Chapter 5

Documentation for Maintenance

Manufacturer Documentation• Documents provided for maintenance of

aircraft• Form/content may vary• Some customized (See Table 5-1)

Manufacturer Documentation• Airplane Maintenance Manual (AMM)

• Formal document (ATA coding system)• Aircraft & on-board equipment

• Explanation of how each system/sub-system works• Basic maintenance described• Various tests performed

• Functional/Operational/Adjustments• Replenishing of various fluids• Other servicing tasks

• Normally excludes repairs to:• Structure• Fiberglass paneling

• Technician signs off logbook/nonroutine work card (NRWC)

Manufacturer Documentation• Component Maintenance Manual (CMM)

• Includes Vendor Manuals (VM)• Many components made by other vendors• Landing gears• Flight crew seats

• Breakdown of all components• Provides part numbers

• Technical data approved by FAA

Manufacturer Documentation• Fault Isolation Manual (FIM)

• Set of fault isolation trees• Block diagram• Troubleshooting• Isolate fault• Identify/pinpoint problems

Manufacturer Documentation• Illustrate Parts Catalog (IPC)

• Parts list/location of all parts• Shows• Assemblies• Subassemblies• Alternate part numbers• Part inter-changeability• Modifications (service bulletin)

• Pre and post modification

Manufacturer Documentation• Storage and Recovery Document (SRD)

• Information about aircraft• Out of service/stored for extended time• Draining certain fluids• Moving aircraft• Protecting components from weather• Part inter-changeability• Old aircraft – separate document• New aircraft – part of AMM

Manufacturer Documentation• Structure Repair Manual (SRM)

• When should damage be fixed?• Minor or major damage?• Airframe specific• Aircraft skin

• Structural damage• Specific tolerances and procedures

• Damage beyond SRM tolerances• Contact manufacturer engineering• Engineering Order (OR)

• How to repair and sign off

Manufacturer Documentation• Maintenance Planning Data Document

(MPD)• List of maintenance/servicing tasks• All items identified by MRB• Tasks listed by groupings

• Certification Maintenance Requirements (CMRs)• Required by FAA

• Maintain aircraft certification

Manufacturer Documentation• Schematic Diagram Manual (SDM)

• Detailed information• Wiring harnesses• Connectors• Interfacing equipment

• Schematics of systems• Electrical• Electronic• Hydraulic• Logic diagrams for applicable systems• Tasks listed by groupings

Manufacturer Documentation• Wiring Diagram Manual (WDM)

• Essential for troubleshooting• Wiring runs for all systems/components• Harnesses

Manufacturer Documentation• Master Minimum Equipment List (MMEL)

• Developed by manufacturer’s engineers• All equipment on aircraft model• Approved by FAA

• Identify equipment that may be• Degraded• Inoperative• May have prescribed fix date

• Airline develops own MEL

Manufacturer Documentation• Dispatch Deviation Guide (DDG)

• MMEL items inoperative/degraded• May required maintenance action prior to dispatch

• Pull/placard circuit breakers• Disconnect power• Tie up loose cables for removed equipment

Manufacturer Documentation• Configuration Deviation List (CDL)

• Similar to DDG but• Involves aircraft configuration• Does not affect airworthiness/safety

• May have restrictions• Icing conditions• Flight speed restrictions• Repair cycle customized by aircraft operator

• Discovered during line checks/pre-post flights• Panels• Gear doors• Flap hinge fairings• Cargo doors• Warning systems

Manufacturer Documentation• Nonessential Equipment and furnishing

Items (NEF)• Do not affect safety/airworthiness• Deferral program• Usually fixed at first available opportunity

• Most common deferred items• Paneling• Cup holders• Missing paint• Cosmetic items

Manufacturer Documentation• Nonessential Equipment and furnishing

Items (NEF)• Do not affect safety/airworthiness• Customized from MMEL• Deferral program• Usually fixed at first available opportunity

• Most common deferred items• Paneling• Cup holders• Missing paint• Cosmetic items

Manufacturer Documentation• Task Cards (TC)

• Selected items chosen• Action completed without entire manual

• Service Bulletins, Letters, Maintenance Tips• Airframe/Engine manufacturer• Modifications• Suggestions

• Bulletins – modification• Improve safety/operation• Detailed description

• Service Letter• Improve maintenance actions without modification

Regulatory Documentation• Federal Aviation Regulations (FAR)

• All aspects of aviation• Private• Commercial• Airports• Navigational aids• ATC• Controllers

Regulatory Documentation• Advisory Circulars(AC)

• Issued by FAA• Provide assistance meetings FAR requirements• Suggestions how to comply• “means, but not the only means”• FAA not trying to micromanage

Regulatory Documentation• Airworthiness Directive (AD)

• Mandatory• Unsafe condition• Service Bulletin could turn into AD

• Description of unsafe condition• Product with AD applies• Corrective action required• Date of compliance• Where to get additional information• Alternative methods of compliance

• Notice of Proposed Rule Making (NPRM)• Intent to change/amend FARs• Public hearings

Airline Documentation• Operations Specification (Ops Spec)

• Required for each aircraft flown• Parent document• Strict FAA requirements• Help from FAA representative

Airline Documentation• Technical Policies and Procedures Manual

(TPPM)• Primary document for M&E• FAA requirement for maintenance manual• Written by engineering• Ensures accuracy• Define exactly M&E functions/activities carried out• Detailed document• Several volumes

Airline Documentation• Inspection Manual (IM)

• Separate document or part of TPPM• All inspection activities

• Mechanic inspection tasks• QC inspector’s tasks• Special inspections (Hard landing, bird strikes)• Required inspection items (RII) program• Required paperwork, forms, reports

Airline Documentation• Quality Assurance Manual (QA)

• Special manual or part of IM• Defines

• Duties/responsibilities• Annual QA processes and procedures• Forms• Follow-up/enforcement procedures of QA write-ups

• Reliability Program Manual• Defines reliability program• Chapter 18

Airline Documentation• Minimum Equipment List (MEL)

• Airline customizes MMEL to their model• Mandatory for airline’s dispatch• Cannot be less restrictive than MMEL• Discourage operation with inoperative equipment• Penalties in passenger/cargo capacity• PIC can refuse to fly

Airline Documentation• Task Cards

• Produced by airline manufacturer• One action only for each card

• Engineering Orders (EO)• Work nor covered in standard maintenance

plan• Official• Issued by engineering• Approved by QA• Could be called work order

ATA Document Standards• Uniform coding system

• All mode/types of aircraft

• Description and Operation (001 - 099)• What system does• Various operational modes• Detailed description of how it works

• Fault Isolation (101 – 199)• Fault trees• Specific faults based on flight deck effects

ATA Document Standards• Maintenance Practices (201 - 299)

• When 2 or more actions must be used to complete task

• Followed by test

• Servicing (301 - 399)• All servicing tasks• Step-by step instructions• Required materials

ATA Document Standards• Removal/Installation (401 - 499)

• Detailed step-by-step• LRUs• All conditions addressed

• Adjustment/Test (501 - 599)• Normal maintenance• Component replacement• Operational test procedures• Functional test procedures

ATA Document Standards• Inspection/Check (601 - 699)

• Zonal inspection activities

• Cleaning/painting (701 - 799)• Aircraft• Washing• Cleaning • Painting

• Approved repairs (801 - 899)• Identifies repairs to• Structure and aircraft skin• Approved by FAA

TPPM• Controlled document• Identifies

• Key personnel• Job functions

• Qualifications definitions

• Maintenance facilities• Layout drawing/maps• Shops• Hangars• Ramps• Other significant buildings

TPPM• Identifies

• Describe in detail activities involving• Maintenance• Inspection• Testing

• Maintenance facilities• Layout drawing/maps• Shops• Hangars• Ramps• Other significant buildings