Major Repairs & Major Alterations Slide 1 - Blue Tuna

1 Major Repairs & Major Alterations Slide 1 Major Repairs AND Major Alterations Slide 2 PurposePurposeTO PROVIDE MECHANICS A FRANK DISCUSSION ON Major Repairs AND Alterations Major Repairs & Major Alterations Slide 3 GOAL:GOAL: PROVIDE THE aviation MECHANIC WITH A GOOD REVIEWOF THE FAA POLICY ON Major Repairs AND Alterations Slide 4 COURSE OVERVIEWCOURSE OVERVIEW REGULATORY AUTHORITY IMPORTANT RULES A/W AND PERFORMANCE STANDARDS DEFINITIONS Major Repairs & Major Alterations Slide 5 COURSE OVERVIEW:COURSE OVERVIEW: Major Repairs Major Alterations Data (Approved and acceptable) STC PROCESS FAA FIELD APPROVALS Slide 6 REGULATORY AUTHORITYREGULATORY AUTHORITY Major Repairs & Major Alterations Slide 7 THE LAW FEDERAL aviation ACT OF 1958 AS AMENDED BYTITLE 49 CODEPUBLIC LAW 103-272 Slide 8 FEDERAL aviation ACT : PUBLIC LAW 103-272 FEDERAL aviation ACT : PUBLIC LAW 103-272 Allows for the issue of: Type Certificates Production Certificates Airworthiness Certificates.

2 Major Repairs & Major Alterations Slide 9 FEDERAL aviation ACT OF 1958: TITLE 49 FEDERAL aviation ACT OF 1958: TITLE 49 ALSO ALLOWS FOR THE DEVELOPMENT OF :RULES Slide 10 RULES YOU SHOULDKNOWRULES YOU SHOULDKNOW LET S GO OVER SOME OF THE AIRWORTHINESS RULES THAT DEFINE ONE OF THE MINIMUMSTANDARDSTHAT A Major repair OR alteration MUST MEET. Major Repairs & Major Alterations Slide 11 RULES:RULES:PART 21 - Certification Procedures for Products and 23 -(CAR--3) Airworthiness Standards, Normal,Utility, Acrobatic and 25 - (CAR--4b) Airworthiness Standards, Transport. Slide 12 RULES:RULES:PART 29 (CAR 7) Airworthiness Standards) Airworthiness Standards, Transport HelicoptersPart 31,Manned Free 33 (CAR 13)AirworthinessStandards, Aircraft Engines. Major Repairs & Major Alterations Slide 13 RULES : RULES : PART 35, (CAR 14) AIRWORTHINESS STANDARDS, PROPELLERS.

3 PART 36, AIRCRAFT NOISE REQUIREMENTS , EXCEPT FIRE FIGHTING AND AGRICULTURAL. Slide 14 RULES:RULES: PART 39 AIRWORTHINESS DIRECTIVES Major Repairs & Major Alterations Slide 15 Question?Question?What do all these regulations have incommon? Slide 16 AnswerAnswerThey set:Airworthiness Standards ! Major Repairs & Major Alterations Slide 17 THESE FAR SETTHESE FAR SETPART-39 PART-43 PERFORMANCE PART-91 PART-121 STANDARDSPART-135 PART-145 Slide 18 THE TWO STANDARDS Major Repairs AND Alterations MUST MEET ARE:THE TWO STANDARDS Major Repairs AND Alterations MUST MEET ARE: Airworthiness Standardsand Performance Standards Major Repairs & Major Alterations Slide 19 Why TWO STANDARDS ? Slide 20 BECAUSE FOR AN AIRCRAFT TO BE AIRWORTHY IT MUST MEET TWOSTANDARDSBECAUSE FOR AN AIRCRAFT TO BE AIRWORTHY IT MUST MEET TWOSTANDARDS Major Repairs & Major Alterations Slide 21 DEFINITION OF AIRWORTHY DEFINITION OF AIRWORTHY Airworthy is when the aircraft meets its type design or properly altered condition and is in a condition for safe operation.

4 (Ref: Act of 58 and the Standard A/W certificate and the glossary of AC ) Slide 22 AIRWORTHYAIRWORTHY TYPE DESIGN = AIRWORTHINESS STANDARD CONDITION FOR SAFE OPERATION= PERFORMANCE STANDARD Major Repairs & Major Alterations Slide 23 DEFINITIONSDEFINITIONS Slide 24 Major repair (Ref: FAR 1) Major repair (Ref: FAR 1)1. A repair that, if improperly done might appreciable effect weight, balance, structural strength, performance characteristics or other qualities affecting airworthiness or:2. That is not done according to ACCEPTED practices or cannot be done by elementary operation. Major Repairs & Major Alterations Slide 25 Major alteration (Ref: FAR 1) Major alteration (Ref: FAR 1)is an alteration not listedin the A/C, engine, or propeller That might appreciable affect weight, balance, structural strength, performance, powerplant operation, flight characteristics, or other qualities affecting airworthiness: or Slide 26 Major alteration (Ref: FAR 1) Major alteration (Ref: FAR 1)2.

5 That is not done according to acceptedpractices or cannot be done by elementaryoperations. Major Repairs & Major Alterations Slide 27 Question? Question? What do the words : Other qualities affectingairworthiness mean to you? Slide 28 OTHER QUALITIESOTHER QUALITIES TYPE OF OPERATIONS ENVIRONMENTAL CONDITIONS UTILIZATION RATE AGE OF THE AIRCRAFT AND IT S COMPONENT PARTS PREVIOUS MAINTENANCE HISTORY Major Repairs & Major Alterations Slide 29 QUESTION ?QUESTION ? WHAT IS THE BASIC DIFFERENCEBETWEEN A Major repair AND A Major alteration ? Slide 30 Major repair ? Major alteration ? Major repair ? Major alteration ? A Major repair ALWAYS RETURNSTHE ITEM BACK TO ITS ORIGINAL TYPE DESIGN. A Major alteration IS A CHANGETO THE ORIGINAL TYPE DESIGN. Major Repairs & Major Alterations Slide 31 Major repair ? Or is ita Major alteration ? Slide 32 QUESTION?

6 QUESTION? SINCE IT IS THE AIRCRAFT MECHANICWHO DECIDES IF A repair IS Major OR MINOR, DOES THE FAA GIVE MECHANICS ANY OTHER GUIDANCE ON WHICH IS WHAT? Major Repairs & Major Alterations Slide 33 SURE DO !SURE DO ! APPENDIX (A)OF PART 43 LISTS Major Repairs AND Alterations TO AIRFRAME, ENGINES, PROPS, AND OTHER COMPONENT PARTS. Slide 34 QUESTION ?QUESTION ? WHAT HAPPENS IF THE repair OR alteration IS NOT INAPPENDIX A OF PART 43? WHAT ELSE CAN THE MECHANIC DO? Major Repairs & Major Alterations Slide 35 THREE POSSIBLE SOLUTIONS THREE POSSIBLE SOLUTIONS FIRST SOLUTION: CONTACT THE MANUFACTURER. SECOND SOLUTION: CONTACT THE NEAREST FAA DISTRICT OFFICE AND ASK FOR HELP. THIRD SOLUTION: ASK THREE (3) QUESTIONS. Slide 36 SOLUTION #3 SOLUTION #3If the repair or alteration fails in such a way that would : 1. prevent continued safe flight2.

7 Prevent a safe landing or3. adversely affect the safety of the crew and passenger. Major Repairs & Major Alterations Slide 37 SUGGESTION SUGGESTION IF ANY ONE OF THE THREE ANSWERS ARE A YES, THENYOU HAVE EITHER AMAJORREPAIR!OR A MAJORALTERATION ! Slide 38 TIME TO LOOK ATDATATIME TO LOOK ATDATA Major Repairs & Major Alterations Slide 39 Data can be:Data can be:Written/Typed InstructionsWEIGHT AND BALANCE REPORTSDESIGN DrawingsPhotographsDocumentsSTRESS ANALYS ISELECTRICAL LOADS CHARTS Slide 40 DATA MUST PROVIDEDATA MUST PROVIDE A DETAILED, COMPLETE, AND ACCURATE DESCRIPTION OF THE PROPOSED alteration OR repair . A DESCRIPTION OF REQUIRED TESTING PROCEDURES. ( FLAMMABILITY OR NOISE ) Major Repairs & Major Alterations Slide 41 DATA ADDRESSESTWO AREAS ONLY:DATA ADDRESSESTWO AREAS ONLY: TYPE DESIGN (FAR ) METHODS, TECHNIQUES, AND PRACTICES TO PERFORM MAINTENANCE.

8 Slide 42 There are two kinds of Data!There are two kinds of Data! Acceptable and Approved Major Repairs & Major Alterations Slide 43 ACCEPTABLE DATAOKACCEPTABLE DATAOK Slide 44 ACCEPTABLE DATA ACCEPTABLE DATA Acceptable Data is used for allmaintenance, except Major Repairs and Major Alterations .(Ref: ) Major Repairs & Major Alterations Slide 45 KINDS OF ACCEPTABLE DATAKINDS OF ACCEPTABLE DATA AC 43-13-1B or 2A. MFG s Service Manuals for aircraft originally TC after Jan. 1, 1980. MFG s Service Bulletins. PART 121/135 Operator s Manuals. Slide 46 APPROVED DATAAPPROVED DATA Major Repairs & Major Alterations Slide 47 Approved Data is used for all Major Repairs and Major Alterations (ref:)Approved Data is used for all Major Repairs and Major Alterations (ref:) Slide 48 FAR REFERENCES :FAR REFERENCES : Mechanics -------------FAR IA-----------------------FAR AIR TAXI---------------FAR AIR CARRIER----------FAR repair STATION------FAR Major Repairs & Major Alterations Slide 49 KINDS OF APPROVEDDATA: FAA ORDER CHG 15 KINDS OF APPROVEDDATA: FAA ORDER CHG 15 TYPE CERTIFICATE DATA AND SPECIFICATIONS.

9 S. T. C. ADs FAA APPROVED STRUCTURAL repair MANUALS. Slide 50 KINDS OF APPROVEDDATA: KINDS OF APPROVEDDATA: DESIGNATED ENGINEERING REPRESENTATIVE. (DER) (8110-3 statement of compliance) DESIGNATED ALTERATIONSTATION. (DAS) APPLIANCE MANUFACTURER S MANUALS. (for Repairs only) Major Repairs & Major Alterations Slide 51 KINDS OF APPROVEDDATA: MFG s Service Manuals for aircraft originally TC prior to Jan. 1, 1980. The data must be appropriate, Applicable, and not contrary to manufacturer s instructions. Same as AC requirements. Slide 52 KINDS OF APPROVEDDATA:KINDS OF APPROVEDDATA: FAA APPROVED DATA. SFAR 36 repair DATA. FAA FORM 337 USED TO APPROVE MULTIPLE Repairs OR Alterations BY THE ORIGINAL MODIFIER. Major Repairs & Major Alterations Slide 53 KINDS OF APPROVED DATA:KINDS OF APPROVED DATA: TECHNICAL AUTHORIZATION. (TSO) PARTS (PMA) DELEGATED OPTION.

10 AUTHORIZATION. (DOA) Slide 54 KINDS OF APPROVED DATA:KINDS OF APPROVED DATA: CAA FORM 337, DATED PRIOR TO 10/1/55. FOREIGN DATA IN THE FORM OF A SERVICE BULLETIN, FOR USE ON CERTIFICATED, FOREIGN MFG. AIRCRAFT WHEN APPROVED BY THE FOREIGN CAA OF THE COUNTRY OF DESIGN UNDER A BILATERAL AGREEMENT. Major Repairs & Major Alterations Slide 55 KINDS OF APPROVED DATA:KINDS OF APPROVED DATA: FAA AND TRANSPORT CANADA CIVIL aviation (TCCA) HAVE A THAT SAYS THAT CERTAIN TCCA AND TCCA DELEGATE repair DESIGNS ARE CONSIDERED FAA APPROVED. THESE ARE LISTED ON THE WEBSITE BELOW: Slide 56 KINDS OF APPROVED DATA: DATA IN THE FORM OF APPLIANCE TYPE APPROVAL ISSUED BY THE MINISTER OF TRANSPORT CANADA FOR THOSE PARTS THAT DO NOT HAVE A TSO. (DOT CANADA CERTIFICATE IN INSTALLATION MANUAL) Major Repairs & Major Alterations Slide 57 KINDS OF APPROVED DATA: ANY FAA-APPROVED SERVICE BULLETINS AND LETTERS OR SIMILAR DOCUMENTS.