EASA Aircraft Maintenance Procedures Training

Module 7 Cat B1
Aircraft Maintenance Practices V (AME 2310)

Maintenance Procedures
EASA PART66 ENABLING OBJECTIVE 17:
MAINTENANCE PROCEDURES
Rev 13/11/21
Issue: 01 Date: Nov 2021 AIRCRAFT MAINTENANCE PRACTICES V

Revision: 0 Date: FOR TRAINING PURPOSES ONLY
Learning Objectives
At the end of this module, students should be able to:
Q Explain the basic concept of maintenance planning.

Q Describe scheduled and unscheduled maintenance.
Issue: 01 Date: Nov 2021 AIRCRAFT MAINTENANCE PRACTICES V Reference: Slide

Revision: 0 Date: ICAT Notes 2
FOR TRAINING PURPOSES ONLY No.
Q Aircraft must receive regular maintenance to remain
airworthy at all times.
Q This is achieved by making various checks, at
intervals throughout the life of the aircraft
Q These intervals can be stated in quantities of flying
hours, calendar time or a combination of both.

Q Periods of maintenance can be small or large
varying from a few hours to a week or two.
Q It is normal to apply a “back stop” to each period for
safety. This a definite last date that the maintenance
must be done early, regardless of hours remaining.
Q Also if the aircraft is flown intensively it might reach
its flying hours target before the calendar cut off, the
maintenance will be carried out at that time.

Q Decisions as to frequency and depth of
maintenance are controlled by the “Type Design
Organisation”
Q The maintenance programme contains listings of all
maintenance actions, frequencies and inspection
points
Q The aircraft has a list of critical parts, with which it
cannot fly without them being serviceable.

Example of Maintenance Schedule
Source: Boeing.com

Maintenance Programme
Q Maintenance programme is a statement of what has
to be done, when it has to be done and how it is to
be done. A description of the general requirements of
a programme is contained in Part M – Aeroplane
Maintenance.
Q The programme should consist of:
Ø Maintenance Planning Document
Ø Approved Maintenance Schedule
Ø Maintenance Manuals
Rev 13/11/21

Maintenance Planning Document
Q Written by either the aircraft constructor or the
'regulatory authority’. at the aircraft design stage
and forms a part of the aircraft Type Certification
requirements in Part - 21.
Q Lists all the maintenance actions that are required
and their periodicity.
Q All subsequent maintenance actions on the aircraft
are based on this document.
Rev 13/11/21

Maintenance Review Board (MRB)
Q Decides the content of the MPD for a large transport aircraft
(over 5730kg MTOM).
Q Determines the maintenance requirements at the aircraft
design and testing stages.
Q Consist of members of the
Ø 'regulatory authority' involved in the type certification
process,
Ø representatives from the aircraft design and
manufacturing organisation.
Rev 13/11/21
Ø airline representatives and technical specialists.

Approved Maintenance Schedule - AMS
Maintenance Schedule is based on the agreed MPD and
approved by the 'regulatory authority', after which it becomes
approved for use on the aircraft type.
Q An aircraft operator may wish to make minor amendments
to the MPD to allow for specific operational requirements.
These amendments have to be approved by the
'regulatory authority’.
Q The amended AMS is approved only for use on the type
of aircraft whilst it is operated by that operator/airline.
Rev 13/11/21

Approved Maintenance Schedule - AMS (continued)
2 types of approved schedule.
Q 'Light Aircraft Maintenance Schedule' (LAMS) for aircraft
below 2730kg MTOM and written by the 'regulatory
authority’ and are automatically approved.
Q For aircraft exceeding 5730kg MTOM written by a
Maintenance Review Board, and are submitted to the
'regulatory authority' for approval. Schedules are often
written using the standard MSG3 (Maintenance Steering
Group) technique.
Rev 13/11/21

Q Approved Technical Publications.
Maintenance manuals – contains the procedures how
tasks are to be carried out. They are written by the
aircraft constructor approved by 'regulatory authority'.
These manuals are written in the ATA 100 format.
Q Task Sheets ('Worksheets' or 'Job cards’).
Task Sheets provide a means of recording the
completion of each step in a task. A scheduled
maintenance inspection may be issued as a package
of Task Sheets.
Rev 13/11/21

Types of Maintenance
1. Block Maintenance
2. Equalised Maintenance
3. Never Exceed Maintenance
Rev 13/11/21

1. Block Maintenance (Progressive maintenance)
Q The maintenance checks increase in their number,
duration and complexity at each successive
servicing period.
Q The first check has a simple content, the next is
larger and the next is larger still.
Q The cycle ends with a major check, after which the
cycle starts over again. Lengthy, in depth
inspections would all be conducted during the major
check.
Rev 13/11/21

2. Equalised Maintenance
Q The content of each servicing are all the same
length.
Q Requirement for an in-depth inspection that would
normally be reserved for a major check, may occur in
one check at the expense of lighter inspection in
other areas.
Q Every area will be properly inspected over an agreed
maintenance cycle.
Rev 13/11/21

3. Never Exceed Maintenance (servicing by opportunity)
Q It is used by operators who wish to coordinate checks with
the times that aircraft may be on the ground for other
reasons.
Q A 'Never Exceed Point' is allotted to each maintenance
action.
Q The operator then schedules in the required inspections
or component replacements when a suitable opportunity
arises but never goes beyond the 'Never Exceed Point’.
Q Extensions maybe applied, example extended by 10%
approved by ‘regulatory authority’ subject to conditional
inspection.
Rev 13/11/21

Never Exceed Maintenance (servicing by opportunity)
Example
Transit Check Every stop
Ramp 1 Every base visit
Ramp 2 Every 100 flying hours
Ramp 3 Every 300 flying hours
Service check Every 400 flying hours
Intermediate check 1 4500 flying hours or 2 years
Intermediate check 2 7000 flying hours or 4 years
Major check 12000 flying hours or 6 years

Rev 13/11/21

Never Exceed Maintenance (servicing by opportunity)
Example
Check A Before each flight
Check B Daily
Check C Every 100 flying hours
Check D Every 450 flying hours or 300 flights
Check 2D Every 900 flying hours or 3 monthly
Check E 3000 flying hours or 15 months
Check F 6000 flying hours or 30 months
Check G 12000 flying hours or 60 months

Rev 13/11/21

Primary Maintenance Processes
These processes are related to how we actually
maintain an item.
Q There are 3 primary maintenance processes: Hard
Time, On-Condition and Condition Monitoring.
Q Hard Time and On Condition - directly concerned
with preventing failure.
Q Condition Monitoring - does not prevent failure but it
can generate subsequent preventative actions.
Rev 13/11/21

Hard Time.
Q Applied to items where the deterioration rate is known and is
limited to an acceptable level by maintenance actions that are
related to either: flying hours, calendar time, a number of
cycles, or a number of landings. The maintenance actions may
include component replacement or servicing.
Q For example, an aircraft wheel and tyre may be scheduled for
replacement at a given number of landings regardless of its
apparent condition.
Q The period would be set by the component manufacturer as
'Mean Time Between Failures (MTBF)’ for the component.
Rev 13/11/21

On-Condition.
Q An item is inspected or tested at specified periods in order to
determine whether it can continue in service.
Q For example, you inspect the oil filters and magnetic chip
detectors of an engine at specified periods. If the filter and
detectors are clear, the engine is judged fit to continue in
service until the next check.
Q The principle is to detect a fault before it can lead to a failure. It
is not a 'fit until failure' policy.
Rev 13/11/21

Condition Monitoring.
Q It relies on defect information gained on items from operational
experience across all operators of the aircraft or equipment
type.
Q The information is collected, analysed and interpreted on
continuing basis as a means of implementing corrective actions.
Q If the statistical data collection reveals an increase in the failure
rate across the fleet, the item can then be placed on Hard Time
or On-Condition maintenance.
Q The thresholds beyond which corrective actions are taken
would depend upon the importance of the item.
Rev 13/11/21

Condition Monitored Maintenance Programme.
Q A maintenance programme that incorporates: Hard Time, On-
Condition and Condition Monitoring.
Q The programme uses statistical data to provide information on
aircraft reliability and the effectiveness of the maintenance
methods.
Q It also provides timely information on where changes to the
programme may improve reliability.
Rev 13/11/21

Part-145 Approved Maintenance
Organizations
Class ratings for Part-145 organizations.
Q Category A. may carry out maintenance on the
aircraft and any component, including engines/
APUs, only whilst such components are fitted to the
aircraft except that such components can be
temporarily removed for maintenance when such
removal is expressly permitted by the aircraft
maintenance manual to improve access.
Q Subdivided into 'Base' or 'Line' maintenance.
Organisation may be approved for either 'Base' or
Rev 13/11/21 'Line' maintenance or both.
Organizations
Q Category B. May carry out maintenance on
uninstalled engines/ APU and engine/ APU
components whilst such components are fitted to the
engine/ APU, except that such components can be
temporarily removed for maintenance when such
removal is expressly permitted by the engine/ APU
manual to improve access for maintenance'.
Rev 13/11/21

Organizations
Q Category C. may carry out maintenance on
uninstalled components, excluding engines/ APUs,
intended for fitment to the aircraft or engine! APU’.
Q They may also carry out maintenance on an installed
component during base or line maintenance or at an
engine/ APU maintenance facility subject to a control
procedure in the organisation's exposition.
Rev 13/11/21

Organizations
Q Category D. Not necessarily related to a specific
aircraft, engine or other component. It relates to the
conduct of specialised services, for example a class
D1 rating covers non-destructive inspections.
Q An organisation holding a class A or B rating may
carry out this type of work on equipment they are
maintaining where their exposition includes the
required procedures..
Rev 13/11/21

Part-145 Exposition
Q Auditable written procedures for meeting the
requirements contained in the organization's
Exposition.
Q An Exposition is an approved document that sets out
the working procedures, means and methods of the
organisation.
Q Compliance with the MOE assures compliance with
the Part – 145 requirements.
Rev 13/11/21

Part – 145 Exposition Requirements
• Facilities
• Personnel
• Record of Certifying Staff
• Equipment, Tools and Materials
• Approved Data
• Certification of Maintenance
• Maintenance Records
• Reporting Un-airworthy Conditions
• Maintenance Procedures and Quality System
Rev 13/11/21 • Maintenance Organisation Exposition
Certificate of Maintenance Review (CMR)
Q Commercial aircraft have to carry a valid Certificate of
Maintenance Review (CMR).
Q Issued following a review of the current maintenance status of
the aircraft against the Approved Maintenance Schedule and
any mandatory modifications or inspections. The CMR shows
the date on which the review was carried out and the date
when the next review is due.
Q Signed by an authorised signatory in the approved
maintenance organisation. Normally a type rated certifying
engineer holding type rating in two categories on the aircraft
type.
Q For light aircraft, the review is often aligned with the annual
check. For large aircraft, the period is usually four months.
Rev 13/11/21

Modification Procedures
Rev 13/11/21

Q Only the Type Certificate holder or aircraft
constructor can submit an application to change a
Type Certificate in accordance with Part-21.
Q Minor modifications of a simple nature that do not
affect the Type Certification may be designed by an
approved organisation and be submitted for
approval by the 'regulatory authority' or by an
approved design authority it may be em bodied and
certified by them.
Rev 13/11/21

Mandatory Modifications
Q May be made by the constructor through the issue
of a Service Bulletin or a modification sheet.
Q The 'regulatory authority' may also classify a
modification as mandatory and issue an
Airworthiness Directive (AD) or an Emergency
Airworthiness Directive.
Q Where there is a safety issue involved, there is often
a limit imposed for the embodiment of this type of
modification in terms of flying hours, cycles or
Rev 13/11/21
calendar time.
Q Modifications are changes made to a particular
aircraft including its engines and component parts.
Q All modifications must be approved iaw EASA OPS
unless the CAA agree they are minor and do not
affect airworthiness.
Q Modifications are approved by the CAA or by the
approved organisation carrying out the modification
programme.

Major Modifications
Q The organisation sends a form, AD282 to the CAA
Q When approved, an approval note is then returned
to the organisation.
Q This allows the modification to be embodied

Minor Modifications
Q The organisation writes to the CAA requesting
permission to embody the Modification
Q When approved the CAA sends a form AD261 back
to permit the embodiment
Q If the Organisation has CAA approval it can
authorise its own modifications, but must keep full
records
Q All modifications are recorded in the aircraft log
book or in a Modification Log book if the aircraft
weighs more than 2730kg.

Certification of Modifications
Q Embodiment of a modification must be carried out and certified
by a Part-145 approved maintenance organisation.
Q Before a CRS is issued, the certifying engineer must ascertain:
Ø all drawings and instructions used correspond with the
Issue number that is specified in the modification
approval document
Ø carried out in accordance with the approved drawings
and instructions and, where required, has been tested
in accordance with the specifications in the instructions
Ø has been satisfactorily inspected and passed.
Ø any alterations to the Weight and Balance Schedule, or
reweighing requirement, have been carried out

Stores Procedures

Stores Procedures
Q All manufacturing and maintenance establishments
will have a stores department which has two
purposes:
Ø To ensure that all materials, parts etc…are to
the correct specification.
Ø To enable important part history to be traced
back to its manufacturer and its raw materials.
Q All stores throughout the EASA system use the same
forms. This ensures that a component moving from all
EASA countries uses the same EASA Form 1

Approved Stores
Q A store that operates within a CAA approved
organisation is known as an “Approved Stores”
Q An Approved store will contain 3 departments
Ø A quarantine store, which accepts items from
other companies and checks they are
satisfactory.
Ø A bonded store which accepts items from the
quarantine store and issues to technicians.
Ø An office or administration centre, which
keeps files and records to enable cross-
checks of transactions.

Approved Stores

Certification and Release Procedures

Q Any maintenance done on aircraft that has a Certificate of
Airworthiness (C of A) must be certified by the technicians
doing the work. (This is a legal requirement)
Q The technicians can have either
Ø personal certification or
Ø company approval.
Q Work is normally certified by an approved engineer or,
completed by a non-approved engineer and certified by
another, approved engineer.
Q Certifying staff must demonstrate that they can determine
when aircraft or aircraft components are ready to release to
service and when they should not be released to service.
Q This Certification is known as a Certificate of
Release to Service.
Q The wording is to a standard format and the
signature certifies that the work has been done in
accordance with EASA 145 and the aircraft is fit for
release to service.

Q 'Base' maintenance - it is acceptable to issue one
Certificate of Release to Service summarizing the
block of maintenance. This requires a unique cross-
reference to a work pack record that contains full
details of the maintenance work carried out.
Q 'Line‘ maintenance work - Certificate of Release to
Service is required for each task.

Certificate of Release to Service
Q This certification should contain details of:
Ø work done
Ø the organisation
Ø the place
Ø aircraft type and registration and/or
component part and serial number.

Interface with Aircraft Operation
There are many links between maintenance and flying.
These include the legislation that dictates how the two
operations work together.
Q IR-OPS (was EASA-OPS) - the rules on how we operate
and maintain our aircraft
Q Tech Log - flight ops, defects, fuel and ground
maintenance
Q Log Books - long term records of flying hours and life
Q Modification Records - records of all the changes
Q Others include the Minimum Equipment List (MEL) and
the Configuration Deviation List (CDL).
Maintenance Inspection
Q All Maintenance no matter what
level is controlled by the
Maintenance schedule. This is
produced by the manufacturer and
dictates the depth and frequency.
Q On Light and private aircraft below
2730kg the Servicing is done iaw
the Light Aircraft Maintenance
Schedule (LAMS) produced by the
CAA
Q This simple schedule divides
maintenance into 50 and 150 hr,
annual and tri-annual inspections

Maintenance Inspection
Q The personnel who do inspections must be licensed by
the CAA or `approved` by their own company.
Q If the company has CAA approval under EASA-145 it is
permitted to control all the maintenance.
Q If the company has additional CAA approval under
EASA-147 it is permitted to train `in house` its engineers.

Quality Assurance
Q An approved company has to have a quality
assurance department under the rules of EASA-145.
Q It is responsible for:
Ø Standards throughout the company
Ø Audits to ensure procedures are followed

Quality Assurance
Inspection
Q the examination of something to establish its
conformity with an approved standard.
Q includes activities such as measuring, examining,
testing, gauging or otherwise comparing an item with
a specified requirement.
Q it is detection orientated in that an item is judged to
either pass or fail.
Rev 13/11/21

Quality Assurance
Quality Control
Q Operational techniques and activities that sustain a
product or service to specified requirements.
Q The object of quality control is to satisfy a customer
by achieving his/her requirements on time at the
minimum cost.
Q Quality control is prevention orientated
Rev 13/11/21

Quality Assurance
Quality Control
Q Operational techniques and activities that sustain a
product or service to specified requirements.
Q The object of quality control is to satisfy a customer
by achieving his/her requirements on time at the
minimum cost.
Q Quality control is prevention orientated
Rev 13/11/21

Quality Assurance
Quality Assurance
Q all the planned and systematic actions necessary to provide
adequate confidence that a product or service will satisfy given
requirements.
Q Example: monitoring the performance of an organisation, and
instituting corrections where necessary, so that it will achieve its
stated outcomes to the required standard.
Q Example: compliance of an organisation with the standard
specified in a maintenance contract.
Q A quality assurance programme usually includes a number of
quality control systems drawn up under a quality plan.
Rev 13/11/21

Quality Assurance
Quality System
Refers to organization's structure, responsibilities, activities,
resources and events that together provide organized
procedures and methods of implementation to ensure the
capability of the organisation to meet its quality
requirements.
Quality Programme
A documented set of activities resources and events serving
to implement the quality system of an organisation.
Rev 13/11/21

Quality Assurance
Quality Plan:
A quality plan is a document derived from the quality programme
setting out the specific quality practices, resources and activities
relevant to a particular contract or project.
Quality Audit:
A quality audit is a systematic and independent examination that is
carried out to determine whether actual quality activities and
related results comply with planned arrangements and whether
these arrangements are implemented effectively and are suitable
to achieve objectives
Rev 13/11/21

Additional Maintenance Procedures
Q Apart from regular maintenance checks many
other procedures are done at irregular intervals,
including:
Ø Aircraft washing
Ø De-icing
Ø Weighing
Ø Sampling (at the request of the
CAA/manufacturer.)
See also: Boeing AMM for more conditional inspection procedures

Control of Life Limited Components

Q There are components that have a `Life’ quoted in
flying hours, cycles or calendar time.
Q The correct terminology for `life’ is Mandatory Life
Limitation
Q The control of lifed items rests with the Technical
Control/Records department.
Q Their replacement is often synchronised with a
scheduled maintenance check.
Q Some items such as batteries, are changed on the
flight line, often at the end of the day’s flying.
Examples of Mandatory Life Limitation:
Ø fatigue life on a structural component in flying
hours
Ø the landing gear legs due for retirement after
10,000 landings,
Ø the batteries due for replacement after 3 or 4
months
Ø a retirement life on an APU measured in
hours running time.

Q The notification for change will be annotated on the
Maintenance statement. This gives all items due
between scheduled maintenance checks.
Q In the front of the Maintenance manual is a chapter
called `Retirement Lives’, `Long life items’ or `Fatigue
lives’, this lists all components and their `lives’.

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Module 7 Cat B1

Aircraft Maintenance Practices V (AME 2310)

Issue: 01 Date: Nov 2021 AIRCRAFT MAINTENANCE PRACTICES V

Q Explain the basic concept of maintenance planning.

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Transit Check Every stop

Ramp 1 Every base visit

Ramp 2 Every 100 flying hours

Ramp 3 Every 300 flying hours

Service check Every 400 flying hours

Intermediate check 1 4500 flying hours or 2 years

Intermediate check 2 7000 flying hours or 4 years

Major check 12000 flying hours or 6 years

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Check A Before each flight

Check C Every 100 flying hours

Check D Every 450 flying hours or 300 flights

Check 2D Every 900 flying hours or 3 monthly

Check E 3000 flying hours or 15 months

Check F 6000 flying hours or 30 months

Check G 12000 flying hours or 60 months

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