Professional Documents
Culture Documents
Module 3 Reference - Maintenance Publications
Module 3 Reference - Maintenance Publications
PUBLICATIONS, FORMS,
AND RECORDS
INTRODUCTION
Screwdrivers, wrenches, and sockets are some of the tools you use to maintain and repair aircraft. However,
another tool that must not be neglected consists of the publications and forms that serve as a guide and record for
your maintenance activities. For example, a typical transport aircraft contains many miles of electric wire for indi-
cating, lighting, and control systems. Attempting to troubleshoot a maintenance problem without access to the
manufacturer's wiring manual would be a frustrating experience. A thorough knowledge of regulatory publica-
tions such as the Federal Aviation Regulations, and nonregulatory material such as manufacturer's manuals, is
every bit as important as the tools in your toolbox.
MAINTENANCE PUBLICATIONS
11. FAR Part 45, Identification and means that the part meets FAA requirements for
Registration manufacturing quality, and is approved for installa-
Markings tion on aircraft.
12. FAR Part 47, Aircraft Registration
13. FAR Part 65, Certification: Airmen other than
Flight Crewmembers
14. FAR Part 91, General Operating and
Flight
Rules
15. FAR Part 121, Certification and
Operations:
Domestic, Flag, and Supplemental Air Carriers
and Commercial Operators of Large Aircraft
16. FAR Part 125, Certification and
Operations:
Airplanes having a seating capacity of 20 or
more passengers, or a maximum
pay load
capacity of 6,000 lbs or more
17. FAR Part 127, Certification and Operation of
Scheduled Air Carriers with Helicopters
18. FAR Part 135, Air Taxi
Operators and
Commercial Operators
19. FAR Part 137, Agricultural Aircraft Operators
20. FAR Part 145, Repair Stations
21. FAR Part 147, Aviation
Maintenance
Technician Schools
22. FAR Part 183, Representatives
of the
Administrator
FAR PART 21
FAR Part 21 lists the requirements for establishing
and maintaining the certification of aircraft and
components. When an aircraft is manufactured, an
inspector determines if it conforms to that model's
type certificate. The type certificate lists all perti-
nent information on an aircraft or accessory design.
If the aircraft is in conformity, it is issued an airwor-
thiness certificate, signifying that it meets the stan-
dards for service. The airworthiness certificate stays
with the aircraft throughout its service life and is
transferred when ownership changes. However, an
aircraft must be maintained properly in order for the
airworthiness certificate to remain valid.
FAR PART 23
FAR Part 23 describes in detail the performance
characteristics various aircraft must demonstrate to
be airworthy. It specifies requirements for every
component and system installed on an aircraft,
often down to the smallest detail. Maintenance
technicians can use Part 23 to verify that a particu-
lar aircraft or component is in conformity with its
type certificate. For example, when cockpit instru-
ments are repaired or replaced, the technician
installing the instrument must check that the range
markings painted on the instrument face are correct.
The aircraft's approved flight manual gives the cor-
rect operating speeds and ranges for that particular
model. Part 23 specifies color codes and instrument
face markings that must be on all flight and engine
instruments.
Airworthiness Directives are issued biweekly. The trol surfaces which affect flutter and vibration
biweekly listings are published for small general characteristics.
aviation aircraft and accessories in one volume, 2. Powerplant major alterations: conversion of an
while the larger aircraft and their accessories are aircraft engine from one approved model to
published in a separate volume. This separation of another, replacing engine structural parts with
different aircraft categories provides operators with parts not supplied by the original manufacturer.
a much simpler means of filing ADs. 3. Propeller major alterations: changes in blade,
hub, or governor design. Installation of a pro
ADs are listed by a six digit numerical number. The peller deicing system.
first two digits denote the year an AD is issued. For 4. Appliance major alterations: alterations of the
example, all ADs issued during the year 1996 begin basic design not made in accordance with rec
with the number 96-. The third and fourth digits of ommendations of the appliance manufacturer
the AD number denote the biweekly issue in which or in accordance with an FAA Airworthiness
the AD was first published. There are twenty six Directive.
issues of the biweekly AD listing issued each year, 5. Airframe major repairs: airframe repairs involv
and the issues are numbered beginning with number ing reinforcing, splicing, and manufacturing of
01. The last two digits indicate the number of the AD primary structural members or their replace
in the specified biweekly listing. For example, the ment, when their replacement is by fabrication
fourth AD issued in the first biweekly publication in such as riveting or welding.
May 1996 would be issued the number: 96-10-04. 6. Powerplant major repairs: separation or disas
sembly of the crankcase or crankshaft of certain
reciprocating powerplants. Special repairs
FAR PART 43 to
structural engine parts by plating, welding, or
FAR Part 43 Maintenance, Preventive
other methods.
Maintenance, Rebuilding, and Alteration is one of
7. Propeller major repairs: any repairs
the most critical sections for the aviation technician
to, or
to study. As its title indicates, Part 43 outlines the
straightening of, steel blades,
fundamental standards for aircraft inspection, main-
shortening of
tenance, and repair, as well as all record keeping
blades, overhaul of controllable pitch
requirements.
pro
pellers.
8. Appliance major repairs: calibration of instru
ments or radios, overhaul of pressure carbure
tors, pressure fuel cells, and oil and hydraulic
pumps.
REPAIRS AND ALTERATIONS
A repair is an operation that restores an item to a This is not a complete listing of major repairs and
condition of practical operation or to original con- alterations. Always refer to the appropriate section
dition, whereas an alteration is any change in the of Appendix A to find out precisely what classifica-
configuration or design of an aircraft. The FAA tion a job falls under before starting. If there is any
divides aircraft repairs and alterations into two cat- question as to whether a repair or alteration is major
egories: major and minor. A major repair is one or minor, contact the local FAA office.
that, if improperly done, might appreciably affect
weight, balance, structural strength, performance,
powerplant operation, flight characteristics, or other The FAA defines minor repairs and alterations as
airworthiness factors. It is also a repair that cannot those that are not major repairs and alterations.
be performed using elementary operations. A major Since this definition is not very specific, it is some-
alteration is an alteration not listed in the product's times difficult to distinguish which category a
specifications that might affect the product's perfor- repair or alteration falls into. However, as a general
mance in a similar fashion to a major repair. rule, the complexity of the work being done is a
good indication of whether a repair or alteration is
Appendix A of FAR Part 43 lists examples of major major or minor. For example, Appendix A of FAR
repairs and alterations to airframes, engines, propellers Part 43 specifically states that replacement of an
and appliances. Some examples are listed below. engine mount by riveting or welding is an airframe
major repair. But if the same engine mount is
1. Airframe major alterations: alterations to wings, attached by bolts and is replaced, it is considered a
fuselage, engine mounts or control systems. minor repair. The same holds true of other airframe
Changes to the wing or to fixed or movable con- and engine components. Generally, if a
part is
Maintenance Publications, Forms, and Records 14-5
replaced with one exactly the same as the original, governing the maintenance, preventive mainte-
and elementary operations are used in the installa- nance, and alteration of U.S. registered aircraft.
tion of a replacement part, the procedure is consid- Unlike Part 43, Subpart E of Part 91 outlines the
ered a minor repair or alteration. Records of minor inspections that must be performed on all aircraft.
repairs and alterations need only be entered into the
aircraft's permanent maintenance records. Inspection of airframes, powerplants, and appli-
ances is the single most effective way to identify
potential problems and ensure safe operation. As a
PREVENTIVE MAINTENANCE result, inspections are one of an aircraft mainte-
Preventive maintenance consists of preservation, nance technician's primary duties. The FAA
upkeep, and the simple replacement of small parts. requires aircraft and their associated components to
Under some circumstances, the FARs allow be inspected regularly. The frequency of these
licensed airmen other than maintenance personnel inspections depends on the type and use of the air-
to perform preventive maintenance. For example, if craft or component.
an aircraft owner holds at least a private pilot
license, the owner can, among other things, change ANNUAL INSPECTIONS
an aircraft's oil and replace or repair a landing gear
tire. A complete listing of those items that are clas- FAR Part 91 states that all general aviation aircraft
sified as preventive maintenance is given in must go through an annual inspection to remain air-
Appendix A of FAR Part 43. worthy. All annual inspections are based on calen-
dar months and, therefore, are due on the last day of
the 12th month after the last annual was completed.
INSPECTION CHECKLISTS For example, if a previous annual was completed on
FAR 43.15 lists the performance criteria for per- June 11, 1995, the next annual inspection is due on
forming inspections and specifically states that a June 30, 1996.
checklist which meets the minimum requirements Annual inspections must be performed regardless of
listed in FAR 43 Appendix D must be used for all the number of hours flown in the previous year.
annual and 100-hour inspections. This, however, Furthermore, they may only be performed by
does not preclude you from developing a more air-frame and powerplant mechanics holding an
extensive checklist or using one prepared by a inspection authorization (IA). The IA can not dele-
repair station or manufacturer. As long as the check- gate the inspection duties to an airframe and pow-
list covers the items listed in Appendix D it may be erplant mechanic, nor may an IA merely supervise
used. Most major aircraft manufacturers provide
an annual inspection.
inspection checklists for their aircraft by type and
model number. These forms are readily available If the person performing the annual inspection finds
through the manufacturer's representatives and are a discrepancy that renders the aircraft unairworthy,
highly recommended. They meet the minimum they must provide the aircraft owner with a written
requirements of Appendix D and contain many notice of the defect. Furthermore, the aircraft may
details covering specific items of equipment
not be operated until the defect is corrected.
installed on a particular aircraft. In addition, they
However, if the owner wants to fly the aircraft to a
often include references to service bulletins and let-
different location to have the repairs performed, a
ters which could otherwise be overlooked.
special flight permit may be obtained to ferry the
aircraft to the place where repairs are to be made.
FAR PART 65
FAR Part 65 discusses the certification requirements 100-HOUR INSPECTION
as well as the privileges and limitations for aviation All general aviation aircraft that are operated for
maintenance technicians. Because of the amount of hire must be inspected every 100 flight hours. This
pertinent information contained in Part 65, Chapter inspection is in addition to the annual inspection
15 is dedicated to discussing Part 65 in detail. requirement, and covers the same items as the
annual inspection. The major difference is that an
A&P technician may perform a 100-hour inspection.
FAR PART 91 As in the case of an annual inspection, the person
FAR Part 91 is entitled General Operating and Flight conducting a 100-hour inspection cannot delegate
Rules of which Subpart E contains the regulations inspection duties.
14-6 Maintenance Publications, Forms, and Records
The operating hours are the primary consideration excluding those times when the system is drained
for determining when the next 100-hour inspection using a preinstalled drain and when the alternate
is due. As the name implies, a 100-hour inspection static source is opened.
is due 100 hours after the last 100-hour inspection
was completed, regardless of the date. However,
there is a provision for extending the 100-hour TRANSPONDER CHECKS
interval, up to a maximum of 10 hours, to permit the
aircraft to fly to a place where the inspection can be A transponder is an electronic device aboard an air-
accomplished. However, when this is done, the craft that enhances the aircraft's identity on an air
number of hours in excess of the 100-hour interval traffic control (ATC) radar screen. Because of the
are deducted from the next inspection interval. For important role transponders play in safety, they
example, if a flight to a place where a 100-hour must be checked every 24 calendar months. This
inspection can be conducted takes the aircraft six requirement is spelled out in FAR 91.413 and test-
hours beyond the 100-hour inspection interval, the ing of transponder equipment must be in accor-
next 100-hour inspection would be due in 94 hours. dance with FAR Part 43, Appendix E
In other words, the next inspection interval is short-
ened by the same amount of time the previous
inspection was extended. EMERGENCY LOCATOR CHECK (ELT)
An emergency locator transmitter (ELT) emits a
radio distress beacon at 121.5 megahertz when it is
PROGRESSIVE INSPECTIONS triggered by the pilot or by abrupt deceleration of
The progressive inspection is designed for aircraft the aircraft. To enhance the chances of rescue in
operators who do not wish to have their aircraft case of an accident, FAR 91.207 requires that all
grounded for several days while an annual or U.S. registered aircraft be equipped with an ELT.
100-hour inspection is being accomplished. Instead, ELTs must be inspected every 12 calendar months
the inspection may be performed in segments each for proper installation, battery condition and expi-
90 days, or at each 25 hour interval. The procedures ration date, operation of the controls and crash sen-
for establishing a progressive inspection program sor, and radio signal strength.
are covered in FAR Part 91.409(d) and the owner
must request this program. Furthermore, approval spEC|AL
must be received from the FAA prior to beginning a
progressive inspection program. At times, unusual incidents dictate that a special
inspection be performed. While not specifically
required by the FARs, most manufacturers have sev-
CONTINUOUS INSPECTION PROGRAMS eral categories of special inspections that must be
performed after an aircraft has been subjected to an
The continuous inspection program is designed for unusual flight condition.
operators of large commercial carrier aircraft operat-
ing under FAR Parts 121, 127, and 135. Like a pro-
gressive inspection program, a continuous inspection Overweight or Hard Landing
program must be approved by the FAA. These inspec-
tion programs are very comprehensive and require This inspection is performed any time an aircraft
complex maintenance facilities with large numbers of has experienced an overweight, or unusually hard
technical personnel. Most large airlines operate under landing. The structural damage which can occur
the continuous inspection programs of FAR Part 121. during this type landing can lead to catastrophic
failure and, therefore, manufacturers typically pub-
lish a set of instructions outlining what should be
ALTIMETER AND STATIC SYSTEM CHECKS inspected as well as the method of inspection used.
FAR 91.411 requires periodic altimeter and static
system checks for aircraft that operate in controlled Severe Turbulence Inspection
airspace under instrument flight rules. These
checks must be made in accordance with the guide- Severe turbulence exerts substantial stress on all
lines stated in FAR Part 43, Appendix E, and per- areas of an aircraft structure. Therefore, when an
formed each 24 months. Furthermore, the test must aircraft flies through severe turbulence, a detailed
be done whenever the static system is inspection of the airframe should be conducted.
opened,
Maintenance Publications, Forms, and Records 14-7
Hot Starts, Stackfires, Sudden Stoppage Within the general subject areas are more specific
Inspections subjects that also have a subject number. For exam-
ple, within the general subject of Aircraft, the spe-
Inspection of an engine after a hot start, stack fire, or cific subject of maintenance, preventive mainte-
sudden stoppage should be in accordance with the nance, and rebuilding and alterations is assigned
manufacturer's instructions. Chapter 14 of AC the number 43, which is also the number of the FAR
43.13-1B contains instructions for sudden stoppage
Part that covers maintenance.
inspections. At times, complete disassembly of the
engine is required to check for hidden damage. One of the most popular Advisory Circulars for
maintenance technicians is in the AC43 series. AC
RECURRING INSPECTIONS
43.13-lB and -2A, Acceptable Methods, Techniques
and Practices is a highly technical publication cov-
At times, an airframe component, engine, or acces- ering most of the aircraft maintenance areas which
sory requires a recurring inspection at specified the A&P technician must service. It contains infor-
intervals. For example, a manufacturer may require mation on standard hardware and torque values,
that a mechanic check the torque of cylinder base acceptable repair methods, and inspection tech-
nuts at every second 100 hour inspection. This niques. [Figure 14-1]
means that the actual interval between inspections
is 200 hours. Another popular AC within the 43 series is
AC43.9-1E which gives information on how to
Airworthiness directives often specify recurring complete of a Major Repair and Alteration Form
inspections after a certain time in service. For (FAA Form 337). In particular, it lists FAA
example, assume a new AD is issued that requires approved data sources that can be used as a
a wing spar cap inspection every 150 hours on air- reference for major repairs and alterations. Data
craft with 7,500 hours in service or less, and every obtained from Airworthiness Directives, approved
50 hours on aircraft with more than 7,500 hours. manufacturer's instructions, Type Certificate Data
Suppose the technician performing a 100-hour Sheets, Supplemental Type Certificates, and
inspection on an aircraft found it had 5,257 hours Technical Standard Orders are considered
in service, and the AD was complied with 28 hours approved.
ago. To determine the next inspection time, sub-
tract 28 hours from the 150 hour inspection inter-
val to get a figure of 122 hours. Add this to the total
airframe time in service to find that the inspection
is due next at 5,379 hours.
ADVISORY
ADVISORY CIRCULARS (ACs) CIRCULAR
Many of the technical publications and regulations
issued by the FAA are complex in nature and often
require additional explanation. As a result, the FAA ACCiPTABUE METHODS,
issues Advisory Circulars (ACs) to inform, explain, TECHNIQUES. M PRACTICES
and provide further guidance. Advisory circulars
are informative only and cannot be used as
approved data unless incorporated into a regulation
or an airworthiness directive. Advisory circulars are
listed in a numerical sequence closely following the
same subject areas covered by the FARs. Some of
the subject areas are:
00 General
10 Procedural Rules
20 Aircraft
60 Airmen
Figure 14-1. The FAA issues Advisory Circulars to explain or
120 Aircarriers, Air Travel Clubs, and clarify the Federal Aviation Regulations. Advisory Circulars
Operators are nonregulatory in nature unless incorporated into an FAR
for Compensation and Hire: Certification and generally do not contain approved data.
and Operations
14-8 Maintenance Publications, Forms, and Records
To improve aviation safety, the FAA gathers infor- 3. The maximum approved rpm and the horse
mation on mechanical problems and difficulties power rating of the engine(s).
discovered by aviation maintenance technicians 4. Propellers approved for use, rpm limits, and
working in the field. When encountering a new or operating restrictions, if any.
unusual maintenance problem, the technician is 5. Airspeed limits for the aircraft in knots and
requested to fill out and mail an FAA Form 8010-4 mph.
Malfunction or Defect Report detailing the problem. 6. Center of Gravity range, in inches from
When the FAA detects a trend forming with a the
particular aircraft or appliance, it publishes this datum.
information in AC43-16, General Aviation 7. Empty weight center of gravity range may be
Airworthiness Alerts. Alerts are issued monthly to listed, if it has been established by the manu
distribute the information gathered with the goal of facturer.
improving service reliability. 8. Location of the reference datum line.
9. Means to level the aircraft for weighing pur
For a complete listing of ACs, the FAA publishes an poses.
advisory circular checklist. Periodically, the 10. All maximum weights allowed for various com
Advisory Circular Checklist (AC 00-2) is revised partments and locations within the aircraft.
and reissued to inform you of the current status of 11. Oil and fuel capacity and
ACs. The checklist also provides you with pricing fuel tank
and ordering information. Some ACs are free while moment arms.
others are available at cost. You can order either 12. Control surface movements in degrees.
type through the Department of Transportation, U.S. 13. Required equipment necessary for operation of
Government Printing Office. the aircraft.
14. Any additional equipment found necessary for
certification of the aircraft.
TYPE CERTIFICATE DATA SHEETS 15. Any placards which must be displayed in full
view of the pilot will be listed in Note #2 of the
As previously discussed, new airframes, data sheet.
power-plants, and appliances are issued a type
certificate once they meet FAA approval. The type
certificate number assigned to the product is also Type Certificate Data Sheets are used during annual
used on the Type Certificate Data Sheet (TCDS), inspections to ensure that an aircraft conforms to its
which lists technical and other information type certificate. For example, a TCDS lists an air-
concerning the product. The type certificate craft's various airspeed limits. These limits must be
number, with the date and revision number of the marked on the face of the aircraft's airspeed indica-
data sheet, is enclosed in a box located in the tor in accordance with FAR Part 23.1545 and the
upper right corner of the data sheet. technician performing the inspection must check
these instrument markings to be sure they agree
An aircraft Type Certificate Data Sheet contains the with those in the TCDS.
information necessary for the proper maintenance
and inspection of an aircraft or its associated equip- The TCDS also contains information required to
ment. Information contained in a TCDS is consid- perform a weight and balance check on an aircraft.
ered approved data for use on a 337 Form. Any For example, the leveling means, location of the
deviation from the items listed in the data sheets is datum, and the center of gravity range are listed in
considered a major alteration and must be docu- the data sheets and must be used in weight and bal-
mented by a Major Repair or Alteration Form, a ance calculations.
Supplemental Type Certificate (STC), or by compli-
ance with an Airworthiness Directive. [Figure 14-2]
AIRCRAFT SPECIFICATIONS
The Type Certificate Data Sheet is the primary Prior to 1958, aircraft were certificated under the
source of information for: Civil Air Regulations. These regulations specified
that information on certificated aircraft, engines,
1. The type and model of approved engine(s) for and powerplants be listed in aircraft specifications.
the model aircraft. The specifications were similar to Type Certificate
2. The minimum fuel grade for the Data Sheets with the addition of an equipment list.
approved Many of the older specifications for one type aircraft
engine(s). often required up to sixty or seventy pages of infor-
mation in the equipment list. The
necessity of
Maintenance Publications, Forms, and Records 14-9
May 7,1973
TYPE CERTIFICATE DATA SHEET NO. A12CE
This data sheet which is part of type certificate No. A12CE prescribes conditions and limitations under
which the product for which the type certificate was issued meets the airworthiness requirements of the
Federal Aviation Regulations.
630
640
600
5600
5200
5000
-2- A12CE
Serial Nos. eligible Model 60: P~3 thru P-126 (except P~123)
Model A60: P-123, P-127 and up (see NOTE 3)
Datum Located 100 in. forward of front pressure bulkhead
Leveling means Drop plumb line between leveling screws in cabin door frame rear edge
Certification basis Part 23 of the Federal Aviation Regulations effective February 1, 1965
as amended by 1,2,3, and 12; and Special Conditions dated May 16, 1967,
forwarded with FAA letter dated June 1, 1967; approved for flight into
known icing conditions when equipped as specified in the approved airplane
flight manual
Application for Type Certificate dated December 22, 1965.
Type Certificate No. A12CE issued February 1,1968, obtained by the
manufacturer under delegation option procedures.
Production basis Production Certificate No. 8 issued and Delegation Option Manufacturer
No. CE-2 authorized to issue airworthiness certificates under delegation
option provisions of Part 21 of the Federal Aviation Regulations.
In addition:
Figure 14-2. A Type Certificate Data Sheet is issued to an aircraft when the FAA approves its design. The TCDS contains important
information for use in aircraft maintenance, (continued)
Maintenance Publications, Forms, and Records 14-11
-3- A12CE
NOTE I. Current weight and balance data including list of equipment included in certificated empty
weight and loading instructions when necessary must be provided for each aircraft at the
time of original certification.
The certificated empty weight and corresponding center of gravity locations must include
unusable fuel of 241b. at (+135).
NOTE 2. The following placard must be displayed in front of and in clear view of the pilot:
"This airplane must be operated in the normal category in compliance with the operation
limitations stated in the form of placardst markings and manuals."
NOTE 3. Fuselage pressure vessel structural life limit refer to the latest revision of the
Airplane Flight Manual for mandatory retirement time.
NOTE 4. Model 60 (S/N P-3 thru P-126 except P-123) when modified to Beech dwg. 60-5008 and
Model A60 (S/N P~l 23, P-127 and up) eligible for a masximum weight of 67751b.
NOTE 5. A landing weight of 6435 lb. must be observed if 10 PR tires are installed on aircraft
not equipped with 60-810012-15 (LH) or 60-810012-16 (RH) shock struts.
END
Figure 14-2. A Type Certificate Data Sheet is issued to an aircraft when the FAA approves its design. The TCDS contains important
information for use in aircraft maintenance, (continued)
14-12 Maintenance Publications, Forms, and Records
updating and revising the specifications became accomplished using engineering data and static and
more costly each year. Because of this, the equip- flight testing information. When a Supplemental
ment list was removed from the specifications and Type Certificate is issued, the holder may alter air-
Type Certificate Data Sheets were issued for new craft to meet the specifications of the certificate,
aircraft and equipment under the provisions of FAR offer kits for the modification, or offer the plans and
Part 23. Newer aircraft are provided with an equip- use of the STC as approved data. STCs which have
ment list which is delivered to the aircraft owner at been issued are published in the Summary of
time of delivery. Many of the newer aircraft models Supplemental Type Certificates, and listed by air-
have this information included in a section of the craft make and model. [Figure 14-3]
aircraft flight operating handbook.
Figure 14-3. Supplemental type certificates are available for aircraft owners who want to install an engine propeller, or appliance that
is not on the original Type Certificate.
14-14 Maintenance Publications, Forms, and Records
hand, cover areas of the engines that are not dealt WIRING MANUALS
with in the airframe manual. The majority of aircraft electrical systems and their
components are illustrated in individual wiring
Maintenance manuals provide information on rou- manuals. Wiring manuals contain schematic dia-
tine servicing, system descriptions and functions, grams to aid in electrical system troubleshooting.
handling procedures, and component removal and They also list part numbers and locations of electri-
installation. In addition, these manuals contain cal system components.
basic repair procedures and troubleshooting guides
for common malfunctions. Maintenance informa-
tion presented in these manuals is considered STRUCTURAL REPAIR MANUALS
acceptable data by the FAA, and may be approved
data for the purpose of major repairs and alterations. For repair of serious damage, structural repair man-
uals are used. These manuals contain detailed infor-
mation for repair of an aircraft's primary and sec-
OVERHAUL MANUAL ondary structure. The repairs described in a struc-
Overhaul manuals contain information on the tural repair manual are developed by the manufac-
repair and rebuilding of components that can be turer's engineering staff, and thus are usually con-
removed from an aircraft. These manuals contain sidered approved data by the FAA.
multiple illustrations showing how individual
components are assembled as well as list individ-
ual part numbers. SERVICE BULLETINS AND NOTES
One way manufacturers communicate with aircraft
owners and operators is through service bulletins and
ILLUSTRATED PARTS CATALOG
service notes. Service bulletins are issued to inform
Parts catalogs show the location and part numbers aircraft owners and technicians of possible design
of items installed on an aircraft. They contain defects, modifications, servicing changes, or other
detailed exploded views of all areas of an aircraft to information that may be useful in maintaining an air-
assist the technician in locating parts. Illustrated craft or component. On occasion, service bulletins are
parts catalogs are generally not considered accept- made mandatory and are incorporated into airworthi-
able data for maintenance and repair by the FAA. ness directives to correct an unsafe condition.
Maintenance Publications, Forms, and Records 14-15
Figure 14-4. To ensure uniformity in maintenance documentation, ATA codes are assigned t all aircraft systems and subsystems.
For example, all brake systems fall under the ATA 32-40 code.
FORMS AND RECORDS
Figure 14-5. When performing an inspection, you must use a checklist that follows the requirements of FAR Part 43, Appendix D.
14-18 Maintenance Publications, Forms, and Records
TYPE: Mark the proper column to identify the nature and extent of maintenance performed. Do
type of repair, i.e., a major repair or a major not show weight and balance calculations on the
alteration. FAA Form 337. Weight and balance information
CONFORMITY STATEMENT: Within item should be entered in the aircraft weight and bal-
number 6 you should enter your name and ance data, not on the repair form. Do not leave
address where it asks for the agency name and any blank spaces where someone else may enter
address. Under the kind of agency, enter a additional information on the form. Line out all
check mark in the proper block followed by unused portions of the form.
your A&P license number under the box asking
for the certificate number. Once the repair or If you have any reservations as to the technical data
alteration is complete read the statement in pertaining to the repair, you should contact the local
section D, and if the information is true and FAA office prior to commencing the repairs. In
correct, date the form and sign your name in many instances, field approval of the repair may be
the space provided. obtained, based on recommendations in AC
If you are employed by a certified repair sta- 43.13-1B, or the maintenance manual supplied by
tion (CRS) the conformity statement would be the aircraft, powerplant, or appliance
filled out differently. For example, in the box manufacturer. In many instances, these publications
asking for the agency's name and address you are acceptable to the Administrator, but are not
would insert the repair station's name and officially approved data. By contacting the local
address, followed by the applicable box being FAA office in advance, the proposed repair
checked and the station's certificate number. procedures can be approved prior to beginning the
The signature of the person performing the repairs. [Figure 14-6]
work would not change.
APPROVAL FOR RETURN TO SERVICE:
This section of the FAA Form 337 is filled in
by a person authorized by FAR Part 65 to
return an aircraft to service after a major FAA FORM 8010-4, MALFUNCTION OR
repair or alteration. DEFECT REPORT
DESCRIPTION OF THE WORK PERFORMED: Information concerning malfunctions and mainte-
The reverse side of the FAA Form 337 contains nance problems encountered on all types of aircraft
space for the technician to completely describe in daily operations is processed through the
the maintenance or alteration performed. When Aviation Standards National Field Office in
doing this, reference should be made to manu- Oklahoma City. This information is published in AC
facturer's drawings, aircraft station numbers, 43-16, "General Aviation Airworthiness Alerts,"
approved data for the type of repairs performed and disseminated throughout the country. This
and all information necessary to ensure that the information makes a significant contribution to the
aircraft has been returned to its original condi- continued safety of aircraft operations and mainte-
tion, or has been altered in accordance with nance by notifying operators of trends and mainte-
approved engineering data. nance problems before they become serious.
Figure 14-6. An FAA Form 337 is used to document major repairs and alterations to airframes, powerplants, propellers, and appliances.
14-20 Maintenance Publications, Forms, and Records
is provided by the FAA for technicians to enter the verify it meets the requirements of FAR Part 21.
basic information as to the type of malfunction or This certificate may also be referred to as an FAA
defective component as well as the type and model Form 8100-2. Airworthiness Certificates are issued
of aircraft. The form is then forwarded to the without an expiration date and, therefore, remain
National Field Office through the local FAA office. valid as long as all maintenance and airworthiness
Submission of these forms is voluntary, but they are directives are complied with, and the aircraft is
very important to the continued safe operation of properly registered in the United States. The air-
general aviation aircraft. If the information is seri- worthiness certificate must be displayed in the air-
ous enough, an Airworthiness Directive (AD) could craft so that it is legible to passengers and
be issued as a result of the information submitted. crewmembers. [Figure 14-8]
[Figure 14-7]
Figure 14-7. Aviation maintenance technicians perform a valuable service by using FAA Form 8010-4 Malfunction or Defect Reports.
This voluntary program gathers information on general aviation maintenance problems.
AIRWORTHINESS CERTIFICATE
The FAA issues an airworthiness certificate to an
aircraft after it is manufactured and inspected to Figure 14-8. A Standard Airworthiness Certificate is issued to
an aircraft and must remain on the aircraft during operation.
Maintenance Publications, Forms, and Records 14-21
REGISTRATION CERTIFICATE ment requires a new set of weight and balance fig-
ures to be calculated.
A Certificate of Aircraft Registration, AC Form
8050-3, is issued by the FA A to an aircraft owner
when an aircraft is purchased. This registration MAINTENANCE RECORDS
remains valid as long as the ownership remains the hi the past, the historical record of aircraft and engine
same. Furthermore, the certificate of registration operating hours, maintenance actions performed, and
must be present in the aircraft whenever the aircraft inspections accomplished on an aircraft and its
is operated. [Figure 14-9] pow-erplants were entered in the aircraft and
powerplant logbooks in chronological order. These
RADIO STATION LICENSE logbooks typically consisted of bound volumes of
simple forms. Entries were made by maintenance
The Federal Communications Commission requires personnel and by the pilot/owner of the aircraft.
all radio transmitters installed in aircraft to be reg- These records were, in many cases, intermixed
istered and licensed if flight operations are con- making record research time consuming and tedious.
ducted outside the United States. This radio station
license must be kept with the aircraft anytime a The present requirements for aircraft records are
radio transmitter is installed and operated during defined in FAR Part 91.417 and clearly state that the
international flights. aircraft owner is primarily responsible for maintain-
ing an aircraft's required maintenance records.
However, as an aircraft technician you are required
OPERATING INSTRUCTIONS
to document any maintenance you perform.
The operating limitations and instructions for a par- Therefore, aircraft records are more of a shared
ticular aircraft are located in an FAA-Approved responsibility. Maintenance records are divided
Airplane Flight Manual or Pilot's Operating into two categories: permanent records, which
Handbook. The flight manual must be on board the must be kept with the aircraft as long as it is in ser-
aircraft during flight. However, aircraft built prior to vice, and temporary records, which can be dis-
March 1, 1979, were certified without an approved posed of after a specified period of time.
flight manual and must have the operating limita-
tions visible on placards, instrument markings, or
approved flight material. PERMANENT RECORDS
Permanent records, as defined by FAR Part 91, are
those records which must be retained by the aircraft
WEIGHT AND BALANCE DATA owner until the aircraft is destroyed or permanently
Since no two aircraft weigh the same, weight and removed from service. If the aircraft is sold, the per-
balance data must be kept with every aircraft. This manent records must be transferred with the air-
data must contain an equipment list that identifies craft. The six types of records in this category are:
the weight and moment of each accessory added to
an aircraft. As discussed in Chapter 6, any modifi- 1. The total time in service of the airframe, each
cation or change to an aircraft or its installed equip- engine, and each propeller.
2. The current status of life-limited parts of each
airframe, engine, propeller, and appliance.
3. The time since the last overhaul of all items on
the aircraft which are required to be overhauled
at a specified time interval.
4. The current inspection status of the aircraft and
the time since last inspection.
5. The current status of applicable Airworthiness
Directives (ADs), including the method of com
pliance, the AD number and revision date, and
the time and date when the next action
is
required, if any.
6. Copies of any FAA Form 337 for each major
Figure 14-9. A Certificate of Aircraft Registration is issued to repair or alteration to the airframe and the cur
an aircraft owner when the aircraft is purchased. rently installed powerplants, rotors, propellers,
and appliances.
U-22 Maintenance Publications, Forms, and Records
These permanent records are maintained in several 2. Records of the 100-hour, annual, or progressive
different ways, depending on the size and complex- inspections. Since these inspections are
ity of the aircraft. For example, for small single repeated at prescribed intervals, the old inspec-
engine aircraft used by private individuals or for tion records may be disposed of when the latest
flight training purposes, simple bound paper log- entry is entered in the aircraft records.
books meet the record keeping requirements of FAR
Part 91. A separate logbook for the airframe, the
engine(s), and the propeller(s) must be maintained The option to dispose of temporary records may not
in order to comply with the regulations. be an easy task for the small general aviation aircraft
owner. Since the record keeping requirements for
these aircraft are easily met by data entries in bound
The aircraft operating time in service require- paper logbooks, removal of these entries would
ments are tracked through the use of a recording probably destroy the logbook or at least produce
tachometer or electrically operated hour meter records that appear incomplete. For this reason, it is
(Hobbs meter) and the current operating time suggested that the temporary maintenance records
should be periodically entered in the aircraft log- for small aircraft be retained and not removed from
books. By doing this, the inspection status of the the aircraft logbooks. However, for an executive or
aircraft, as well as the time accumulated since the corporate aircraft operator, the aircraft maintenance
the last inspection, are easily computed by refer- records are typically maintained by a record keep-
ence to the time recorded at the last inspection. ing staff. Furthermore, the aircraft logbooks often
The current status of life-limited parts installed consist of loose leaf binders making removal and
on the airframe, engine(s), propeller(s), rotor, and disposal of aircraft maintenance records easy.
appliances are entered in the appropriate logbook,
with the date and hours in service at the time of
installation. In the event there is previous operat-
ing time on a component or appliance you are
installing, the time should be noted and the MAINTENANCE RECORD ENTRIES
replacement times corrected as necessary.
FAR 43.9 requires that certain information be
entered into an aircraft's maintenance records after
The current status of applicable airworthiness a repair or alteration is performed and the aircraft is
directives and the other required data may be returned to service. Upon completion of the work,
entered on a separate AD record and attached to the the person releasing the aircraft to service must
aircraft logbooks. A separate AD record should be make a logbook entry containing at least the follow-
maintained for the airframe, engines, propellers, ing information.
and appliances. Recurring ADs, and the necessary
actions required, should be clearly marked and 1. A description of work performed, or reference
recorded in the applicable logbooks.
to acceptable data.
2. The date the work was completed.
3. The name of the person performing the work.
4. If the work performed on the item was per
formed satisfactorily, the signature, certificate
TEMPORARY RECORDS number, and kind of certificate held by the per
Temporary records are those records which may son approving the work. The signature consti
be disposed of after the work is repeated or super- tutes the approval for return to service only for
seded by other work or for one year after the work the work performed.
is completed. There are two categories of tempo-
rary records. For example, if you make a repair to a dent in tubu-
lar steel joined at a cluster by welding a reinforcing
1. Records of maintenance to an airframe, engine, plate over the dented area, your logbook entry
propeller, rotor, or appliance. This refers to should describe the work done as well as the date
maintenance actions of a routine nature, such as used to make the repair. [Figure 14-10]
repacking wheel bearings and other minor
maintenance actions which are periodically If an inspection is performed, FAR 43.11 specifies
repeated and are not major repairs or major that the person releasing the aircraft to service must
alterations. make a logbook entry containing:
Maintenance Publications, Forms, and Records
14^23
Figure 14-10. A maintenance logbook entry should briefly describe the work performed and reference an approved maintenance
manual source. In this example, AC 43-13.1 A states that a dent a tubuBar steeS cBuster is repaired by welding a specially formed
steel plate over the dented area and surrounding tubes.
The inspection type and a brief description of discrepancies and unairworthy items dated
o f its extent. (date) has been provided for the aircraft owner or
The date of the inspection and the aircraft operator." [Figure 14-11]
total time in service.
The signature, certificate number, and type of
certificate held by the person approving or dis-
approving the item for return to service. Except
for progressive inspections, an airworthy
aircraft release must contain a statement similar
to "I certify that this aircraft has been inspected
in accordance with (insert type) inspection
and was determined to be in airworthy
condition."