MAJOR REPAIRS AND MAJOR REPAIRS AND ALTERATIONSALTERATIONS

FLIGHT STANDARDS SERVICE

FEDERAL AVIATION ADMINISTRATION

Introduction Introduction

TO PROVIDE GUIDANCE FOR:– Determining the category of a repair or

alteration.

– Ensuring that the aircraft can be returned to service in accordance with the approved technical data.

AGENDAAGENDA

Learn of ways to determine major or minor.

Be able to determine what kinds of data are required.

Understand the record keeping requirements for major and minor repairs and alterations.

Overview Overview

Will allow for better understanding of:– Airworthiness

– Conformity

– Types of Data

– Regulatory Compliance

KEY DEFINITIONSKEY DEFINITIONS

Airworthiness Type design Type Certificate Conformity Alteration Repair

AIRWORTHINESSAIRWORTHINESS

Conforms to a Type Design!(We will talk about this in more detail later!)

Is in a condition for Safe Flight!(Ask yourself...Will the pilot be able to take-off, conduct the flight and land the aircraft safely?)

The Standard Airworthiness The Standard Airworthiness CertificateCertificate

The FAA Act of 1958...Provides the Authority and basis for issuance:– Establishes: That the aircraft must conform to a

Type certificate...AND ...be in a condition for safe flight.

– ALSO... Establishes: that it will remain in effect as long as the maintenance, preventive maintenance and alterations are done I/A/W Parts 21, 43 and 91 of the Federal Aviation Regulations

ConformityConformity

Are inspections accomplished that are concerned with determining that the materials, parts process, heat treatment, fabrication procedures, and installations involved conform with the approved technical data.

Question?Question?

WHAT DOES THE WORD APPROVED MEAN TO YOU?

Questions to ask while Questions to ask while checking Conformity checking Conformity

Are the materials, parts, etc.... FAA approved? Do they have traceability?

Are the materials used IN CONFORMITY with the Drawings?

Questions to ask while Questions to ask while checking Conformity(cont...)checking Conformity(cont...)

Are these materials, parts, etc... approved for installation?

If special processes have been involved during repair or manufacture...was it done I/A/W FAA approved process specifications?

Type DesignType Design

– Drawings and Specifications.– Dimensions, materials, and processes that went

into the development of the aircraft, engine or propeller.

– Information necessary to define the structural strength of the product.

– Airworthiness Limitations.– Special Inspections and maintenance program.– Other data as required.

Type CertificateType Certificate

A document issued by the FAA to the applicant who has proven that his/her aircraft, engine or propeller meets all the requirements of the FAR(s) pertaining to that product.

The issuance of the Type Certificate “Approves” the Type Design.

AlterationAlteration

A change to the the aviation product FORM or FUNCTION which is not spelled out in the original design standard.

– REMEMBER.... “THE DEFINITION OF AIRWORTHINESS?”

RepairRepair

A restoration of the aviation product to its original design standard.

– REMEMBER... “ CONFORMITY?”

LETS REVIEW WHAT LETS REVIEW WHAT WE’VE LEARNED SO FAR WE’VE LEARNED SO FAR

TODAY! TODAY! What is a Type Design? What is a Type Certificate? What is Conformity? What makes an aircraft airworthy? Where do we find the definition of

airworthiness? What Part of the FAR(s) describes these

issues?

ARE YOU CONFUSED ABOUT ARE YOU CONFUSED ABOUT MAJOR AND MINOR MAJOR AND MINOR

REPAIRS?REPAIRS?

There is help out there!– FAR Part 43, Appendix A.– Your local Flight Standards Office.– Designated Engineering Representatives.– FAA Engineering.

WHAT IS A MAJOR WHAT IS A MAJOR REPAIR?REPAIR?

...A repair that, if improperly done, might affect weight, balance, structural strength, performance, powerplant operation, flight characteristics, or other qualities affecting airworthiness...

or:A repair, that if not done in accordance with acceptable practices or cannot be done by elementary operations. (FAR PART 1)

A MAJOR ALTERATION IS... A MAJOR ALTERATION IS...

... an alteration not listed in the aircraft, engine, or propeller specifications... (REMEMBER TYPE CERTIFICATES?)... that:

...might appreciably affect weight, balance, structural strength, performance, powerplant, flight characteristics, or other qualities affecting airworthiness. or:

A MAJOR ALTERATION IS A MAJOR ALTERATION IS (cont..)(cont..)

...is not in accordance with acceptable practices or cannot be done by elementary operation. (FAR PART 1)

A word about: APPLIANCE A word about: APPLIANCE MAJOR ALTERATIONS:MAJOR ALTERATIONS:

An alteration of the basic design which is not made in accordance with the recommendations of the appliance manufacturer or in accordance with an FAA Airworthiness Directive– * instruments *parts

* mechanism *equipment

SO WHAT ABOUT MINOR SO WHAT ABOUT MINOR REPAIRS AND REPAIRS AND

ALTERATIONS?ALTERATIONS?

If it can not be classified as Major...they are considered Minor.

Must be accomplished using those methods, techniques, and practices acceptable to the Administrator.

Accomplished using elementary operations. Requires a record entry only!

DATA............DATA............ApprovedAccepted

““APPROVED DATA”APPROVED DATA”

Type Certificate Data Sheets Aircraft Specifications Airworthiness Directives Manufacturer’s FAA-Approved Data

““APPROVED DATA” (cont.)APPROVED DATA” (cont.)

Designated Engineering (DER) Approved Data with FAA Form 8110-3,Statement of Compliance.

Designated Alteration Station (DAS) Approved Data.

Appliance Manufacturer’s manuals (even though they are not specified as FAA Approved.)

““APPROVED DATA” APPROVED DATA” (cont.)(cont.)

Structural Repair Manuals (SRMs) when specifically approved.

FAA Form 337(s) when the data has been previously approved and will be used for the basis of field approval.

Delegation Option Authorization Data. Service Bulletins if specifically approved.

ALSO: ALSO: AC 43.13-1AAC 43.13-1A

“Acceptable Methods, Techniques, and Practices-Aircraft Inspection and Repair.

– When appropriate to the product being repaired,– Directly applicable to the repair being made.– Not contrary to Manufacturer’s data.

““ACCEPTABLE DATA”ACCEPTABLE DATA”

Manufacturer’s maintenance manuals. Manufacturer’s Service Bulletins and

technical Info.. Advisory Circulars 43.13-1A or 43.13-2A (If

Applicable). Far Parts 121 and 135 Operator’s

Maintenance Manuals. FAA Field Approvals.

Approval for return to service Approval for return to service after Major Repairs/Alterationsafter Major Repairs/Alterations

Can certificated mechanics approve and return to service after maintenance and alteration?

YES!.....................But:YES!.....................But:

Only for repairs and alterations that are minor in nature.

(FAR 65.85[Airframe] & [FAR 65.87[Powerplant]

So who can approve for return So who can approve for return to service after Major Repairs to service after Major Repairs

and Alterations?and Alterations? Certificated Mechanics with Inspection

Authorization. (FAR 65.95) Certificated and rated Repair Stations. Air Carriers (PART 135 and 121). Designated Alteration Stations (DAS) The manufacturer approve for return to

service after alterations only.

In addition:In addition:

FAA Aviation safety Inspector (Airworthiness)

FAA Designee Persons approved by Transport Canada

Airworthiness Group (AMO).

RECORD KEEPING RECORD KEEPING REQUIREMENTSREQUIREMENTS

FAR Part 43, Appendix B will tell you how to record Major Repairs and Alterations.

Each Person performing a Each Person performing a Major Repair/Alteration Major Repair/Alteration

SHALL:SHALL:

Execute FAA Form 337 at least in duplicate.

Provide a signed copy to the owner. Forward a signed copy to the local FAA

office.

Repair Station Option for Repair Station Option for Major Repairs Major Repairs ONLYONLY::

Use the customer work order and record the repair in the aircraft logs.

Give the owner a signed copy of the work order.

Keep a copy of the work order for two years.

In addition: Provide a Maintenance Release.

MAINTENANCE RELEASEMAINTENANCE RELEASE

Indicate what has been repaired. That the repair was inspected. State that it has been approved for return to

service.– Identify the work order number on file.– Date and signed by an authorized person.– Certificate number of the Repair Station.

Any Questions?Any Questions?