faa presents all you wanted to know about major repairs major alterations

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Page 1: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS
Page 2: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FAA PRESENTSFAA PRESENTS

ALL YOU WANTED TO KNOW ABOUTALL YOU WANTED TO KNOW ABOUT

MAJOR REPAIRSMAJOR REPAIRSMAJOR MAJOR

ALTERATIONSALTERATIONS

FAA PRESENTSFAA PRESENTS

ALL YOU WANTED TO KNOW ABOUTALL YOU WANTED TO KNOW ABOUT

MAJOR REPAIRSMAJOR REPAIRSMAJOR MAJOR

ALTERATIONSALTERATIONS

Page 3: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

YOUR INSTRUCTORYOUR INSTRUCTOR YOUR INSTRUCTORYOUR INSTRUCTOR

BILL O’BRIENBILL O’BRIEN

FAA INSPECTOR FAA INSPECTOR

202 267-3796202 267-3796

Page 4: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

PurposePurpose PurposePurposeTO PROVIDE MECHANICS A TO PROVIDE MECHANICS A FRANK FRANK DISCUSSION ON DISCUSSION ON MAJOR REPAIRS AND MAJOR REPAIRS AND ALTERATIONSALTERATIONS

Page 5: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

GOAL:GOAL: GOAL:GOAL:

PROVIDE THE AVIATION PROVIDE THE AVIATION MECHANIC WITH A MECHANIC WITH A GOOD GOOD REVIEWREVIEW OF THE FAA OF THE FAA POLICY ON MAJOR REPAIRS POLICY ON MAJOR REPAIRS AND ALTERATIONSAND ALTERATIONS

Page 6: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

COURSE COURSE OVERVIEW OVERVIEW COURSE COURSE OVERVIEW OVERVIEW EVALUATIONEVALUATION REGULATORY AUTHORITYREGULATORY AUTHORITY IMPORTANT RULESIMPORTANT RULES A/W AND PERFORMANCE A/W AND PERFORMANCE

STANDARDS STANDARDS DEFINITIONSDEFINITIONS

Page 7: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

COURSE COURSE OVERVIEW OVERVIEW:: COURSE COURSE OVERVIEW OVERVIEW:: MAJOR REPAIRSMAJOR REPAIRS MAJOR ALTERATIONSMAJOR ALTERATIONS Data (Approved-Acceptable)Data (Approved-Acceptable) STC PROCESSSTC PROCESS FAA FIELD APPROVALFAA FIELD APPROVAL

Page 8: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

COURSECOURSE OVERVIEW OVERVIEW COURSECOURSE OVERVIEW OVERVIEW

FIELD APPROVALS FIELD APPROVALS WHAT WORKS! WHAT WORKS!

ANDAND

WHAT DOES NOT!WHAT DOES NOT!

Page 9: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

QUESTION ?QUESTION ? QUESTION ?QUESTION ?

WHAT IS ANOTHER WHAT IS ANOTHER

WORD FOR :WORD FOR :

“ “EVALUATION?”EVALUATION?”

Page 10: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

ANSWER:ANSWER: ANSWER:ANSWER:

TESTTEST IS ANOTHER WORD IS ANOTHER WORD

FOR EVALUATION. FOR EVALUATION. IT IS NOW TIME TO TESTIT IS NOW TIME TO TEST

YOUR KNOWLEDGE ONYOUR KNOWLEDGE ON

MAJOR REPAIRS ANDMAJOR REPAIRS AND

ALTERATIONS . ALTERATIONS .

Page 11: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

TEST INSTRUCTIONSTEST INSTRUCTIONS TEST INSTRUCTIONSTEST INSTRUCTIONS

BE SURE TO PUT YOUR NAME, BE SURE TO PUT YOUR NAME, ADDRESS, FAA CERTIFICATE ADDRESS, FAA CERTIFICATE NUMBER, ON THE TOP OF THE NUMBER, ON THE TOP OF THE TEST PAPER TO ENSURE TEST PAPER TO ENSURE ACCURATE GRADING OF THE ACCURATE GRADING OF THE TEST PAPER.TEST PAPER.

Page 12: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

TEST INSTRUCTIONSTEST INSTRUCTIONS

TEST INSTRUCTIONSTEST INSTRUCTIONS

TIMED TEST--20 MINUTES.TIMED TEST--20 MINUTES. NO TALKING ORNO TALKING OR

COMPARING ANSWERS.COMPARING ANSWERS. IF YOU FINISH EARLY YOU CAN IF YOU FINISH EARLY YOU CAN

LEAVE THE ROOM. LEAVE THE ROOM. HAND IN THE TEST TO THE FAA HAND IN THE TEST TO THE FAA

FOR GRADING.FOR GRADING.

Page 13: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

REGULATORY REGULATORY AUTHORITY AUTHORITYREGULATORY REGULATORY AUTHORITY AUTHORITY

Page 14: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FEDERAL FEDERAL AVIATION ACT OF AVIATION ACT OF

1958 1958 AMENDED BYAMENDED BY

TITLE 49 U.S. CODETITLE 49 U.S. CODEPUBLIC LAW 103-272PUBLIC LAW 103-272

FEDERAL FEDERAL AVIATION ACT OF AVIATION ACT OF

1958 1958 AMENDED BYAMENDED BY

TITLE 49 U.S. CODETITLE 49 U.S. CODEPUBLIC LAW 103-272PUBLIC LAW 103-272

Page 15: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FEDERAL AVIATION FEDERAL AVIATION ACT : ACT : PUBLIC LAW 103-272PUBLIC LAW 103-272

FEDERAL AVIATION FEDERAL AVIATION ACT : ACT : PUBLIC LAW 103-272PUBLIC LAW 103-272

Allows for the issue of:Allows for the issue of:Type CertificatesType CertificatesProduction CertificatesProduction CertificatesAirworthiness Airworthiness

Certificates ....and....Certificates ....and....

Page 16: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FEDERAL AVIATION FEDERAL AVIATION ACT OF 1958: ACT OF 1958: TITLE 49 TITLE 49

FEDERAL AVIATION FEDERAL AVIATION ACT OF 1958: ACT OF 1958: TITLE 49 TITLE 49

ALSO ALLOWS FOR THE ALSO ALLOWS FOR THE

DEVELOPMENT OF :DEVELOPMENT OF :

RULESRULES

Page 17: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

RULES YOU SHOULDRULES YOU SHOULD KNOW KNOW RULES YOU SHOULDRULES YOU SHOULD KNOW KNOW

LET’S GO OVER SOME OF THE LET’S GO OVER SOME OF THE AIRWORTHINESS RULES THAT AIRWORTHINESS RULES THAT DEFINE ONE OF THE DEFINE ONE OF THE MINIMUMMINIMUM STANDARDSSTANDARDS THAT A MAJOR THAT A MAJOR REPAIR OR ALTERATION MUST REPAIR OR ALTERATION MUST MEET.MEET.

Page 18: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

RULES:RULES: RULES:RULES:

PART 21 PART 21 - Certification Procedures - Certification Procedures

for Products and Parts..for Products and Parts..

PART 23 PART 23 - (CAR--3) Airworthiness - (CAR--3) Airworthiness Standards, Normal, Standards, Normal,

Utility, Acrobatic and Utility, Acrobatic and

Commuter.Commuter.

PART 25 PART 25 - (CAR--4b) Airworthiness - (CAR--4b) Airworthiness

Standards, Transport.Standards, Transport.

Page 19: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

RULES:RULES: RULES:RULES:

PART 29 (CAR 7) PART 29 (CAR 7) Airworthiness Standards,Airworthiness Standards,

Transport Category: Rotorcraft.Transport Category: Rotorcraft.

PART 31 (NONE) PART 31 (NONE) Airworthiness Standards, Airworthiness Standards,

Manned Free Balloons..Manned Free Balloons..

PART 33 (CAR 13)PART 33 (CAR 13) Airworthiness Airworthiness

Standards, Aircraft Engines..Standards, Aircraft Engines..

Page 20: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

RULES : RULES : RULES : RULES :

PART 35, (CAR 14) PART 35, (CAR 14) AIRWORTHINESS AIRWORTHINESS STANDARDS, PROPELLERS.STANDARDS, PROPELLERS.

PART 36PART 36, AIRCRAFT NOISE , AIRCRAFT NOISE REQUIREMENTS , EXCEPT FIRE REQUIREMENTS , EXCEPT FIRE FIGHTING AND AGRICULTURAL FIGHTING AND AGRICULTURAL

Page 21: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

RULES:RULES: RULES:RULES:

PART 39PART 39 AIRWORTHINESS AIRWORTHINESS

DIRECTIVES.DIRECTIVES.

Page 22: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SPECIAL FAR ( SFAR)SPECIAL FAR ( SFAR) SPECIAL FAR ( SFAR)SPECIAL FAR ( SFAR)

SFAR 27 SFAR 27 - Fuel venting and - Fuel venting and exhaust emission requirements exhaust emission requirements for turbine Powered Aircraft.for turbine Powered Aircraft.

SFAR 23 AND 41 SFAR 23 AND 41 - Additional - Additional standards for commuter aircraft.standards for commuter aircraft.

Page 23: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SPECIAL REGULATIONSPECIAL REGULATION SPECIAL REGULATIONSPECIAL REGULATION (S.R.) - Older aircraft(S.R.) - Older aircraft

S.R. 407S.R. 407- Additional Airworthiness - Additional Airworthiness standards on DC-3 and Lockheed Model standards on DC-3 and Lockheed Model 18 aircraft.18 aircraft.

S.R. 422 (A)(B) S.R. 422 (A)(B) - Additional Airworthiness - Additional Airworthiness Standards for early turbojet aircraft. (B Standards for early turbojet aircraft. (B 707, 720, 727, DC-8, DC-9, and Convair 707, 720, 727, DC-8, DC-9, and Convair 880, 990880, 990))

Page 24: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Question?Question? Question?Question?

What do all these What do all these

regulations have inregulations have in

common?common?

Page 25: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

AnswerAnswer AnswerAnswer

They set:They set:

Airworthiness Airworthiness

Standards ! Standards !

Page 26: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

THESE FAR SETTHESE FAR SET THESE FAR SETTHESE FAR SET

PART-39 PART-39

PART-43 PERFORMANCE PART-43 PERFORMANCE

PART-91PART-91

PART-121PART-121 STANDARDS STANDARDS

PART-135PART-135

PART-145PART-145

Page 27: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Two StandardsTwo Standards Two StandardsTwo Standards

Airworthiness StandardAirworthiness Standard

and and Performance StandardPerformance Standard

Page 28: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Why TWO Why TWO STANDARDS ?STANDARDS ?

Page 29: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

BECAUSE FOR AN BECAUSE FOR AN AIRCRAFT TO BE AIRCRAFT TO BE

“AIRWORTHY” IT MUST “AIRWORTHY” IT MUST MEET MEET TWOTWO STANDARDS STANDARDS

BECAUSE FOR AN BECAUSE FOR AN AIRCRAFT TO BE AIRCRAFT TO BE

“AIRWORTHY” IT MUST “AIRWORTHY” IT MUST MEET MEET TWOTWO STANDARDS STANDARDS

Page 30: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

DEFINITION OF DEFINITION OF “AIRWORTHY” “AIRWORTHY”

DEFINITION OF DEFINITION OF “AIRWORTHY” “AIRWORTHY”

Airworthy is when the aircraft Airworthy is when the aircraft meets its meets its type design type design and is and is in a in a condition for safe operation. condition for safe operation.

(Ref: Act of 58 and the Standard A/W certificate)(Ref: Act of 58 and the Standard A/W certificate)

Page 31: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

AIRWORTHYAIRWORTHY AIRWORTHYAIRWORTHY

TYPE DESIGN TYPE DESIGN = AIRWORTHINESS = AIRWORTHINESS STANDARDSTANDARD

CONDITION FOR SAFE CONDITION FOR SAFE OPERATIONOPERATION = PERFORMANCE = PERFORMANCE STANDARDSTANDARD

Page 32: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

INTERIM SUMMARYINTERIM SUMMARY INTERIM SUMMARYINTERIM SUMMARY

Federal Aviation Act of 1958Federal Aviation Act of 1958 Airworthiness StandardsAirworthiness Standards (FAR 21, 23, 25, (FAR 21, 23, 25,

27, 29, 31, 33, 35, 36, 39, SFAR and S.R..)27, 29, 31, 33, 35, 36, 39, SFAR and S.R..) Performance Standards:Performance Standards:

(FAR 39, 43, 91, 121, 135,(FAR 39, 43, 91, 121, 135,

and 145.)and 145.)

Page 33: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

INTERIM SUMMARYINTERIM SUMMARY INTERIM SUMMARYINTERIM SUMMARY

DEFINITION OF AIRWORTHYDEFINITION OF AIRWORTHY

““TWO STANDARDS,” A MAJOR TWO STANDARDS,” A MAJOR ALTERATION OR REPAIR MUST ALTERATION OR REPAIR MUST MEET THE MEET THE A/C TYPE CERTIFICATION A/C TYPE CERTIFICATION RULES RULES AND MEET THE AND MEET THE PERFORMANCE RULESPERFORMANCE RULES IN PART 43. IN PART 43.

Page 34: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

DEFINITIONSDEFINITIONSDEFINITIONSDEFINITIONS

Page 35: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Major Repair Major Repair (Ref: FAR 1) (Ref: FAR 1) Major Repair Major Repair (Ref: FAR 1) (Ref: FAR 1)

1. A repair that, if improperly done might 1. A repair that, if improperly done might appreciable effect weight, balance, appreciable effect weight, balance, structural strength, performance structural strength, performance characteristics or other qualities affecting characteristics or other qualities affecting airworthiness or:airworthiness or:

2. That is not done according to ACCEPTED 2. That is not done according to ACCEPTED practices or cannot be done by elementary practices or cannot be done by elementary operation.operation.

Page 36: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Major AlterationMajor Alteration (Ref: FAR 1) (Ref: FAR 1) Major AlterationMajor Alteration (Ref: FAR 1) (Ref: FAR 1)

is an alteration not is an alteration not listedlisted in the A/C in the A/C engine or propeller specifications.engine or propeller specifications.

1. That might appreciable affect 1. That might appreciable affect weight, balance, structural strength, weight, balance, structural strength, performance, powerplant operation, performance, powerplant operation, flight characteristics, or other flight characteristics, or other qualities affecting airworthiness: orqualities affecting airworthiness: or

Page 37: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Major AlterationMajor Alteration (Ref: FAR 1) (Ref: FAR 1) Major AlterationMajor Alteration (Ref: FAR 1) (Ref: FAR 1)

2. That is not done according 2. That is not done according to to acceptedaccepted practices or practices or cannot be done by cannot be done by elementaryelementary operations operations..

Page 38: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Question? Question? Question? Question?

What do the words :What do the words :

““Other qualities affectingOther qualities affecting

airworthiness” mean to you?airworthiness” mean to you?

Page 39: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

OTHER QUALITIESOTHER QUALITIES OTHER QUALITIESOTHER QUALITIES

TYPE OF OPERATIONSTYPE OF OPERATIONS ENVIRONMENTAL CONDITIONSENVIRONMENTAL CONDITIONS UTILIZATION RATEUTILIZATION RATE AGE OF THE AIRCRAFT AND IT’S AGE OF THE AIRCRAFT AND IT’S

COMPONENT PARTSCOMPONENT PARTS PREVIOUS MAINTENANCE HISTORYPREVIOUS MAINTENANCE HISTORY

Page 40: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

QUESTION ?QUESTION ? QUESTION ?QUESTION ?

WHAT IS THE BASIC WHAT IS THE BASIC DIFFERENCEDIFFERENCE BETWEEN A BETWEEN A MAJOR REPAIR AND A MAJOR REPAIR AND A MAJOR ALTERATION? MAJOR ALTERATION?

Page 41: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

MAJOR REPAIR ?MAJOR REPAIR ? MAJOR ALTERATION? MAJOR ALTERATION? MAJOR REPAIR ?MAJOR REPAIR ? MAJOR ALTERATION? MAJOR ALTERATION?

A MAJOR REPAIR ALWAYS A MAJOR REPAIR ALWAYS RETURNSRETURNS THE ITEM BACK TO THE ITEM BACK TO ITS ORIGINAL TYPE DESIGN.ITS ORIGINAL TYPE DESIGN.

A MAJOR ALTERATION IS A A MAJOR ALTERATION IS A CHANGECHANGE TO THE ORIGINAL TO THE ORIGINAL TYPE DESIGN.TYPE DESIGN.

Page 42: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

QUESTION?QUESTION? QUESTION?QUESTION?

S INCE IT IS THE S INCE IT IS THE AIRCRAFT AIRCRAFT MECHANICMECHANIC WHO DECIDES IF A WHO DECIDES IF A REPAIR IS MAJOR OR MINOR, REPAIR IS MAJOR OR MINOR, DOES THE FAA GIVE DOES THE FAA GIVE MECHANICS ANY OTHER MECHANICS ANY OTHER GUIDANCE ON WHICH IS WHAT?GUIDANCE ON WHICH IS WHAT?

Page 43: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SURE DO !SURE DO ! SURE DO !SURE DO !

APPENDIX (A) OF PART 43 APPENDIX (A) OF PART 43 LISTS MAJOR REPAIRS AND LISTS MAJOR REPAIRS AND ALTERATIONS TO ALTERATIONS TO AIRFRAME, ENGINES, PROPS, AIRFRAME, ENGINES, PROPS, AND OTHER COMPONENT AND OTHER COMPONENT PARTS.PARTS.

Page 44: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

QUESTION ?QUESTION ? QUESTION ?QUESTION ?

WHAT HAPPENS IF THE REPAIR WHAT HAPPENS IF THE REPAIR OR ALTERATION IS NOT IN OR ALTERATION IS NOT IN APPENDIX A OF PART 43? APPENDIX A OF PART 43? WHAT ELSE CAN THE WHAT ELSE CAN THE MECHANIC DO?MECHANIC DO?

Page 45: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

THREE POSSIBLE THREE POSSIBLE SOLUTIONS SOLUTIONS THREE POSSIBLE THREE POSSIBLE SOLUTIONS SOLUTIONS

FIRST SOLUTIONFIRST SOLUTION: CONTACT : CONTACT THE MANUFACTURER.THE MANUFACTURER.

SECOND SOLUTIONSECOND SOLUTION: CONTACT : CONTACT THE NEAREST FAA DISTRICT THE NEAREST FAA DISTRICT OFFICE AND ASK FOR HELP. OFFICE AND ASK FOR HELP.

THIRD SOLUTIONTHIRD SOLUTION: ASK THREE : ASK THREE (3) QUESTIONS. (3) QUESTIONS.

Page 46: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SOLUTION #3SOLUTION #3 SOLUTION #3SOLUTION #3

If the repair or alteration If the repair or alteration fails fails in in such a way that would : such a way that would :

1. prevent continued safe flight1. prevent continued safe flight

2. prevent a safe landing or2. prevent a safe landing or

3. adversely affect the safety of3. adversely affect the safety of

the crew and passengerthe crew and passenger..

Page 47: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SUGGESTION SUGGESTION SUGGESTION SUGGESTION

IF ANY ONE OF THE IF ANY ONE OF THE

THREE ANSWERS ARE ATHREE ANSWERS ARE A

““YES” THEN YOU HAVE YES” THEN YOU HAVE

EITHER A EITHER A MAJORMAJOR REPAIR REPAIR

OR A OR A MAJORMAJOR ALTERATION ALTERATION

Page 48: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

TIME TO LOOK ATTIME TO LOOK AT

DATADATA

TIME TO LOOK ATTIME TO LOOK AT

DATADATA

Page 49: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

There are two kinds There are two kinds of Data! of Data! There are two kinds There are two kinds of Data! of Data!

““Acceptable”Acceptable”

and “Approved”and “Approved”

Page 50: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Data can be:Data can be: Data can be:Data can be:

Written/Typed InstructionsWritten/Typed Instructions WEIGHT AND BALANCE REPORTSWEIGHT AND BALANCE REPORTS

DESIGN DrawingsDESIGN DrawingsPhotographsPhotographs DocumentsDocuments STRESS STRESS ANALYS IS ANALYS IS ELECTRICAL LOADS CHARTSELECTRICAL LOADS CHARTS

Page 51: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

DATA ADDRESSESDATA ADDRESSES TWO AREAS ONLY: TWO AREAS ONLY: DATA ADDRESSESDATA ADDRESSES TWO AREAS ONLY: TWO AREAS ONLY:

TYPE DESIGN TYPE DESIGN (FAR 21.31)(FAR 21.31)

METHODS, TECHNIQUES, METHODS, TECHNIQUES, AND PRACTICES TO AND PRACTICES TO PERFORM PERFORM MAINTENANCE.MAINTENANCE.

Page 52: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

DATA MUST PROVIDEDATA MUST PROVIDE DATA MUST PROVIDEDATA MUST PROVIDE

A DETAILED, COMPLETE, AND A DETAILED, COMPLETE, AND ACCURATE DESCRIPTION OF ACCURATE DESCRIPTION OF THE PROPOSED ALTERATION THE PROPOSED ALTERATION OR REPAIR.OR REPAIR.

A DESCRIPTION OF REQUIRED A DESCRIPTION OF REQUIRED TESTING PROCEDURES . (E.G. TESTING PROCEDURES . (E.G. FLAMMABILITY OR NOISE FLAMMABILITY OR NOISE ))

Page 53: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

ACCEPTABLE DATAACCEPTABLE DATA

OK OK

ACCEPTABLE DATAACCEPTABLE DATA

OK OK

Page 54: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

ACCEPTABLE DATA ACCEPTABLE DATA ACCEPTABLE DATA ACCEPTABLE DATA

Acceptable Data Acceptable Data is used for is used for allall maintenance, except major maintenance, except major repairs and major alterations.repairs and major alterations.

(Ref: 43.13)(Ref: 43.13)

Page 55: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

KINDS OF ACCEPTABLE KINDS OF ACCEPTABLE DATA DATA KINDS OF ACCEPTABLE KINDS OF ACCEPTABLE DATA DATA

AC 43-13-1B or 2A.AC 43-13-1B or 2A.MFG’s Service Manuals.MFG’s Service Manuals.MFG’s Service Bulletins.MFG’s Service Bulletins.PART 121/135 Operator’s PART 121/135 Operator’s

Manuals.Manuals.

Page 56: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

APPROVED DATAAPPROVED DATA

FAAFAAOKOK

APPROVED DATAAPPROVED DATA

FAAFAAOKOK

Page 57: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Approved Data Approved Data is used for is used for all all major repairs and major major repairs and major alterations (ref:) alterations (ref:)

Approved Data Approved Data is used for is used for all all major repairs and major major repairs and major alterations (ref:) alterations (ref:)

Page 58: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FAR REFERENCES :FAR REFERENCES : FAR REFERENCES :FAR REFERENCES :

IA--------------------------FAR 65.95IA--------------------------FAR 65.95 AIR TAXI----------------FAR 135.437AIR TAXI----------------FAR 135.437 AIR CARRIER---------FAR 121.379AIR CARRIER---------FAR 121.379 REPAIR STATION---FAR 145.51REPAIR STATION---FAR 145.51

Page 59: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

KINDS OF APPROVEDKINDS OF APPROVED DATA: DATA: KINDS OF APPROVEDKINDS OF APPROVED DATA: DATA:

TYPE CERTIFICATE DATA TYPE CERTIFICATE DATA AND SPECIFICATIONS AND SPECIFICATIONS

S. T. C.S. T. C. AIRWORTHINESS AIRWORTHINESS

DIRECTIVES (ADs)DIRECTIVES (ADs)

Page 60: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

KINDS OF APPROVEDKINDS OF APPROVED DATA DATA KINDS OF APPROVEDKINDS OF APPROVED DATA DATA

DESIGNATED ENGINEERING DESIGNATED ENGINEERING

REPRESENTATIVE (DER)REPRESENTATIVE (DER) DESIGNATED ALTERATIONDESIGNATED ALTERATION

STATION (DAS)STATION (DAS) APPLIANCE MANUFACTURER’S APPLIANCE MANUFACTURER’S

MANUALSMANUALS

Page 61: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

KINDS OF APPROVEDKINDS OF APPROVED DATA: DATA: KINDS OF APPROVEDKINDS OF APPROVED DATA: DATA:

FAA APPROVED DATA.FAA APPROVED DATA. SFAR 36 REPAIR DATA.SFAR 36 REPAIR DATA. FAA FORM 337 USED TO FAA FORM 337 USED TO

APPROVE MULTIPLE APPROVE MULTIPLE REPAIRS /ALTERATIONS REPAIRS /ALTERATIONS

BY THE ORIGINAL MODIFIER BY THE ORIGINAL MODIFIER

Page 62: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

KINDS OF APPROVED KINDS OF APPROVED DATA: DATA: KINDS OF APPROVED KINDS OF APPROVED DATA: DATA:

TECHNICAL STANDARDTECHNICAL STANDARD

ORDER AUTHORIZATION. ORDER AUTHORIZATION. PARTS MANUFACTURERPARTS MANUFACTURER

AUTHORIZATION. (PMA)AUTHORIZATION. (PMA) DELEGATED OPTION DELEGATED OPTION

AUTHORIZATION. (DOA)AUTHORIZATION. (DOA)

Page 63: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

KINDS OF APPROVED KINDS OF APPROVED DATA: DATA: KINDS OF APPROVED KINDS OF APPROVED DATA: DATA:

CAA FORM 337, DATED CAA FORM 337, DATED

PRIOR TO 10/1/55.PRIOR TO 10/1/55.

FOREIGN BULLETINS, FOR FOREIGN BULLETINS, FOR

USE ON U.S. CERTIFICATED USE ON U.S. CERTIFICATED

FOREIGN AIRCRAFT WHEN FOREIGN AIRCRAFT WHEN

APPROVED BY A FOREIGN CAA .APPROVED BY A FOREIGN CAA .

Page 64: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

KINDS OF APPROVED KINDS OF APPROVED DATA: DATA: KINDS OF APPROVED KINDS OF APPROVED DATA: DATA:

FOREIGN BULLETINS ON US FOREIGN BULLETINS ON US CERTIFICATED PRODUCT WHEN CERTIFICATED PRODUCT WHEN APPROVED BY THE FOREIGN CAA APPROVED BY THE FOREIGN CAA UNDER A BILATERAL AGREEMENTUNDER A BILATERAL AGREEMENT

OTHER DATA APPROVED BYOTHER DATA APPROVED BY

THE ADMINISTRATOR THE ADMINISTRATOR

Page 65: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Approved Data-----For Approved Data-----For Repairs Only Repairs Only Approved Data-----For Approved Data-----For Repairs Only Repairs Only

Use AC 43.13-IB if the repair is:Use AC 43.13-IB if the repair is: Appropriate to the productAppropriate to the product Applicable to the repairApplicable to the repair Not contrary to mfg’s dataNot contrary to mfg’s data Must reference AC’s chapter, page and Must reference AC’s chapter, page and

paragraph where data is found. paragraph where data is found.

Page 66: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

QUESTION ?QUESTION ? QUESTION ?QUESTION ?

WHERE IS THE WHERE IS THE AUTHORITY AUTHORITY THAT GIVE THE MECHANIC, IA THAT GIVE THE MECHANIC, IA TO USE THE ACCEPTABLE TO USE THE ACCEPTABLE REPAIR DATA IN AC 43.13-1B AS REPAIR DATA IN AC 43.13-1B AS APPROVED DATA FOR A APPROVED DATA FOR A MAJOR MAJOR REPAIR REPAIR ? ?

Page 67: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

ANSWERANSWER

ANSWERANSWER

PERMISSION BY THE FAA TO PERMISSION BY THE FAA TO USE THE ACCEPTABLE DATA IN USE THE ACCEPTABLE DATA IN AC 43-13-1B AS AC 43-13-1B AS APPROVED APPROVED DATADATA IS FOUND ON THE FIRST IS FOUND ON THE FIRST

PAGE (SIGNATURE PAGE) OF PAGE (SIGNATURE PAGE) OF THE AC .THE AC .

Page 68: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Data that is not approved or Data that is not approved or acceptable acceptable Data that is not approved or Data that is not approved or acceptable acceptable

Sales Catalog InformationSales Catalog Information NewslettersNewsletters Magazines articlesMagazines articles Parts Manual (Illustrated)Parts Manual (Illustrated)

Page 69: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

IMPORTANT NOTICEIMPORTANT NOTICE IMPORTANT NOTICEIMPORTANT NOTICE

If your not sureIf your not sure

of the data callof the data call

the FAA!the FAA!

If your not sureIf your not sure

of the data callof the data call

the FAA!the FAA!

Page 70: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SUPPLEMENTAL TYPE SUPPLEMENTAL TYPE CERTIFICATESCERTIFICATES

SUPPLEMENTAL TYPE SUPPLEMENTAL TYPE CERTIFICATESCERTIFICATES

Page 71: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Supplemental type Supplemental type Certificate (STC) is: Certificate (STC) is: Supplemental type Supplemental type Certificate (STC) is: Certificate (STC) is:

A A major change major change to a type to a type design but not great enough design but not great enough to require a new application to require a new application for type certificate. (Ref: for type certificate. (Ref: 21.113)21.113)

Page 72: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

S.T.C. Process :S.T.C. Process : Data submitted Data submitted S.T.C. Process :S.T.C. Process : Data submitted Data submitted

Application made to FAAApplication made to FAAFAA assigns an engineerFAA assigns an engineerApplicant and FAA meetApplicant and FAA meetDevelopment of a mutually Development of a mutually acceptable programacceptable program

Page 73: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

STC PROCESS : Data STC PROCESS : Data submitted (con’t) submitted (con’t) STC PROCESS : Data STC PROCESS : Data submitted (con’t) submitted (con’t)

SUBMIT DATA: SUCH AS DRAWINGS, SUBMIT DATA: SUCH AS DRAWINGS, PROCESSES, PARTS USED, ETC. PROCESSES, PARTS USED, ETC.

FLIGHT MANUAL SUPPLEMENTSFLIGHT MANUAL SUPPLEMENTS OPERATING MANUALSOPERATING MANUALS COPY OF INSTALLATION COPY OF INSTALLATION

INSTRUCTIONSINSTRUCTIONS

Page 74: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

S.T.C. Process DataS.T.C. Process Data submitted (con’t) submitted (con’t) S.T.C. Process DataS.T.C. Process Data submitted (con’t) submitted (con’t)

Rating of electrical equipmentRating of electrical equipmentWeight and balanceWeight and balancePlacardsPlacardsMarkings on instrumentsMarkings on instrumentsCopy of installation instructionsCopy of installation instructions

Page 75: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

S.T.C. Process : Data S.T.C. Process : Data submitted (con’t) submitted (con’t) S.T.C. Process : Data S.T.C. Process : Data submitted (con’t) submitted (con’t)

Any aircraft certified after January 28, Any aircraft certified after January 28, 1981 a manual for continued 1981 a manual for continued airworthiness is required (Ref 21.50)airworthiness is required (Ref 21.50)

One copy of all substantiating data One copy of all substantiating data showing compliance to the applicable showing compliance to the applicable FAR or CAR.FAR or CAR.

Page 76: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SuggestionSuggestion SuggestionSuggestion

Designated Engineering Rep. (DER) Designated Engineering Rep. (DER) can be a engineer or test pilot who for can be a engineer or test pilot who for a fee a fee will represent the FAA for will represent the FAA for specific certification functions.. They specific certification functions.. They can speed up the process but use of can speed up the process but use of DER’s are DER’s are not mandatory.not mandatory.

Page 77: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

S.T.C. ProcessS.T.C. Process S.T.C. ProcessS.T.C. Process

Development of the type inspection Development of the type inspection authorization (T.I.A.)authorization (T.I.A.)

TIA sets the requirements forTIA sets the requirements for

- - Conformity InspectionsConformity Inspections

- Flight tests- Flight tests Satisfactory Completion of the Satisfactory Completion of the

Inspections and Tests an S.T.C. is Inspections and Tests an S.T.C. is issued.issued.

Page 78: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

S.T.C. can be:S.T.C. can be: S.T.C. can be:S.T.C. can be:

Transferred from one Transferred from one individual to another or:individual to another or:

Sold an an “approved” Sold an an “approved” process for a major repair or process for a major repair or alterationalteration

Page 79: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

WarningWarning WarningWarning

Before you Buy an S.T.C.Before you Buy an S.T.C. Ensure that it is compatible with Ensure that it is compatible with

other STC on your aircraft.other STC on your aircraft.

Ensure it is for your particular Ensure it is for your particular

make and model aircraft.make and model aircraft.

Page 80: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

WARNINGWARNING WARNINGWARNING

PART 91.403 GENERAL WILL CHANGE PART 91.403 GENERAL WILL CHANGE TO RELFLECT THE NEW 1996 LAW TO TO RELFLECT THE NEW 1996 LAW TO PROTECTED INTELLECTUAL DATA.PROTECTED INTELLECTUAL DATA.

IT WILL REQUIRE INSTALLERS OF IT WILL REQUIRE INSTALLERS OF AN STC TO HAVE PERMISSION FROM AN STC TO HAVE PERMISSION FROM THE STC HOLDER TO USE THE STCTHE STC HOLDER TO USE THE STC

Page 81: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Field ApprovalsField ApprovalsField ApprovalsField Approvals

Page 82: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

DEFINITION:DEFINITION: DEFINITION:DEFINITION:

Field ApprovalField Approval: is the granting of: is the granting of

FAA approval, by an FAA A/WFAA approval, by an FAA A/W

Inspector, (FSDO) by examining Inspector, (FSDO) by examining

data, or by physical inspection ordata, or by physical inspection or

testing, or approving multiple testing, or approving multiple

installations by the same modifier installations by the same modifier

Page 83: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Field Approval FactsField Approval Facts Field Approval FactsField Approval Facts

–Not found in the FARsNot found in the FARs

–Policy onlyPolicy only

–FAA Airworthiness FAA Airworthiness

Inspector sign Block 3 of FAA Inspector sign Block 3 of FAA Form 337Form 337

Page 84: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Field Approval FactsField Approval Facts Field Approval FactsField Approval Facts

There are only 3 kinds of field There are only 3 kinds of field approvals:approvals:

1. Examination of Data only!1. Examination of Data only!

““Approves” acceptable data for Approves” acceptable data for

major repairs/major alterationsmajor repairs/major alterations

Page 85: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FIELD APPROVAL FACTSFIELD APPROVAL FACTS FIELD APPROVAL FACTSFIELD APPROVAL FACTS

2. Physical inspection, 2. Physical inspection, demonstration, or testing of demonstration, or testing of the repair or alteration.the repair or alteration.

Page 86: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FIELD APPROVALFIELD APPROVAL FACTS FACTS FIELD APPROVALFIELD APPROVAL FACTS FACTS

3. 3. Examination of Data only Examination of Data only for duplication on identical for duplication on identical make and model by the make and model by the original original modifier.modifier.

Page 87: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

NoticeNotice NoticeNotice

You You are not are not entitled to a Field entitled to a Field Approval even if the Form 337 Approval even if the Form 337 is “perfect.”is “perfect.”

Page 88: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Why Not?Why Not? Why Not?Why Not?

1. Field Approvals are policy only and 1. Field Approvals are policy only and are not regulatory.are not regulatory.

2. Authority to grant a field 2. Authority to grant a field

approval res ts on the FAAapproval res ts on the FAA

A/W Inspector alone ! A/W Inspector alone !

Page 89: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SuggestionSuggestion SuggestionSuggestion

If your field approval request has If your field approval request has been denied try another inspector.been denied try another inspector.

If it is denied twice--check your If it is denied twice--check your paper work.paper work.

Page 90: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Question ?Question ? Question ?Question ?

What What can not can not be be

field approved?field approved?

Page 91: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Installations that:Installations that: Installations that:Installations that:

Increase in gross weightsIncrease in gross weightsMajor changes in C.G. rangeMajor changes in C.G. rangeAny repair or modification than Any repair or modification than affects structural integrity, flight, affects structural integrity, flight, or ground handling.or ground handling.

Page 92: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

INSTALLATIONS THATINSTALLATIONS THAT INSTALLATIONS THATINSTALLATIONS THAT

Changes to control surface travel.Changes to control surface travel. Changes to control surface Changes to control surface

dimensions.dimensions. Changes to the aircraft’s Changes to the aircraft’s

dimensions.dimensions.

Page 93: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Installations thatInstallations that Installations thatInstallations that

Changes to landing gear, Changes to landing gear, brakes, or strutsbrakes, or struts

Major modification to Major modification to avionics equipment avionics equipment operationoperation

Page 94: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

INSTALLATIONS THATINSTALLATIONS THAT INSTALLATIONS THATINSTALLATIONS THAT

CHANGE FUEL VENTSCHANGE FUEL VENTS INSTALL NEW FUEL OR OIL INSTALL NEW FUEL OR OIL

SYSTEMSSYSTEMS CHANGES TO FIRE CHANGES TO FIRE

EXTINGUISHING SYSTEMSEXTINGUISHING SYSTEMS CHANGE ENGINE COOLINGCHANGE ENGINE COOLING

Page 95: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

INSTALLATIONS THATINSTALLATIONS THAT INSTALLATIONS THATINSTALLATIONS THAT

CHANGE TO “IF” FREQUENCYCHANGE TO “IF” FREQUENCY CHANGES THAT DEVIATE CHANGES THAT DEVIATE

FROM THE DESIGN FROM THE DESIGN ENVIRONMENTAL ENVIRONMENTAL PERFORMANCE.PERFORMANCE.

Page 96: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FIELD APPROVALS FIELD APPROVALS THAT REQUIRE FAA THAT REQUIRE FAA ENGINEERING INPUT: ENGINEERING INPUT:

FIELD APPROVALS FIELD APPROVALS THAT REQUIRE FAA THAT REQUIRE FAA ENGINEERING INPUT: ENGINEERING INPUT:

SUBSTITUTION OF PARTSSUBSTITUTION OF PARTS CERAMIC COATINGSCERAMIC COATINGS WELDING OF PROPELLERSWELDING OF PROPELLERS ALTERNATIVE MEANS OF ALTERNATIVE MEANS OF

COMPLYING WITH AD.COMPLYING WITH AD. USE OF SYNTHETIC RESIN GLUESUSE OF SYNTHETIC RESIN GLUES

Page 97: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FIELD APPROVALS THATFIELD APPROVALS THAT REQUIRE FAA REQUIRE FAA ENGINEERING APPROVALENGINEERING APPROVAL

FIELD APPROVALS THATFIELD APPROVALS THAT REQUIRE FAA REQUIRE FAA ENGINEERING APPROVALENGINEERING APPROVAL

NEW MAGNESIUM OR CHROME NEW MAGNESIUM OR CHROME APPLICATIONSAPPLICATIONS

NEW WELDING OR BRAZING NEW WELDING OR BRAZING PROCESSESPROCESSES

USE OF SYNTHETIC COVERINGSUSE OF SYNTHETIC COVERINGS

Page 98: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

INCOMPLETE INCOMPLETE INSTALLATIONS INSTALLATIONS INCOMPLETE INCOMPLETE INSTALLATIONS INSTALLATIONS

AIRCRAFT WITH INCOMPLETE AIRCRAFT WITH INCOMPLETE OR PIECEMEAL INSTALLATIONS OR PIECEMEAL INSTALLATIONS CAN BE APPROVED CAN BE APPROVED FOR RETURN FOR RETURN TO SERVICE IF THE FOLLOWING TO SERVICE IF THE FOLLOWING HAS BEEN ACCOMPLISHED:HAS BEEN ACCOMPLISHED:

Page 99: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

INCOMPLETE INCOMPLETE INSTALLATIONS INSTALLATIONS INCOMPLETE INCOMPLETE INSTALLATIONS INSTALLATIONS

THE ALTERATION DATA HAS THE ALTERATION DATA HAS BEEN FAA APPROVEDBEEN FAA APPROVED

THE INCOMPLETE INSTALLATION THE INCOMPLETE INSTALLATION WILL NOT AFFECT THE SAFE WILL NOT AFFECT THE SAFE OPERATION OF THE AIRCRAFTOPERATION OF THE AIRCRAFT

Page 100: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

INCOMPLETEINCOMPLETE INSTALLATIONS INSTALLATIONS INCOMPLETEINCOMPLETE INSTALLATIONS INSTALLATIONS

THE EQUIPMENT INSTALLED IS THE EQUIPMENT INSTALLED IS DEACTIVATED AND PLACARDEDDEACTIVATED AND PLACARDED TO PREVENT USETO PREVENT USE

WEIGHT AND BALANCE RECORDS WEIGHT AND BALANCE RECORDS ARE CURRENTARE CURRENT

MAINTENANCE RECORDS ENTRY MAINTENANCE RECORDS ENTRY MADE AND SIGNED OFFMADE AND SIGNED OFF

Page 101: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

INCOMPLETE INCOMPLETE INSTALLATION INSTALLATION INCOMPLETE INCOMPLETE INSTALLATION INSTALLATION

OPERATOR IS ADVISED OF THE OPERATOR IS ADVISED OF THE STATUS OF THE EQUIPMENT STATUS OF THE EQUIPMENT INSTALLED.INSTALLED.

WHEN THE INSTALLATION IS WHEN THE INSTALLATION IS COMPLETED A CONFORMITY COMPLETED A CONFORMITY INSPECTION MAY BE REQUIRED.INSPECTION MAY BE REQUIRED.

Page 102: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

HERE IS SOMETHING NEW HERE IS SOMETHING NEW FROM THE PEOPLE WHO FROM THE PEOPLE WHO

BROUGHT YOU ADsBROUGHT YOU ADs

Page 103: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FIELD APPROVAL FOR FIELD APPROVAL FOR MAJOR ALTERATIONS MAJOR ALTERATIONS ADDITIONAL REQUIREMENTSADDITIONAL REQUIREMENTS MECHANICS MUST SUBMIT MECHANICS MUST SUBMIT

INSTRUCTIONS FOR CONTINUED INSTRUCTIONS FOR CONTINUED AIRWORTHINESS. AIRWORTHINESS.

IN OTHER WORDS HOW ARE YOU IN OTHER WORDS HOW ARE YOU GOING TO MAINTAIN THE GOING TO MAINTAIN THE ALTERATION FOR THE REST OF THE ALTERATION FOR THE REST OF THE TIME IT IS ON THE AIRCRAFT.TIME IT IS ON THE AIRCRAFT.

Page 104: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FIELD APPROVAL FOR FIELD APPROVAL FOR MAJOR ALTERATIONS MAJOR ALTERATIONS

THE FAA INSPECTOR “ACCEPTS” THE THE FAA INSPECTOR “ACCEPTS” THE INSTRUCTIONS FOR CONTINUED INSTRUCTIONS FOR CONTINUED AIRWORTHINESS ONLY.AIRWORTHINESS ONLY.

THE ICA’S SHOULD BE COMPLETE THE ICA’S SHOULD BE COMPLETE ENOUGHT SO THE ALTERATIONS IS ENOUGHT SO THE ALTERATIONS IS MAINTAINED IN AN AIRWORTHY MAINTAINED IN AN AIRWORTHY CONDITION, INCLUDE REPLACEMENT CONDITION, INCLUDE REPLACEMENT OF PARTS.OF PARTS.

Page 105: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

INSTRUCTIONS FOR INSTRUCTIONS FOR CONTINUING AIRWORTHINESSCONTINUING AIRWORTHINESS MAKE IT EASY ON YOURSELF---USE MAKE IT EASY ON YOURSELF---USE

THE FAA ICA CHECKLISTTHE FAA ICA CHECKLIST REMEMBER: THE ICA IS NOT FOR REMEMBER: THE ICA IS NOT FOR

THE FAA’S BENEFIT BUT TO HELP THE FAA’S BENEFIT BUT TO HELP THE NEXT MECHANIC WHO MUST THE NEXT MECHANIC WHO MUST INSPECT OR MAINTAIN THE MAJOR INSPECT OR MAINTAIN THE MAJOR ALTERATION THAT YOU ALTERATION THAT YOU INSTALLED.INSTALLED.

Page 106: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Helpful Hints

for Field

Approval

Helpful Hints

for Field

Approval

Page 107: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

1. Check out the Form 3371. Check out the Form 3371. Check out the Form 3371. Check out the Form 337

Did you read the fine print on the Did you read the fine print on the Form?Form?

Have you read AC-43-9-1G Have you read AC-43-9-1G Instructions for completing FAA Instructions for completing FAA Form 337?Form 337?

Hint:Hint:

(Check appendix B of Part 43)(Check appendix B of Part 43)

Page 108: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

2. IS IT MAJOR OR 2. IS IT MAJOR OR MINOR? MINOR?2. IS IT MAJOR OR 2. IS IT MAJOR OR MINOR? MINOR?

Make a determination if theMake a determination if the

repair or alteration is major orrepair or alteration is major or

minor.minor.

Hint: (Check Appendix A of Part 43 Hint: (Check Appendix A of Part 43 or ask the 3 questions)or ask the 3 questions)

Page 109: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

3. SEE THE FAA FIRST!3. SEE THE FAA FIRST!3. SEE THE FAA FIRST!3. SEE THE FAA FIRST!

Do Do NOTNOT cut metal, splice cut metal, splice

wire, or install equipment wire, or install equipment

until you received the Field until you received the Field

Approval!Approval!

Page 110: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

4. FIND OUT WHAT THE 4. FIND OUT WHAT THE FAA WANTS OR NEEDS FAA WANTS OR NEEDS 4. FIND OUT WHAT THE 4. FIND OUT WHAT THE FAA WANTS OR NEEDS FAA WANTS OR NEEDS

Talk TO the FAA Inspector Talk TO the FAA Inspector about about the major repair or alteration you are the major repair or alteration you are planning.planning.

Find out what data the inspector Find out what data the inspector needs to see!needs to see!

Page 111: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

5. BE REASONABLE !5. BE REASONABLE !5. BE REASONABLE !5. BE REASONABLE !

Allow a reasonable time Allow a reasonable time period for the approval.period for the approval.

Hint:Hint:

(30 days is (30 days is

Reasonable)Reasonable)

Page 112: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

6. Gather your Data:6. Gather your Data:6. Gather your Data:6. Gather your Data:

Check the type Certification rules.Check the type Certification rules. PART PART 23 or CAR 323 or CAR 3 PART 25 or CAR 4PART 25 or CAR 4 AC 43.13 1B or 2AAC 43.13 1B or 2A Documents, photos, processes.Documents, photos, processes.

Hint: Are they current?Hint: Are they current?

Page 113: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

7. CAN THE FAA7. CAN THE FAA UNDERSTAND WHAT UNDERSTAND WHAT YOU WANT TO DO? YOU WANT TO DO?

7. CAN THE FAA7. CAN THE FAA UNDERSTAND WHAT UNDERSTAND WHAT YOU WANT TO DO? YOU WANT TO DO?

Format your data in a reasonable Format your data in a reasonable straight forward manner.straight forward manner.

Hint: Does your data, repair or Hint: Does your data, repair or alteration conflict with other alteration conflict with other alterations or repairs?alterations or repairs?

Page 114: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

8. HOW SECURE IS 8. HOW SECURE IS SECURE ? SECURE ?8. HOW SECURE IS 8. HOW SECURE IS SECURE ? SECURE ?

Have you looked at the aircraft’sHave you looked at the aircraft’s

structural requirements? structural requirements?

Can a new piece of equipment stay Can a new piece of equipment stay

where you put it?where you put it?

Hint: See Chapter 1 of AC43.13-2A on Hint: See Chapter 1 of AC43.13-2A on how to work up design loads.how to work up design loads.

Page 115: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

9. 9. Are you building any Are you building any hazards into the aircraft?hazards into the aircraft?9. 9. Are you building any Are you building any hazards into the aircraft?hazards into the aircraft? Structurally?Structurally?

Operationally?Operationally?

Are the parts used PMA-TSO Are the parts used PMA-TSO approved?approved?

Page 116: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

10. 10. GETTING IT APPROVEDGETTING IT APPROVED10. 10. GETTING IT APPROVEDGETTING IT APPROVED

SUBMIT ASUBMIT A COMPLETED BUT UN- COMPLETED BUT UN-SIGNED SIGNED FAA FORM 337 TO THE FAA. FAA FORM 337 TO THE FAA.

SUGGEST THAT A COVER LETTER SUGGEST THAT A COVER LETTER THAT DESCRIBES THE REPAIR OR THAT DESCRIBES THE REPAIR OR ALTERATION IN DETAIL IS ALTERATION IN DETAIL IS ATTACHED TO THE 337.ATTACHED TO THE 337.

Page 117: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

MY STARS AND GARDERS MY STARS AND GARDERS ITS BEEN APPROVED ! ! ! ITS BEEN APPROVED ! ! ! MY STARS AND GARDERS MY STARS AND GARDERS ITS BEEN APPROVED ! ! ! ITS BEEN APPROVED ! ! !

BUT WHAT DO YOU BUT WHAT DO YOU

REALLY HAVE ?REALLY HAVE ?

Page 118: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

You have one of three You have one of three Kinds of Field Approvals Kinds of Field Approvals You have one of three You have one of three Kinds of Field Approvals Kinds of Field Approvals

1.1. Data approvalData approval

2.2. Approval by physical Approval by physical inspection or testinginspection or testing

3.3. Data approval for multiple Data approval for multiple repairs or alterationsrepairs or alterations

Page 119: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

DON’T FORGET, YOU GETDON’T FORGET, YOU GET TO SHARE THE BLAME TO SHARE THE BLAME DON’T FORGET, YOU GETDON’T FORGET, YOU GET TO SHARE THE BLAME TO SHARE THE BLAME

The Form 337 still needs the The Form 337 still needs the conformity statement signed and the conformity statement signed and the approval for return to service block approval for return to service block checked, as well as the aircraft’s checked, as well as the aircraft’s maintenance records completed.maintenance records completed.

Page 120: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

A completed Form 337A completed Form 337A completed Form 337A completed Form 337

1 - goes to the owner/operator1 - goes to the owner/operator

1 - to the FAA within 48 hours1 - to the FAA within 48 hours

A fuel tank in the baggage or CabinA fuel tank in the baggage or Cabin

1 - goes to the owner/operator1 - goes to the owner/operator

1 - to the FAA written 48 hours1 - to the FAA written 48 hours

1 - stays in the cockpit/cabin1 - stays in the cockpit/cabin

Page 121: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

FORM 337 RECORD FORM 337 RECORD KEEPING REQUIREMENTS KEEPING REQUIREMENTS FORM 337 RECORD FORM 337 RECORD KEEPING REQUIREMENTS KEEPING REQUIREMENTS

FAA FORM 337 FOR MAJOR FAA FORM 337 FOR MAJOR REPAIRS IS KEPT FOR 1 YEAR.REPAIRS IS KEPT FOR 1 YEAR.

FAA FORM 337 FOR MAJOR FAA FORM 337 FOR MAJOR ALTERATION IS KEPT FOREVER ALTERATION IS KEPT FOREVER (REF: 91. 417) (REF: 91. 417)

Page 122: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SummarySummary SummarySummary

-Major Repair --returns it to its -Major Repair --returns it to its original type design. original type design.

–Major Alteration--alters the type Major Alteration--alters the type Design.Design.

–Data is required.Data is required.

–Acceptable / Approved Data.Acceptable / Approved Data.

Page 123: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SummarySummary SummarySummary

AC 43.13-1B AC 43.13-1B “Approved Data”“Approved Data”

– Appropriate to the productAppropriate to the product

– Applicable to the repairApplicable to the repair

– Not contrary to MFR.DATANot contrary to MFR.DATA

– Chapter/page/ paragraphChapter/page/ paragraph

Page 124: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

SUMMARYSUMMARY SUMMARYSUMMARY

UNAPPROVED DATAUNAPPROVED DATA

S. T. C. PROCESSS. T. C. PROCESS

FIELD APPROVAL PROCESSFIELD APPROVAL PROCESS

Page 125: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

REVIEWREVIEW REVIEWREVIEW

Now let’s go Now let’s go over the test!over the test!

Now let’s go Now let’s go over the test!over the test!

Page 126: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

Test AnswersTest Answers Test AnswersTest Answers

1-1-BB 2-B2-B 3-C3-C

4-D4-D 5-A5-A 6-A 6-A

7-C7-C 8-D8-D 9-D9-D

10-D10-D 11-D 11-D 12-C12-C

13-A13-A 14-D 14-D 15-A 15-A

16-B16-B 17-C17-C 18-C 18-C

19-B19-B 20-C20-C

Page 127: FAA PRESENTS ALL YOU WANTED TO KNOW ABOUT MAJOR REPAIRS MAJOR ALTERATIONS

MAJOR REPAIRS AND MAJOR REPAIRS AND MAJOR ALTERATIONS MAJOR ALTERATIONS MAJOR REPAIRS AND MAJOR REPAIRS AND MAJOR ALTERATIONS MAJOR ALTERATIONS

THE ENDTHE END

THANKS FOR PARTICIPATINGTHANKS FOR PARTICIPATING

THE ENDTHE END

THANKS FOR PARTICIPATINGTHANKS FOR PARTICIPATING