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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA

DEPARTAMENTO DE CONTROL DE CALIDAD


CENTRO DE CAPACITACIÓN MasAir
ETOPS

Extended range Twin engine OPerationS

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The 767 Is Used Extensively For ETOPS Worldwide
Through September 2007

• 57% of the 767 operators are ETOPS operators. 767-ET-0003•


12-13-7-DH/KW/CJ
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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

THE INFORMATION CONTAINED IN THIS MANUAL HAS BEEN PREPARED BY CENTRO DE CAPACITACIÓN
MasAir WITH INFORMATION EXTRACTED FROM AIRCRAFT MAINTENANCE MANUAL IN ORDER TO PROVIDE
TECHNICAL TRAINING.

AT MOMENT OF ELABORATION ITS CONSIDERED UPDATED, ALL TECHNICAL DATAS, LIMITS AND
TOLERANCES USED ON THIS MANUAL AND SHOULD BE USED

FOR TRAINING PURPOSES ONLY

THE INFORMATION FOR FIELD JOBS MUST BE OBTAINED FROM CURRENT MANUALS.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir

OBJETIVE:

At the end of training the parcipant will be able to recognice the importance of the maintenance labors in the qualification
implementación and maintenance to assure the reliability of the MasAir fleet

PARTICULAR OBJETIVE:

1. At the end of the training the particiant will recognice when the aircraft requires a PDSC for a ETOPS flight
2. At the end of the training the participant will be able to comply with a Pre - Departure Service Check in conjunction with a
ETOPS DAILY CHECK or a ETOPS TRANSIT CHECK
3. At the end of the training the participant will be able to differentiate between the requirements in case of a PDSC and the
GTB requeriments for a ETOPS flight
4. At end of training the participant familiarize with the content of the MasAir ETOPS Manual to determinate the procedures,
components and limitations for DOWNGRADE (in accordance with the MEL) and UPGRADE the ETOPS certification for the
Masair fleet

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 1 “INTRODUCTION”

This chapter contains the scope related to this topics used into the MasAirs’ ETOPS Manual: Objective, Regulatory Compliance, Document
structure, Control, Document Revisions, Document distribution and Approval, Feedback, Abbreviations and Acronyms, Definitions.

Objective.- The Objective of this ETOPS Manual is to identify the Supplementary Maintenance Program requirements and
organizational responsibilities for Extended-range Two-engine Operations (ETOPS) at Aerotransportes Mas de Carga S.A. de C.V.
(MasAir).

Regulatory Compliance.- The ETOPS Manual has been elaborated in compliance with the requirements established in the FAA
Advisory Circular AC 120-42B, the Boeing D6T11604 document Configuration, Maintenance and Procedures (CMP) for Extended
Range (ER) Operations with two-Engine Airplane (ETOPS) and the DGAC Mexico Norma Oficial Mexicana NOM-093-SCT3-2002.

Responsibilities.- Consist in all functions, responsibilities and duties of personnel involved in the ETOPS operations for the ETOPS
Flight follow-up and control.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 2 “ ORGANIZATION”

This chapter contains information related to the functions, duties and responsibilities of the personnel involved in MasAir’s ETOPS
operations.

Maintenance and
Engineering
Director

Quality Control Maintenance Engineering Maintenance


Manager Manager Manager Store Chief

Quality Control Maintenance Chief of Analysis Engineering and Record


MEL Inspector Supervisor Planning and Reliability Keeping
Control

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 3 “ETOPS APPROVED AIRCRAFT”

This chapter contains information related to: List of Aircraft and Boeing Certification.

Boeing Certification for ETOPS.- Any airplane added to the ETOPS fleet must comply with the current revision of the Configuration
Maintenance and Procedures (CMP) document applicable to that airplane/engine combination. Since time of delivery
the Masair fleet complies with the CMP requirements. Enclosed is a copy for The Boeing Company ETOPS 180 min Certification
letter since the aprobal date for each aircraft

The Type Certificate Data Sheet on the Airplane Flight Manual (AFM) Section 3.1 contains the type design approval for each aircraft

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 4 “CONFIGURATION CONTROL”

The policies and procedures explained in this chapter; as the governing modifications (SB, SL, AD) and ETOPS parts control, assure
that the airplane will continue to comply with the applicable ETOPS configuration requirements for the airplanes listed in Chapter 3.
Has approval for ETOPS operations and complies with the ETOPS configuration standards identified in the Configuration, Maintenance
and Procedures (CMP) document (Boeing document D6T11604). This chapter is divided in two big groups:

Engine and Airframe Modification Procedures:


¾Incorporation of ETOPS Service Bulletins (SB) and Service Letters (SL)
¾Schedule of Service Bulletins (SB) and Service Letters (SL) Incorporation
¾Incorporation of Airworthiness Directives (AD)

ETOPS Parts Control:


¾Purpose of Parts Control
¾Parts Control Procedure
¾Updating of MasAir ETOPS Parts List
¾Borrowed Parts
¾ETOPS Fly-Away Kit (FAK)

ETOPS Parts Control. - The MasAir ETOPS Parts Control Program is implemented to ensure that ETOPS airplanes is kept in the ETOPS
configuration as defined by the latest revision of the CMP document.

The program includes parts control at the home base and out stations as well as borrowed and loaned parts.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 5 “DISPATCH CONFIGURATION AND MAINTENANCE REQUIREMENTS”

This chapter of the manual refers to the use of: Minimum Equipment List, Dispatch Deviation Guide, and Airworthiness Directives.

Minimum Equipment List

The MasAir Minimum Equipment List (MEL) has developed from the FAA Master Minimum Equipment List (MMEL), and approved by it.
MasAir’s responsibility to formulate and review the MEL lies on Operational Engineering.

Certain items in this MMEL have different dispatch requirements for ETOPS flights than for non- ETOPS flights. These differences have
been noted in the Mas Air MEL with the acronym “ER” in bold-faced type next to each applicable item. The Mas Air MEL document will be
used as the dispatch authority for all ETOPS flights.

Dispatch Deviation Guide

The Dispatch Deviation Guide (DDG) establishes the maintenance and operational procedures for flight dispatch with some inoperative or
missing items. The Dispatch Deviation Guide (DDG) will be used as supplementary material as necessary.

Refer to Airplane Flight Manual Appendix Configuration Deviation List (CDL) for guidance.

Airworthiness-Directives

In case of conflict between MEL, DDG and a AD, the FAA Airworthiness Directive compliance will take precedence over the MEL or DDG.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 6 “ETOPS PRE-DEPARTURE SERVICE CHECK (PDSC)”

This chapter contains information related to the requirements, responsibilities and policies to apply the ETOPS Pre-Departure Service
Check, and is divided in next manner:

General ETOPS PDSC Requirements / Responsibilities

Definition of the ETOPS PDSC


Etops TRANSIT CHECK or Etops DAILY CHECK + ETOPS Pre-Departure Service Check

Additional ETOPS Requirements

ETOPS PDSC Policy


ETOPS and Non-ETOPS Flights
Diversions for Non-ETOPS Maintenance Reasons
Diversions for ETOPS Maintenance Reasons

Prior to dispatch an airplane to an ETOPS flight, an ETOPS Pre-Departure Service Check is required. Primary responsibility for PDSC
procedures and conduct lies with the Line Maintenance supervisors. The PDSC must be performed by an ETOPS qualified Maintenance
Technician.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

General ETOPS PDSC Requirements

The ETOPS Pre-departure Check is an addition to the ETOPS transit Check, Job Card B767 — MY TRANSIT CHECK.

The ETOPS Transit Check is intended to assure continuous serviceability of a transiting airplane. This check is planned for use at an
enroute stop and is basically a walk-around inspection, which requires a check of the airplane interior and exterior for obvious damage,
leaks, proper operating equipment, security of attachment and required servicing and review of the Maintenance Flight Log (MEL), plus
the APU service oil required.

Additional ETOPS Requirements.- ETOPS airplanes require that the cargo compartment CLASS E fire suppression capacity be suitable
for the duration of the approved diversion time plus 15 minutes, (180 + 15 min)

Damage to cargo compartment liners and door seals could cause a loss of extinguisher agent concentration and reduce fire suppression
capability.

Therefore, Mas Air will check cargo compartment liners for tears and punctures on the ETOPS Pre-Departure Service Check
(MY-ETOPS PDSC) prior to loading cargo, in accordance with de AMM and the SRM.

Cargo door seals will be inspected for damage prior to closing the doors after cargo loading has been completed.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS
ETOPS PDSC Policy

ETOPS and Non-ETOPS Flights

For all ETOPS flights, the MY-ETOPS PDSC must be conducted prior to departure by an ETOPS qualified and authorized
mechanic. On non-ETOPS flights utilizing ETOPS airplanes, the PDSC is not required. However, the ETOPS Transit Check is still
required and oil added recorded but it is not required to be done by an ETOPS qualified mechanic.

If the aircraft presents a Gate Turn Back (GTB), an ETOPS Pre-Departure Check must be performed prior to dispatch. If no jobs
performed at the cargo compartments, so they still closed during the turn back, the section at the MY-ETOPS PDSC of Cargo
Compartment inspection could be not performed.

If the aircraft presents a Gate Turn Back (GTB) or after maintenance jobs it is taxi from the maintenance base to the Cargo
Gate, a ETOPS Pre-Departure Service Check (MY-ETOPS PDSC) must be performed prior to dispatch.

In case that the previous conditions are not complied, the aircraft cannot operate in an ETOPS flight.

Diversions for Non-ETOPS Maintenance Reasons

If a diversion occurs due to reasons that are not ETOPS significant system related (e.g. weather at arrival airport), an ETOPS Pre-
Departure Service Check is required prior to dispatch, if the flight is to continue under ETOPS.

The ETOPS Pre-Departure Service Check (MY-ETOPS PDSC) should be conducted under the direction of the Maintenance Supervisor
on duty for the ETOPS Flight follow-up and control (MS-ETOPS) by a previous authorized and qualified mechanic.

If there are any open log items that are sensitive to ETOPS, Maintenance Supervisor in charge for the ETOPS Flight follow-up and
control must be notified for disposition prior to dispatch. The qualified and authorized mechanic must have to correct any
discrepancy in accordance with the procedures established at the General Maintenance Manual and the Minimum Equipment List as
applicable.

If the next leg of the flight can be flown non-ETOPS, a PDSC is not required.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

Diversions for ETOPS Maintenance Reasons

If a diversion occurs due to reasons that are ETOPS significant system related, an ETOPS PDSC, performed by an ETOPS qualified
mechanic, is required prior to dispatch if the flight is to continue under ETOPS. The local authorized mechanic, the onboard mechanic,
or the certified maintenance agency may start maintenance under the direction of the Maintenance Supervisor in charge for the
ETOPS Flight follow-up and control. An ETOPS qualified mechanic must oversee or perform the maintenance.

If the next leg of the flight can be flown non-ETOPS a PDSC is not required, the ETOPS Transit check, and oil check are still required
provided that the following conditions are met:

1) The airplane complies with the MEL requirements for non-ETOPS operations.

2) Non-routine maintenance performed by the local authorized mechanic, the onboard mechanic, or the certified maintenance
agency has been directed by the Maintenance Supervisor in charge for the ETOPS Flight follow-up and control.

3) All maintenance and servicing has been accomplished in accordance with the Aircraft Maintenance Manual and to the
satisfaction of Maintenance Supervisor in charge for the ETOPS Flight follow-up and control

4) Maintenance Supervisor in charge for the ETOPS Flight follow-up and control, the flight crew, Operations Control and Dispatch
have been notified and agree to operate the airplane on a non-ETOPS route under non-ETOPS requirements.

5) The downgrade procedure has been performedin accordance with Mel, and the specific decal installed.

6) Maintenance Supervisor in charge for the ETOPS Flight follow-up and control has entered a Deferred Maintenance Item (DMI)
form for a down line station to check that all maintenance performed by the diversion site local authorized mechanic, the
onboard mechanic, or the certified maintenance agency conforms to the ETOPS configuration requirements.

7) The down line station check must be made by an ETOPS qualified mechanic and must be made prior to any subsequent
ETOPS operation.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 7 “ETOPS SIGNIFICANT SYSTEMS”

To support monitoring, reporting, and corrective action requirements contained in this manual, the ETOPS significant systems are defined
and identified at this section.

All malfunctions or degradations in any of these systems during ETOPS and Non-ETOPS operations are subject to the problem
investigation, corrective action and follow up procedures of the ETOPS event oriented Reliability Program and the verification of
maintenance action requirements.

ATA CHAPTER ATA SECTION ETOPS SIGNIFICANT SYSTEM


21 -31 Cabin Pressure Control System
Air Conditioning -51 Air Conditioning (AC) Packs
-51 Air Temperature Control
-58 E/E Cooling
24 -00 Electrical Power
Electrical Power -20 AC Power Generation
-21 Power & Regulation
-23 Fault Sensing
-25 HMG System
-34 DC Power Meters
26 -10 Detection
Fire Protection -11 Engine Fire Detection
-15 APU Fire Detection
-16 Lower Cargo Smoke Detection
-23 Cargo Compartment Fire Extinguishing
28 -22 Engine Fuel Feed System
Fuel -25 APU Fuel Feed System
-41 Fuel Quantity Indicating System (FQIS)
-43 Fuel Temperature Indicating System

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

ATA CHAPTER ATA SECTION ETOPS SIGNIFICANT SYSTEM


30 -11 Wing Thermal Anti-Icing
Ice & Rain -21 Engine Inlet Thermal Anti-Icing
Protection -31 Pitot Static Probe Anti-Icing
-33 Total Air Temperature (TAT) Probe Heat
-34 Engine Probe Heat
-41 Flight Compartment Window Anti-Icing
34 Navigation -43 Weather Radar System
36 Pneumatic -11 Air Supply Distribution System
49 -11 Auxiliary Power Unit (APU)
Airborne Auxiliary -13 APU Mounts
Power -14 APU Harness
-15 APU Air Intake
-16 APU Drains and Vents
-21 APU Engine
-27 APU and Generator Lubrication Systems
-31 APU Fuel System
-41 APU Ignition/Starting System
-51 APU Cooling Air System
-53 APU Surge Bleed System
-61 APU Control System
-71 APU Exhaust Gas Temperature Indicating
System
-81 APU Exhaust System
All Engine Chapter-Section items are ETOPS Significant EXCEPT those listed below:
70-79 77-31 Airborne Vibration Monitoring (AVM) System
Engines 78-31 Thrust Reverser System
78-34 Thrust Reverser Control System

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 8 “ETOPS RELIABILITY PROGRAM”

MasAir ETOPS Reliability Program is an event oriented reliability program; each applicable event is reported and investigated. The ETOPS
Reliability Program is in addition to the MasAir Reliability Program, which uses a Statistical Evaluation System and also uses an Event
Analysis System currently in place for the B767 airplane.

ETOPS RELIABILITY PROGRAM is constituted by:

Reporting Requirements
ETOPS Reliability Event Log
Analysis and Corrective Action
Identification of ETOPS Tasks
APU Start Program

Reporting Requirements

Quality Control will notify to the regulatory authority (FAA) and to the Reliability Control Board within 72 hours of any events
reportable under the MasAir ETOPS Reliability Program.

Reporting requirements apply to the airframe/engine combination utilized in ETOPS, including events occurring on non-ETOPS
flights. In addition to events normally reported to the regulatory authority (Federal Aviation Administration — FAA), the
following events will also be included:

1) In-flight shutdowns (IFSD);


2) Diversions or Air Turn Backs;
3) Uncommanded power changes or surges;
4) Inability to control the engine or obtain desired power;
5) Problems with ETOPS significant systems (ETOPS significant system failures);
6) Any other event detrimental to ETOPS.

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DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

Identification of ETOPS Tasks

Time limits/check intervals for maintenance tasks are reflected in the Scheduled Maintenance and Inspection Program. Tasks
which have been determined to be necessary for the continued reliability of ETOPS significant systems or components are
identified in the task listing by the word “ETOPS”, also appears on the task cards associated with the ETOPS tasks to assure
awareness by line station personnel.

APU Start Program

The APU In-Flight Start Monitoring Program for Mas Air is in accordance with the FAA Advisory Circular 120-42A, which
stipulates that the APU start and run reliability be monitored and verified in order to ensure adequate reliability for ETOPS.
The APU In-Flight Start Monitoring will be controlled through the Stabilized Cruise APU Start Check. This has a monthly
application interval APU in-flight starts shall be attempted on the following flights:

1) All non-ETOPS flights greater than four hours in length with the APU in ETOPS configuration per the current CMP
document.
2) The return (to home station) portion of all ETOPS flights greater than four hours.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 9 “POWER PLANT SYSTEM MONITORING PROGRAM”

Monitoring Process

Engineering and Reliability is responsible for monitoring all IFSD events and calculating the IFSD rate. The IFSD rate is to be
computed on an overall basis as well as a 12-month rolling average. IFSD rate per 1000 engine hours is to be calculated for the
entire fleet of each airframe/engine combination involved in ETOPS operations. Engineering and Reliability will include the rate data
in the monthly Reliability report.

Report and follow-up IFSD event

The Maintenance Supervisor in charge for the ETOPS Flight follow-up and control (MS-ETOPS), is responsible for the ETOPS flight
follow-up, this means that he must be the first person advice for an IFSD. The (MS-ETOPS) will report immediately to the Operative
Organization for any In Flight Shut Down event (IFSD). The advice could be via e-mail, telephone, fax or any other available media.
At a first stage, the report must include the following personnel:

Maintenance Manager
Operations Department
Flight Dispatch Department
Planning and Capacity Department

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 10 “OIL CONSUMPTION MONITORING PROGRAM”

For ETOPS airplanes, engine and APU oil consumption will be monitored on a flight-by-flight basis to identify exceedance of alert
limits or the development of significant upward trends in consumption.

Data collection will begin two months prior to the start of ETOPS and continue for all flights (ETOPS and non-ETOPS). The purpose
of this action is to establish a baseline consumption level for each engine and APU.

Oil Consumption Program Procedures/Data Collection

Engine and APU oil must be checked and serviced in accordance with Top-off procedure, as necessary, to the FULL level prior to
dispatch on an ETOPS flight.

At ETOPS flights the mechanic must made contact with the Maintenance Supervisor in charge for the ETOPS Flight follow-up and
control (MS-ETOPS). Mechanics at line stations will transfer the data using the best available method (telephone, fax, telex, etc.).

MS-ETOPS will calculate the oil consumption rates for the previous flight leg and determine if the rates are acceptable, based on the
flow chart below. If the rate is not acceptable for any engine or APU, the problem will be investigated by Engineering in order to
determine the cause of the problem. Corrective action will be implemented by Maintenance before the airplane is dispatched for
ETOPS.

If the oil consumption rates are acceptable, or when a detected problem has been corrected, the airplane can be released for
ETOPS, providing other restraints have been cleared.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 11 “ENGINE CONDITION MONITORING PROGRAM”

The purpose of the Engine Condition Monitoring (ECM) program is to continuously monitor engine performance and to initiate timely
corrective action when necessary. This program will ensure that engine limit margins are maintained so that a prolonged single-
engine diversion may be conducted without exceeding approved engine limits.

ECM Program Procedures/Data Collection

The ECM program utilizes the SAGE (System for the Analysis of Gas Engines, GE Program) computer software provided by GE,
engine manufacturer, to provide trending reports on the applicable engine parameters.

ECM Program - Corrective Actions

Whenever an engine limit margin becomes a concern, Engineering will investigate the problem to determine the cause.

If it is necessary, an Engineering Order will be issued defining corrective action required.

After corrective action has been implemented, verification of the maintenance will be performed in accordance with Chapter 12 of
this ETOPS Manual.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 12 “ETOPS MAINTENANCE OPERATING RESTRICTIONS POLICY”

Identical Maintenance Action on Multiple Similar Elements in ETOPS significant systems should not be undertaken at the
same maintenance visit without certain precautions being taken.

Identical Maintenance Action on Multiple Similar Elements is defined as the same task (i.e. repair, replacement, or
disassembly) is being performed on more than one of similar systems during the same maintenance visit, and, except in the case of
engine-driven components, on the same component.

Engine-driven components are considered equivalent; consequently the replacement of such components in any combination on both
engines qualifies as an identical maintenance action. Examples of the above would include:

•Removal of both engine oil filters and both chip detectors;

•Replacement of both IDGs, EDPs,

•Replacement of the #1 IDG and the #2 EDP, etc

NOTE: Servicing of fluids and gases is not considered multiple maintenance action or identical maintenance action.

When a task for similar systems needs to be applying at the same check package, the Maintenance Manager will program two
different work teams to perform the job.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

Interchangeability of Components (Swapping)

It is not recommended Swapping components between ETOPS aircraft similar primary systems for troubleshooting
purposes-, this could induce another failure.

In Example: installing #1 IDG in the #2 IDG position for troubleshooting.

The Maintenance Manager must authorize swapping of components for troubleshooting purposes, when there is no
other means of determining the cause of the malfunction.

If an exchange of unit is performed in ETOPS significant systems, a Non-ETOPS flight or a verification flight must be performed
before an ETOPS flight.

Positive verification of system integrity per Chapter 13 is required for both systems.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 13 “RESOLUTION OF AIRPLANE DISCREPANCIES”

Prior to subsequent ETOPS operation a positive verification that the corrective action taken to resolve problems significant to ETOPS
has been effective is required.

Built-in Test Equipment (BITE), checks performed per the Fault Isolation Manual (FIM) or the Maintenance Manual (MM), may
accomplish verification. Under certain circumstances, it may be necessary to verify success of the maintenance action during a
verification flight

Verification of Maintenance Action Requirements

Verification of maintenance action is required in the following circumstances:

1) An ETOPS significant system failure;


2) An In-Flight Shut Down, uncommanded power change or surge, or inability to control an engine or obtain desired power;
3) Failures of systems listed in FAR 21.3 and FAR 121.703;
4) Maintenance performed on multiple, similar systems (as defined in Chapter 12);
5) Swapping components in ETOPS significant systems for troubleshooting purposes (Refer Chapter 12.2);
6) An engine replacement.

Maintenance Supervisor on Duty for the ETOPS Flight follow-up and Control (MS-ETOPS) may determine any other maintenance
actions or conditions which will require verification on a case-by-case basis. For this analysis he could request assistance with Quality
Control and / or Engineering Manager.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

Maintenance Actions Report

When a Maintenance action is required the Maintenance Supervisor in charge for the ETOPS Flight follow-up and Control (MS-
ETOPS) will inform to the Operative Organization the kind of actions performed, as well as the estimated time needed.

The intend of report is maintain a clear channel of communication, in order to kept involved areas informed of the damage, fail,
evaluation and corrective action status.

The MS-ETOPS or his designee will send in a regular time interval o when relevant information is generated, the information via e-
mail, fax, telephone, or any available media.

Determination of the Need for In-flight Verification

In the event that maintenance action cannot be verified by normal ground tests, or the problem or fault cannot be duplicated on the
ground, an in-flight verification will be required.

Maintenance Supervisor on Duty for the ETOPS Flight follow-up and Control will be contacted to determine the necessity for a
verification flight. A verification flight should be used ONLY in the following circumstances:

a) There is no effective ground check or test;


b) There is not a procedure to check or test at the Maintenance Manual;
c) BITE checks do not adequately verify system operation or effectiveness of the corrective action;
d) The system can only be finally confirmed fixed during actual operation in the air, the fault cannot be duplicated on ground);

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

Verification Flight Definition

A verification flight is a revenue or non-revenue flight during which the flight crew is asked to assist maintenance in order to confirm
that an ETOPS significant system is operating normally, or that an ETOPS significant problem has been resolved.

The duration or required number of flights is determined by Maintenance Supervisor in charge for the ETOPS Flight follow-up and
Control in consultation with Quality Control Manager and Engineering Manager.

The verification flight may be conducted on a non-ETOPS flight or during the first 60 minutes of an ETOPS revenue flight; in
example: prior to entry into the ETOPS portion of the flight).

Verification Flight Procedures

The Quality Control Manager with the Maintenance Supervisor on Duty for the ETOPS Flight follow-up and Control and/or
Maintenance Manager determine if a verification flight is required.

Items which may require Verification Flights will be discussed with the Maintenance Supervisor in charge for the ETOPS Flight follow-
up and Control, Quality Control Manager and Engineering Manager for resolution.

After 60 minutes from Takeoff, or the minimum duration specified by the departing line station or Maintenance Supervisor on Duty
for the ETOPS Flight follow-up and Control, prior to the ETOPS entry point, the flight crew will indicate the confirmation or failure of
the system either through radio contact with Maintenance Supervisor in charge for the ETOPS Flight follow-up and Control, or a
logbook write-up.

If during the verification flight, the problem recurs, the flight crew will contact Maintenance Supervisor in charge for the ETOPS
Flight follow-up and Control and Dispatch for resolution. If the problem does not reoccur but associated flight deck or associated
airframe sensory indications are experienced, the flight crew will contact Maintenance Supervisor in charge for the ETOPS Flight
follow-up and Control and Dispatch for resolution.

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DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 14 “ETOPS TRAINING PROGRAM”

The ETOPS Maintenance Training program is included in the Normal Maintenance-Training Program. The goal of the ETOPS training
program is to ensure that all personnel involved in ETOPS are provided the necessary training to emphasize the special nature of
ETOPS maintenance requirements and to assure that ETOPS programs are properly accomplished.

Recurrent ETOPS training is provided for ETOPS qualified maintenance personnel this instruction will be performed in a periodic
manner and in accordance with the requirements and defective find out, as well as significant changes on the ETOPS Program.

Recurrent training focuses on the following:

1) Significant changes to MasAir ETOPS Program;


2) Significant ETOPS airplanes modification and configuration changes;
3) Review of ETOPS Training as required by local management,
4) Reinforcement of ETOPS concepts and requirements.

At ETOPS remote stations, other airlines maintenance personnel and/or contractors otherwise qualified on the type of airplanes, they
must have to be trained MasAir ETOPS Maintenance Training Program. For this personnel MasAir Quality Control Manager will
expend an authorization letter, which is personal and not transferable.

26 TRAINING ONLY JULY/2011


DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 15 “DOWNGRADE AND UPGRADE ETOPS AIRCRAFT CERTIFICATION”

Downgrade ETOPS Aircraft operations certifications:

The MasAir Maintenance Supervisor must downgrade the operation configuration condition every time a malfunction report
affects to a system or component involved in this type of operation, and a corrective action is not performed prior to dispatch, and
whenever the number of components required for ETOPS Operation according to the MEL is reduced.

The discrepancy or report will have to be transferred to the Deferred Maintenance Item log book (DMI) for its control in accordance
with the MEL. At the same time the operation of the aircraft must be DOWNGRADE from ETOPS 120 to a NON ETOPS operation
according to the MEL, being necessary to install the NON ETOPS decal at the lower right corner of the flight log cover and a NON
ETOPS decal must be placed at the DMI Board located on the front side of the cockpit entrance door.

Upgrade ETOPS Aircraft Operations Certification

Means the action to restitute the aircraft operations certification to a superior level to which is received, and no more than the
authorized, after perform the maintenance corrective actions in accordance with the aircraft maintenance manuals and the airworthy
release is authorized by the certificated mechanic

According to the results obtained in the corrective actions, the authorized personnel will be able to restitute the Certification
Operation of the airframe from NON ETOPS to a maximum of ETOPS 120, previous verification of the limitations indicated in the
MEL.

The upgrade will be able to take place in the main Base or the stations were technical personnel is properly authorized

The authorized personnel may have three possible options respect the release of the aircraft and they are: Downgrade, Upgrade or
Maintain the ETOPS operation.

27 TRAINING ONLY JULY/2011


DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

CHAPTER 16 “FORMATS”

28 TRAINING ONLY JULY/2011


Mas Air
ETOPS Pre- Departure Service Check.
A/C TYPE / SERS JOB CARD CARD REV REV. DATE TASK PAGE
JULY/2011

767-316F/ MY-ETOPS PDSC ORGINAL 06/30/06 CHECK/INSP 1 OF 1


Accomplish following items PRIOR to dispatch an ETOPS flight
A. Fuselage / Empenage
Visually Inspect the condition of:
1. Forward cargo compartment linings (AMM 25-52-00/601)
2. Aft cargo compartment linings (AMM 25-52-00/601)
3. Bulk cargo compartment linings (AMM 25-52-00/601)
4. Main deck cargo door seal and installation (AMM 52-09-02/401)
5. Forward cargo door seal and installation (AMM 52-09-02/401)
6. Aft cargo door seal and installation (AMM 52-09-02/401)
7. Bulk cargo door seal and installation (AMM 52-09-02/401)
8. Main deck cargo door surround structure and seal depressor (SRM 53-00-15/101)
9. Forward cargo door surround structure and seal depressor (SRM 53-00-15/101)
10. Aft cargo door surround structure and seal depressor (SRM 53-00-15/101)
Accept compliance of all above items
Print Name Signature License nbr. Date Station
B. Engine one (1)
Check IDG oil level as follow:
1. Open the IDG access panel

TRAINING ONLY
Note: Do not do an oil level check on a disconnected IDG because the indication will be incorrect
2. Make sure the engine has been shut down within 5 to 30 minutes before checking oil level
3. Clean the face of the oil level indicator if it is necessary. Look into the view port of the oil level indicator
4. Assure the white marks align, found in the view port, in a straight line
Note: A flash light can be necessary to see the white marks. Do not point the light directly into the view port. Reflections
can cause incorrect indications
5. If you see a silver mark in the view port, the oil level in the IDG is low
6. Do the IDG servicing procedure (AMM 12-13-03/301)
7. Close the IDG access panel
Accept compliance of all above items
Print Name Signature License nbr. Date Station
C. Engine two (2)
Check IDG oil level as follow:
1. Open the IDG access panel
Note: Do not do an oil level check on a disconnected IDG because the indication will be incorrect
2. Make sure the engine has been shut down within 5 to 30 minutes before checking oil level
3. Clean the face of the oil level indicator if it is necessary. Look into the view port of the oil level indicator
4. Assure the white marks align, found in the view port, in a straight line
Note: A flash light can be necessary to see the white marks. Do not point the light directly into the view port. Reflections
can cause incorrect indications
5. If you see a silver mark in the view port, the oil level in the IDG is low
6. Do the IDG servicing procedure (AMM 12-13-03/301)
7. Close the IDG access panel
Accept compliance of all above items

29
Print Name Signature License nbr. Date Station
Job card: MY-ETOPS PDSC
ETOPS OIL CONSUMPTION MONITORING FORM

Registration: ESN (POS 1):


(1) ESN (POS 2):
(2)
Eng. No. 1 Eng. No. 1 APU
APU Hour APU Elapsed Total Block Engine No 1 Engine No 2 APU (Qts / Hour) (Qts / Hour) (Qts / Hour)
Date (UTC) F.Log page
meter reading time time oil added oil added oil added Oil Oil Oil
consumption consumption consumption
(3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Note: To calculate the maximum Real Oil Consumption reference to the B767-MY TRANSIT CHECK Job Card page 5 of 5

ENGINE OIL CONSUMPTION LIMIT: .55 QTS/HOUR IAW B767 AMM 71-00-00 (14)
APU OIL CONSUMPTION LIMIT: .33 QTS/HOUR IAW B767 AMM 49-11-00 (15)

ETOPS OIL CONSUMPTION MONITORING FORM

30 TRAINING ONLY JULY/2011


JULY/2011

STABILIZED CRUISE A.P.U. START CHECK LIST - MY-49-0008


THE REASON FOR THIS PROGRAM, IS TO DETERMINE THE A.P.U. RELIABILITY USING A STABILIZED
CRUISE A.P.U. START CHECK.
AFTER FLIGHT CREW PERFORMS THIS CHECK, REMOVE FROM THE AIRPLANE, AND SEND TO
RELIABILITY ENGINEER
AIRCRAFT: ______________
PERFORM STABILIZED CRUISE A.P.U. START CHECK, ONLY IN THE FOLLOWING CONDITIONS:
a) WHEN THIS CHECK LIST IS ON BOARD AND RELIABILITY ENGINEER HAS SCHEDULED THIS
CHECK LIST.
b) 3 HOURS AFTER REACHING CRUISE ALTITUDE.
c) PERFORM ONLY ONE A.P.U. START IN FLIGHT

TRAINING ONLY
d) OPERATE A.P.U. FOR THREE (3) MINUTES, WITHOUT LOAD AND THEN STOP.
e) RECORD THE APU START CHECK AT MAINTENANCE FLIGHT LOG, INCLUDING ITEMS LISTED
BELOW.
DATE: _____________________ (dd/mmm/yy)
LEG: ______________________
CRUISE ALTITUDE: _______________________
O.A.T.: ___________________
HOURS FROM TAKE-OFF: _________________________
DISCREPANCIES OBSERVED DURING THE A.P.U. START:
Captain Print Name and Signature

31
FORM MY-49-0008
Aircraft Departure Debriefing Report
JULY/2011

Rev 02 Form MYM-012


Date Flight Number
Registry Flight Log N° Input (Leg)
Flight & Block Hours STA Block Time Flight Time Delay Time
FROM
TO
Fuel Loaded in Fuel Order Rem Fuel Kg. Block fuel kg.
LT GAL
Engine Oil added (Quarts) Hydraulic added (Quarts)
ENG 1 ENG 2 APU LH CTR RH OXYGEN PRESS
Maintenance Service Man / Hours License N° Mechanic Name

TRAINING ONLY
(A) Defect Description (B) Action Taken
A1 B1
ATA Number: License N° Mechanic Date
(A) Defect Description (B) Action Taken
A2 B2
ATA Number: License N° Mechanic Date
(A) Defect Description (B) Action Taken
A3 B3
ATA Number: License N° Mechanic Date
(A) Defect Description (B) Action Taken
A4 B4
ATA Number: License N° Mechanic Date
PART NAME POS. P / N OFF S / N OFF P / N ON S / N ON

32
DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

DECALS

As a manner to identify the ETOPS operations Mas Air have issue two identifying decals, for ETOPS 120 and for NO ETOPS
operations

The use of the decals self-adhesive will be according to the Downgrade and Upgrade ETOPS Aircraft operations certifications.

ETOPS 120 Decal (P/N MY-ETOPS 120)

When the aircraft has no restrictions to operate as ETOPS 120, the ETOPS 120 Decals must be installed.

Decal description:

White color circle with 35-millimeters for diameter and the ETOPS 120 letters in blue color.

33 TRAINING ONLY JULY/2011


DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

NO ETOPS Decal (P/N MY-NO ETOPS)

The NO ETOPS Decals must be installed.

Decal description:
A 35-millimeter diameter circle in yellow color with the NO ETOPS letters in red color

34 TRAINING ONLY JULY/2011


DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

ETOPS Approved Part


Use to identify ETOPS approved parts. The identification decal must be installed at the ‘Serviceable tag” (Form MYM-001) of the
component

Decal description:
A 25-millimeter diameter circle in white color with ETOPS PART in blue color

35 TRAINING ONLY JULY/2011


DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

ANNEX A

CONFIGURATION, MAINTENANCE, AND PROCEDURE STANDARDS CONTROL

This Annex presents the Model 767 airplane configuration, maintenance and procedure standards for extended range operations
(ETOPS) up to 120 minutes diversion time from an alternate airport.

1. A list of maintenence Manual or service letter item which are non operational for ETOPS
2. A list of Operations Manual Bulletins which are non optional for ETOPS

ANNEX B

RESTRICTED ETOPS PARTS FOR ETOPS OPERATIONS

This Annex presents the Model 767 airplane with CF6-80C2 FADEC engine list installed for the Approved ETOPS parts for ETOPS
missions. This Restricted ETOPS parts list is a component of the MasAir Parts Control Program implemented to ensure that ETOPS
airplanes is kept in the ETOPS configuration as defined by the latest revision of the CMP document.
The list is dividide by ATA 100 chapter

36 TRAINING ONLY JULY/2011


DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir
ETOPS

ANNEX C

MAINTENANCE BASES

At this Annex Mas Air presents the list for the Maintenance Bases divided in two categories: Main Base and Stations.

Main Base

The Main Base and Operations Center is located at Aeropuerto Internacional de la Ciudad de México, México D.F.

The total facilities include sufficient ramp area and work area for the accomplishment of required work operations. Storage
segregation and protection of ETOPS parts, materials, and tooling are provided within the facility.

Maintenance Stations

Class I Bases are those stations where full time maintenance personnel are assigned and flight ETOPS could be originated or
arrive.

a. GDL e. VCP
b. MIA f. LIM
c. LAX g. EZE
d. SCL

Class II Bases are those stations where maintenance personnel may be available full or part time. Class II bases provide
services, checks, and maintenance for aircraft transiting or temporarily operated from such locations.

37 TRAINING ONLY JULY/2011


DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir

ANEXO D

BIOGRAPHY

Advisory Circular 120‐42B


Subjet: EXTENDED RANGE OPERATION WITH TWO – ENGINE AIRPLANES (ETOPS)

767 Configuration Maintenance and Procedeures (CMP) for Extended Range Operations with two‐ engine airplanes
Boeing Document No. D6T11604

Boeing 767 Configuration, Maintenance and Procedures Supplement Volume 1 of 2


Boeing Document No. D6T11605

Boeing Configuration, Maintenance and Procedures Supplement Volume 2 of 2


Boeing Document No. D6T11605

ETOPS Guide Volume II Maintenance Program Guidelines


Boeing Document No. D621t401

ETOPS Significant System Guide (757/767)


Boeing Document No. M‐7360‐d535

ETOPS Pre‐ Departure Service Check Study


Boeing Document No. D526

38 TRAINING ONLY JULY/2011


DIRECCIÓN DE MANTENIMIENTO E INGENIERÍA
DEPARTAMENTO DE CONTROL DE CALIDAD
CENTRO DE CAPACITACIÓN MasAir

TANKS FOR YOUR PARTICIPATION

PREPARATED BY

MARCOS AVELAR

Comments and Suggestions:

mavelarz@masair.com
525 55 5701 6900
Ext. 104

39 TRAINING ONLY JULY/2011