by test • Servicing (301 - 399) • All servicing tasks • • Step-by step instructions Required materials

ATA Document Standards • Removal/Installation (401 - 499) • Detailed step-by-step • LRUs • All conditions addressed • Adjustment/Test (501 - 599) • Normal maintenance • Component replacement • • Operational test procedures Functional test procedures

ATA Document Standards • Inspection/Check (601 - 699) • Zonal inspection activities • Cleaning/painting (701 - 799) • Aircraft • • • Washing Cleaning Painting • Approved repairs (801 - 899) • Identifies repairs to • • Structure and aircraft skin Approved by FAA

TPPM • Controlled document • Identifies • Key personnel • Job functions • Qualifications definitions • Maintenance facilities • • • Layout drawing/maps Shops Hangars Ramps Other significant buildings

TPPM • Identifies • Describe in detail activities involving • • • Maintenance Inspection Testing