(Maintenance Procedures) PDF

PIA TRAINING CENTRE (PTC) Module 7 - MAINTENANCE PRACTICES
Category – A/B1 Sub Module 7.20 - Maintenance Procedures
MODULE 7
Sub Module 7.20
MAINTENANCE PROCEDURES
ISO 9001:2008 Certified For Training Purpose Only

PTC/CM/B1.1 Basic/M7/04 Rev. 00
7.20 Mar 2014
Contents
MAINTENANCE PROCEDURES --------------------------------------------------- 1

MAINTENANCE PLANNING ------------------------------------------------------- 1
MODIFICATION PROCEDURES --------------------------------------------------- 1
STORES PROCEDURES ------------------------------------------------------------- 2
CERTIFICATION PROCEDURES --------------------------------------------------- 3
INTERFACE WITH AIRCRAFT OPERATION ------------------------------------- 3
ADDITIONAL MAINTENANCE PROCEDURES---------------------------------- 5
CONTROL OF LIFE LIMITED COMPONENTS ----------------------------------- 5

7.20 - i Mar 2014
MAINTENANCE PROCEDURES The maintenance program contains a list of the most significant
items and recommendations as to the maintenance actions,
An aircraft has to receive regular maintenance, of varying recommended frequencies and sampling/inspection points. It
depths to remain fully airworthy at all times. This is achieved in will also contain a program that monitors engine critical parts
most circumstances by making various checks, at intervals, and the inspections to be done on those parts.
throughout the life of the aircraft. These intervals can be stated
in quantities of flying hours, calendar time or combinations of All aircraft have a list of critical parts, with which it cannot fly
the two systems. without them being serviceable, or which can be dispensed
with, providing other parts can cover for the missing part.
MAINTENANCE PLANNING
MODIFICATION PROCEDURES
The periods of maintenance can be small or large. The aircraft
can be in for a short period of maintenance over-night (or Modifications are changes made to a particular aircraft,
perhaps no longer than two days), whilst, on a large including all its components, engines, propellers, radio
maintenance period, the aircraft might be in the hangar for a apparatus, accessories, instruments, equipment and their
week or two, depending on the type of aircraft. respective installations.
It is normal to apply what is known as a ‘back-stop’ to each With the exception of modifications which the NAA agree to be
period for safety. For example, if the frequency of each of such a minor nature that airworthiness is unaffected, all
maintenance action is every 100 flying hours, then there will modifications must be approved in accordance with the relevant
probably be a calendar ‘back-stop’ of one month. This means parts of EASA regulations. The modifications are approved by
that if the aircraft is only flown for 25 hours during one month, the NAA or by the ‘Approved Organization’ carrying out the
then it will have its maintenance done on the last day of that modification program.
month, regardless if its low hours.
Modifications must be such that the design of the aircraft, when
Equally, if the aircraft is intensively flown day-and-night, it might modified, complies at least with the requirements which applied
reach its 100 hours after 19 days. It will then receive its when the aircraft was originally certified.
maintenance at that time, as a result of its intensive flying. The
decision as to the frequency and depth of this maintenance is
controlled by the ‘Type Design Organization’, the organization
which designed the aircraft.

7.20 - 1 Mar 2014
When a modification is being designed, a decision has to be STORES PROCEDURES

made as to whether the modification is to be classified as
‘Minor’ or ‘Major’. The installing of a new type of engine would All aircraft and component manufacturing and maintenance
most definitely be a major modification, whilst changing the type establishments will have a stores department, whose object is
of clips holding cables together would be a minor one. It is twofold. Its purpose, firstly, is to ensure that all materials, parts,
somewhere in the middle when the decision as to the grading of components etc. used on aircraft are to the correct specification.
a modification has to be decided by the NAA. The second purpose of the stores is to enable the history of any
important part to be traced back to its original manufacture and
Major modifications its raw materials.
The organization request approval from NAA and, when All stores transactions use the same forms throughout the
approved, an approval note is returned to the organization. This EASA system as well as the USA and Canada. This system
allows the modification to be embodied. ensures that a store in one part of this country will receive a
component from within the UK, all EASA countries or North
Minor modifications America on the same form. This is known throughout the EASA
system as the EASA Form 1.
The organization writes to the NAA, requesting permission to
embody the modification and, when approved, the NAA sends a Stores that operate within an organization that is approved by
form, back, to permit embodiment. the NAA to operate, with little control or supervision from the
NAA, is known as an ‘Approved Stores’.
If the organization has NAA approval, it is permitted to approve
its own modifications. All the organization has to do is to keep An Approved Store will contain three main departments:
full records of the design and embodiment of the modification.
1. A quarantine store, which accepts items from other
All modifications are recorded in the aircraft documentation, companies and checks that they are satisfactory.
either inside the Airframe Log Book, if the aircraft weighs less
than 2730 kg or in a separate Modification Record Book if the 2. A bonded store which takes items from the quarantine
aircraft weighs more than 2730 kg. store, after approval, and, when requested, issues those
components to the servicing technicians.
3. An office or administration centre, which keeps adequate

files and records, to enable cross-checking of any
transaction through the store system.
7.20 - 2 Mar 2014
CERTIFICATION PROCEDURES INTERFACE WITH AIRCRAFT OPERATION
Any maintenance done on an aircraft that has a Certificate of There are many links between aircraft maintenance and the
Airworthiness (C of A) has to be certified by the technician(s) flying done by both commercial and private operations. These
doing the work. Depending on the company they work for, the links, or interfaces, include the legislation that dictates how the
technicians can have either personal certification or approval by two operations are to work together.
their own company. The legal requirement is quoted as: ‘An
aircraft shall not fly unless there is in force a Certificate of For the larger commercial companies, all the legislation is
Release to Service issued in respect of any overhauls, currently laid down under JAR-OPS, produced by the JAA JAR-
modifications, repairs or maintenance to the aircraft or its OPS controls many facets of commercial flying. This can
equipment’. include how the company maintains its aircraft, (or how it sub-
contracts the work elsewhere); how the documentation and
Normally the work is either certified by an approved engineer or, publications record all the information needed for both the
completed by a non-approved engineer and certified by another, engineers and the flight crew and how the quality of the whole
approved engineer. This certification is known as a Certificate of operation is kept to an acceptable standard. The communication
Release to Service. of information between maintenance and flying personnel is
normally via a number of different publications such as:
The wording on the document for signature is to a standard
format and certifies that the work has been done in accordance I. The Technical Log Book (Tech. Log)
with EASA 145 and that the aircraft is fit for release back to II. The Log Books (Aircraft, Engine and Propeller)
service. III. The Modification Records.
The certification should also contain particulars of the work The Tech. Log contains all details of the sector by sector flight
done or the inspection completed and the organization and operations, such as flight times, defects, fuel (on arrival and
place at which the work was done. It is also required that the uplifted), other ground maintenance and replenishments.
aircraft type and registration or component type, part and serial
number shall be recorded as applicable. There are a number of The Log Books are usually kept within the records department,
minor maintenance operations that do not require certification/ but they are a long term record of not only the total flying hours,
release to service. This can include minor maintenance, done but of the life remaining on engines and propellers and the
by the pilot, on a small private aircraft. maintenance checks done on the aircraft.

7.20 - 3 Mar 2014
The Modification Records allow all to see what changes, If a company has CAA approval under JAR-145, it is permitted
(modifications), have been embodied to the aircraft. These to control all of the maintenance it does as well as, in some
changes might require different flight operations or maintenance instances (with the additional approval under JAR-147), the ‘in
actions than prior to their embodiment. house’ training of its own engineers.
An approved company has to introduce a Quality Assurance

MAINTENANCE INSPECTION/ QUALITY CONTROL/ Department, to the strict rules laid down in JAR-145. This
QUALITY ASSURANCE department controls the standards of the company from the
lowliest worker on the hangar floor to the Accountable Manager,
All maintenance done on the aircraft, from the Pre-Departure usually the managing director. It is responsible for all of the
Inspection (made before every flight); to the heavy Check ‘D’ engineers and their approvals. It also examines engineers and
inspection (done every four to six years), is controlled from the trainees, prior to their examination by the CAA.
Maintenance Schedule. This publication is produced by the
aircraft manufacturer, and dictates the depth and frequency of The Quality department also makes ‘audits’ throughout the
work at which each inspection is completed. company, at intervals, to ensure all the procedures, laid down in
the company manuals, are being followed.
On light aircraft, the maintenance is normally done in
accordance with a Schedule produced by the CAA, called the When certain operations are being done on an aircraft, whereby
Light Aircraft Maintenance Schedule, (LAMS). there might be catastrophic consequences to the aircraft if the
work was not done correctly, then a duplicate inspection is
This is a simple schedule, common to all private aircraft below required. This involves two engineers; one of whom completes
2730kg, which divides the maintenance into 50 and 150 flying the work while the second (who has had nothing to do with the
hour, annual and tri-annual inspections. task), checks the work and signs that it has been completed
correctly.
The personnel who do any of the inspections have to be either
licensed by the CAA or ‘approved’ by their own company, (if the
company is itself approved by the CAA). The types of aircraft
being serviced, and their use, will control which type of
qualification they require.

7.20 - 4 Mar 2014
ADDITIONAL MAINTENANCE PROCEDURES
Apart from the regular maintenance checks, listed in the The control of the replacement of components, on completion of
Maintenance Manual, there are a number of additional their lives, rests with the Technical Control/Records department,
maintenance procedures that are done at irregular intervals. which monitors all of the aircraft documents.
These could include washing the aircraft, de-icing it in the When an item is due for replacement, the work is often
winter, weighing it after certain operations and painting it when synchronised with a scheduled maintenance check, so that the
its condition warrants it. The information and the correct aircraft is out of service for the minimum amount of time. It is
procedures will probably be found in the maintenance manuals. normal, however, for small items such as batteries, to be
(Under Washing, De-icing, Weighing and Painting). changed on the flight line, often at the end of the day’s flying,
with the battery replacement being done at the same time as
Other work done, in addition to the normal regular maintenance, the daily inspection.
might include an on-going sampling program or condition
monitoring, which is done during the normal day-to-day The notification of the correct day for the replacement will be
operation of the aircraft. These tasks would probably be annotated on a document called the Maintenance Statement,
organized at the request of the local CAA office, to comply with which gives all items due for replacement, in between
an airworthiness request from the manufacturer. scheduled maintenance checks.
CONTROL OF LIFE LIMITED COMPONENTS In the front of the Maintenance Manual is a chapter, variously
entitled ‘Retirement Lives’; ‘Long Life Items’ or ‘Fatigue Lives’.
On almost any aircraft, there will be a number of components
that have a stated ‘life’, usually quoted in flying hours, cycles, This chapter lists the retirement lives of many components and
calendar time or operating hours. parts with long lives, which can include such items as engine
‘hot-end’ components, landing gear legs and major structural
The correct terminology for ‘life’ is Mandatory Life Limitation. items that have retirement lives in the thousands of flying
The components will have been given a life for various reasons. hours/cycles.
For example, a fatigue life on a structural component in flying
hours; the landing gear legs due for retirement after 10,000 This list will be monitored by the Technical Records department,
landings, the batteries due for replacement after 3 or 4 months and the aircraft documents will be annotated and the work cards
and a retirement life on an APU measured in hours running etc., raised when the task is required to be done.
time.

7.20 - 5 Mar 2014
INSPECTION FUNDAMENTALS Airframe and engine inspections may range from preflight
GENERAL inspections to detailed inspections. The time intervals for the
inspection periods vary with the models of aircraft involved and
Inspections are visual examinations and manual checks to the types of operations being conducted. The airframe and
determine the condition of an aircraft or component. An aircraft engine manufacturer's instructions should be consulted when
inspection can range from a casual walk around to a detailed establishing inspection intervals.
inspection involving complete disassembly and the use of
complex inspection aids. Aircraft may be inspected using flight hours as a basis for
scheduling, or on a calendar inspection system. Under the
An inspection system consists of several processes, including: calendar inspection system, the appropriate inspection is
(1) Reports made by mechanics or by the pilot or crew flying an performed on the expiration of a specified number of calendar
aircraft and (2) regularly scheduled inspections of an aircraft. An weeks. The calendar inspection system is an efficient system
inspection system is designed to maintain an aircraft in the best from a maintenance management standpoint. Scheduled
possible condition. Thorough and repeated inspections must be replacement of components with stated hourly operating
considered the backbone of a good maintenance program. limitations is normally accomplished during the calendar
Irregular and haphazard inspection will invariably result in inspection falling nearest the hourly limitation.
gradual and certain deterioration of an aircraft. The time which
must eventually be spent in repairing an aircraft thus abused In some instances, a flight-hour limitation is established to limit
often totals far more than any time saved in hurrying through the number of hours that may be flown during the calendar
routine inspections and maintenance. interval.
It has been proven that regularly scheduled inspections and Aircraft operating under the flight-hour system are inspected
preventive maintenance assure airworthiness. Operating when a specified number of flight hours are accumulated.
failures and malfunctions of equipment are appreciably reduced Components with stated hourly operating limitations are
if excessive wear or minor defects are detected and the proper normally replaced during the inspection that falls nearest the
use of records concerning these inspections cannot be hourly limitation.
overemphasized.

7.20 - 6 Mar 2014
REQUIRED INSPECTIONS CHECKLIST
Federal Aviation Regulations (FAR) provide for the inspection of Always use a checklist when performing the inspection. The
all civil aircraft at specific intervals, depending generally upon checklist may be of your own design, one provided by the
the type of operations in which they are engaged, for the manufacturer of the equipment being inspected, or one obtained
purpose of determining their overall condition. Some aircraft from some other source. The checklist should include the
must be inspected at least once each 12 calendar months, while following:
inspection is required for others after each 100 hours of flight. In
other instances, an aircraft may be inspected in accordance 1. Fuselage and hull group
with an inspection system set up to provide for total inspection
of the aircraft over a calendar or flight-time period. a. Fabric and skin–for deterioration, distortion, other
evidence of failure, and defective or insecure attachment
In order to determine the specific inspection requirements and of fittings.
rules for the performance of inspections, reference should be
made to the Federal Aviation Regulations which prescribe the b. Systems and components–for proper installation,
requirements for the inspection and maintenance of aircraft in apparent defects, and satisfactory operation.
various types of operations.
c. Envelope gas bags, ballast tanks, and related parts–for
INSPECTION TECHNIQUES condition.
Before starting an inspection, be certain all plates, access 2. Cabin and cockpit group
doors, fairings, and cowling have been opened or removed and
the structure cleaned. When opening inspection plates and a. Generally–for cleanness and loose equipment that
cowling, and before cleaning the area take note of any oil or should be secured.
other evidence of fluid leakage.
b. Seats and safety belts–for condition and security.
c. Windows and windshields–for deterioration and

breakage.
d. Instrument–for condition, mounting, marking, and (where

practicable) for proper operation.

7.20 - 7 Mar 2014
e. Flight and engine controls–for proper installation and h. Exhaust stacks–for cracks, defects, and proper
operation. attachment.
f. Batteries–for proper installation, and charge. i. Accessories–for apparent defects in security of

mounting.
g. All systems–for proper installation, general condition,
apparent defects, and security of attachment. j. All systems–for proper installation, general condition
defects, and secure attachment.
3. Engine and nacelle group
k. Cowling–for cracks and defects.
a. Engine section–for visual evidence of excessive oil, fuel,
or hydraulic leaks, and sources of such leaks. l. Ground run-up and functional check— check all power
plant controls and systems for correct response, all
b. Studs and nuts–for proper torquing and obvious defects. instruments for proper operation and indication.
c. Internal engine–for cylinder compression and for metal

particles or foreign matter on screens and sump drain 4. Landing gear group
plugs. If cylinder compression is weak, check for
improper internal condition and improper internal a. All units–for condition and security of attachment.
tolerances.
b. Shock absorbing devices–for proper oleo fluid level.
d. Engines mount–for cracks, looseness of mounting, and
looseness of engine to mount. c. Linkage, trusses, and members–for undue or excessive
wear, fatigue, and distortion.
e. Flexible vibration dampeners–for condition and
deterioration. d. Retracting and locking mechanism for proper operation.
f. Engine controls–for defects proper travel, and proper e. Hydraulic lines–for leakage.
safetying.
e. Electrical system–for chafing and proper operation of
g. Lines, hoses, and clamps–for leaks, condition, and switches.
looseness.

7.20 - 8 Mar 2014
g. Wheels–for cracks defects, and condition of bearings. 6. Empennage group
h. Tires–for wear and cuts. a. Fixed surfaces–for damage or obvious defects, loose
fasteners, and security of attachment.
i. Brakes–for proper adjustment.
b. Movable control surfaces–for damage or obvious
j. Floats and skis–for security of attachment and obvious defects, loose fasteners, loose fabric, or skin distortion.
defects.
c. Fabric or skin–for abrasion, tears, cuts or defects,
5. Wing and center section distortion, and deterioration.
a. All components–for condition and security. 7. Propeller group
b. Fabric and skin–for deterioration, distortion, other a. Propeller assembly–for cracks, nicks, bends, and oil
evidence of failure, and security of attachment. leakage.
d. Internal structure (spars, ribs compression members)– b. Bolts–for proper torquing, and safetying
for cracks, bends, and security.
c. Anti-icing devices–for proper operations and obvious
e. Movable surfaces–for damage or obvious defects, defects.
unsatisfactory fabric or skin attachment and proper
travel. d. Control mechanisms–for proper operation, secure
mounting, and travel.
f. Control mechanism–for freedom of movement,
alignment, and security. 8. Communication and navigation group
g. Control cables–for proper tension, fraying, wear and a. Radio and electronic equipment–for proper installation
proper routing through fairleads and pulleys. and secure mounting.
b. Wiring and conduits–for proper routing, secure

mounting, and obvious defects.

7.20 - 9 Mar 2014
c. Bonding and shielding–for proper installation and AIRCRAFT LOGS

condition.
"Aircraft logs" as used in this handbook is an inclusive term
d. Antennas–for condition, secure mounting and proper which applies to the aircraft logbook and all supplemental
operation. records concerned with the aircraft. The logs and records
provide a history of maintenance and operation, control of
9. Miscellaneous maintenance schedules, and data for time replacements of
components or accessories.
a. Emergency and first-aid equipment–for general condition
and proper stowage. The aircraft logbook is the record in which all data concerning
the aircraft is recorded. Information gathered in this log is used
b. Parachutes, life rafts, flares, etc. – inspect in accordance to determine the aircraft condition, date of inspections, time on
with the manufacturer's recommendations. airframe and engines. It reflects a history of all significant events
occurring to the aircraft, its components, and accessories, and
c. Autopilot system–for general condition, security of provides a place for indicating compliance with FAA
attachment, and proper operation. Airworthiness Directives or manufacturers' service bulletins.
PUBLICATIONS
Aeronautical publications are the sources of information for

guiding aviation mechanics in the operation and maintenance of
aircraft and related equipment. The proper use of these
publications will greatly aid in the efficient operation and
maintenance of all aircraft. These include manufacturers'
service bulletins, manuals, and catalogs, as well as FAA
regulations, airworthiness directives, advisory circulars, and
aircrafts, engine and propeller specifications.

7.20 - 10 Mar 2014
Bulletins particles inspection; and (11) a list of special tools.
Service bulletins are one of several types of publications issued Overhaul Manual
by airframe, engine, and component manufacturers.
The manufacturer's overhaul manual contains brief descriptive
The bulletins may include: (1) The purpose for issuing the information and detailed step-by-step instructions covering work
publication; (2) the name of the applicable airframe, engine, or normally performed on a unit away from the aircraft. Simple
component; (3) detailed instructions for service, adjustment, inexpensive items, such as switches and relays, on which
modification or inspection, and source of parts, if required; and overhaul is uneconomical, are not covered in the overhaul
(4) the estimated number of man hours required to accomplish manual.
the job.
MAINTENANCE PROCEDURES
Maintenance Manual
Continued airworthiness would need an operator certification.
The aircraft maintenance manual provided by the manufacturer The men who work on the aircraft for the purpose of certification
contains complete instructions for maintenance of all systems have to qualify for a license or approval. And other certificate
and components installed in the aircraft. It contains information known as certificate of approval is required by the authorities to
for the mechanic who normally works on units, assemblies, and an organization which complies with the laid down requirements
systems, while they are installed in the aircraft, and not for the for an approved organization.
overhaul mechanic. A typical aircraft maintenance manual
contains: (1) A description of the systems such as electrical, A maintenance program is selected in conformity with the
hydraulic, fuel, control, etc.; (2) lubrication instructions setting requirements of various certificates for the purpose of
forth the frequency and the lubricants and fluids which are to be continuous airworthiness. The maintenance program is chalked
used in the various systems; (3) pressures and electrical loads out on the concept of the periodic maintenance processes.
applicable to the various systems; (4) tolerances and
adjustments necessary to proper functioning of the airplane; (5) Maintenance: The actions required for restoring or maintaining
methods of leveling, raising, and towing; (6) methods of an item in serviceable condition.
balancing control surfaces; (7) identification of primary and
secondary structures; (8) frequency and extent of inspections
necessary to the proper operation of the airplane; (9) special
repair methods applicable to the airplane; (10) special
inspection techniques requiring X-ray, ultrasonic, or magnetic

7.20 - 11 Mar 2014
Maintenance Schedule Base Maintenance
The aircraft for which a Certificate of Airworthiness is in force It involves routine maintenance tasks with higher intervals. Base
shall be maintained in Airworthy condition. All the maintenance Maintenance requires proper facilities and place to carry out
on the aircraft shall be carried out in accordance with the heavy maintenance tasks.
approved maintenance schedule.
MAINTENANCE CHECKS
Preventive Maintenance or Scheduled Maintenance or 1. Service Checks

Routine Maintenance.
 These checks are performed after each flight, at the
The maintenance performed at definite intervals to retain an end of a day of flight operations, and/or before first
item in a serviceable condition by systematic inspection, flight of the day.
detection, replacement of worn items. Adjustments, calibration,
cleaning etc. it involved simple or minor preventive operations  These checks are usually referred to as transit check,
and replacements of those parts which do not involve complex turn around check, lay over check, pre-flight check or
assembly or operation for example removal installation of tires, simply as service check.
brake assemblies, replenishing hydraulic fluids.  These checks involve minor checks, defect
rectification. (Pireps/Maint.)
Line Maintenance
It is the maintenance consisting of routine tasks with low 2. 'A', 'B', 'C', Checks
intervals like servicing, cleaning, refueling and some
inspections. The non routine line maintenance ranges from the  These checks are performed at their scheduled interval,
removal / installation of Black boxes to removal/installation of usually after 100 to 3000 flying hours. These checks
engine. Line maintenance is "departure oriented" and any time demand longer grounding time depending on the type of
consuming items are deferred to next base visit. aircraft and the type of operations involved.
 They have lesser frequency as compared to service

checks.

7.20 - 12 Mar 2014
 These checks are cumulative, that is, all the lower PRIMARY MAINTENANCE PROCESSES
checks are concurrently performed with these major
checks. 1. On Condition
3. D – Check or Heavy Maintenance This is also a preventive process but one in which the items
inspected or tested at the periods in order to determining
 This is the longest interval check and is performed after whether it can continue in service. The fundamental purpose of
three to five years of operation. Checks with lesser the 'on condition maintenance process' is to remove an item
frequency require more grounding time. before its failure in service. On condition process does not
mean the 'fit it and forget it' philosophy.
 This check involves internal structural inspections, cabin
refurbishment, paint renewal etc. On condition maintenance is restricted to those units or systems
or portions of the structure on which a determination of
 This check is cumulative, that is, all the lower checks are condition can be made by repetitive inspections or tests. This
concurrently performed with this major check. Aircraft is necessarily mean a careful scrutiny and examination of items
completely overhauled. through visual or non destructive aids to ensure that the
condition is satisfactory at the time of inspection and shall
remain satisfactory till next inspection is due. It is important that
these inspections are repeated at the regular intervals. The
length of the interval is fairly short at the beginning and then
gradually increasing as service experience is becoming
available. When on condition items exceed the limit and not
considered satisfactory they are removed and sent to shop for
overhaul.

7.20 - 13 Mar 2014
2. Condition Monitoring 4. Hard Time
The condition monitoring is not a preventive maintenance This is a preventive process in which the known deterioration of
process. It does not have a hard time non or condition an item is limited to an acceptable level by the maintenance
elements. It is the one which information on item condition action carried out at time related periods. For example number
gained from operational experience is collected, analyze and of landings, number of cycles, Calendar time. The maintenance
interpreted on a continuing basis as a means of implementing action normally done is servicing, overhaul or replacement in
corrective procedures thereby resulting in modifications and accordance with methods prescribed in relevant manual, so that
maintenance program changes. In other words it is a statically the item concerned is either replaced or restored to such a
controlled process. The condition monitoring is the only condition that it can be released for service for a further
maintenance process in which failure or malfunction is allowed specified period. The individual hard times are determined by
to occur, but only nominated failure. The condition monitoring is the manufacturer during testing processes or by the airline as a
applicable only to items whose functions do not require a result of its operation experience. The hard time intervals
preventive maintenance to ensure operating safety. On usually apply to the total life of the parts or to the overhaul of the
condition items are subjected to periodic inspection to items. Nowadays hard time items rarely make up more than 2%
determining the extent of the deterioration in performance and or 3% of all scheduled maintenance tasks. Flap links and
are removed when they cross that point and sent to shop for landing gear parts are typical hard time replacement items. The
overhaul. hard time maintenance is the oldest and best known primary
maintenance process and its requirement is drastically reduced
Hard Time and On Condition items are airworthy and safe as the aircraft technology and design criteria have moved from
items. Condition monitored items are those which do not relate fabric covered bi-planes to wide-body jets.
to safety. They are redundant being more than one.

7.20 - 14 Mar 2014
AIRCRAFT MAINTENANCE DOCUMENTS FOR CONTINUED c: All the defects recorded in the Technical Log have been
AIRWORTHINESS rectified or deferred in accordance with CAA approved
procedure;
Certificate of Release to Service
d: All certificates Release to Service required have been
A certificate of Release to Service shall be issued after issued.
accomplishment of inspections, repairs, replacements,
modifications overhaul & scheduled Maintenance Tasks on the Certificate of Maintenance Review will be signed by the
aircraft / equipment in accordance with the requirements of following who have at least eight years of experience of
Airworthiness Directorate, CAA (Pak) / Joint Aviation aircraft maintenance which includes at least two years
Requirements (JAR 145) and Instructions of the Manufacturer. recent experience involving certification of Maintenance.
According to the requirements this certificate will be signed by; 1. Appropriately Licensed Aircraft Maintenance Engineer
holding at least two categories in the appropriate sub
a: Appropriately Licensed Aircraft Maintenance Engineer, division (Other than category-X, DR Compass) of the
particular aircraft type.
b: Person(s) approved by the Airworthiness Directorate as
competent to issue such certificate; 2. Person(s) authroized by Airworthiness Directorate
competent to issue such certificate.
c: Person(s) authorized by an organization approved by the
Airworthiness Directorate to ssue such certificate.
Certificate of Fitness for Flight
Certificate of Maintenance Review
This Certificate will be issued prior to TEST FLIGHT. This
This certificate ensures that; Certificate will be signed by AMEs/Persons authorized by
Airworthiness Directorate to sign Certificate of Maintenance
a: All maintenance specified in the approved Maintenance Review. It will be valid for a period not exceeding seven days
Schedule has been carried out. from the issue date. The certificate will be issued in duplicate.
One Copy will be carried.
b: All modifications & inspections classified as mandatory by
Airworthiness Directorate have been earned out;

7.20 - 15 Mar 2014
APPROVED STORES MODIFICATIONS
Quarantine Store It is an alteration to an aircraft, its component units, introduced

subsequent to receipt and acceptance by the operator and
The quarantine store is the input side of an approved store. designed to increase safety, improved performance, meet
All incoming parts and raw material is held until proved to changes in operating requirements and / or assure positive and
conform to specification. Component parts are given an substantial economic savings.
approved stores serial number by the quarantine stores
correlating it to hte relevant approved certificate. Whilst in the Modification Embodiment:
quarantine store goods are batched to ensure continuity of
identity, raw materials are colour identified and temporary Classification of Modification:
protective treatments are repaired or applied as required. A
register of incoming goods is kept and when the inspection staff The modifications are classified by the evaluation Committee.
are satisfied that all requirements have been met the goods are
passes to the bonded store. 1. MANDATORY: It is time barred - it calls for embodiment
within the specified period.
Bonded Store
2. ESSENTIAL: As soon as possible after modification
The bonded store is the outgoing side of an approved store parts became available.
and as such must be kept separate from the quarantine store. It
should contain only aircraft spares and associated equipment 3. ON REPACEMENT BASIS: On replacement when
that have been proved to conform to specification. The batch unmodified stocks are utilized/exhausted. All
numbers of the spares are entered on a record card to maintain replacement stocks are to be of modified type.
Identity and where raw material is issued the identification is
retained until last. 4. OPTIONAL: It may or may not be embodied. It is
optional.
5. DEFERRED: Deferred for a given period of time to

obtain further experience. To be re-evaluated.
6. INFORMATION: For record propose only.

7.20 - 16 Mar 2014
TEST FLIGHT Note: Removal / installation of same component will also be

considered as replacement.
A test flight is required in the following cases;
USEFUL INFORMATION
1. Specific requirements (Refer to concerned MM)
QUALITY
a) Aircraft grounded for more than specific number of The quality of a product is the degree to which it meets the
days eg 60 days for B737-300. requirement of the customer. With manufactured product quality
is a combination of quality of design and quality of manufacture.
b) More than 50 percent power changed. (three
engines out of 4 replaced) QUALITY CONTROL
A management system for programming and coordinating the

c) Following a Check D. quality maintenance and improvement efforts of the various
group in an Organization, so as to permit the completion of
d) Flight control surfaces replaced. aircraft maintenance in compliance with both CAA requirements
and any specific company or customer requirement affecting
e) Wings and central section replaced. airworthiness.
2. Major repair subsequent to damage. QUALITY ASSURANCE
Overall authority for the supervision of quality standard enabling

3. Performance evaluation. those standards set by the system of quality control to be
enforced. The implementation of the Quality Control
4. Quality control requirements. requirements should normally be assigned to a Quality Manager
who will be responsible for the operation of Quality Assurance
5. CAA requirements. tasks utilizing as necessary, a staff of Quality Assurance
engineers, who shall be appropriately qualified and
6. AME requires. experienced, and in sufficient numbers, to properly undertake
the work performed by the Quality Department.

7.20 - 17 Mar 2014
AIRCRAFT ON GROUND (AOG) ENGINE OPERATING CYCLE
The highest priority designation to process a requirement for a A completed engine thermal cycle including the application of
spare part(s) and/or maintenance action. Indicates that an takeoff power.
aircraft is unable to continue or be returned to revenue service
until the appropriate action is taken. SUPERSONIC CYCLE
SNAG A completed supersonic flight sequence comprising

acceleration through Mach 1 and deceleration to subsonic flight.
A known or suspected malfunction, or defect found by flight NOTE: One aircraft operating cycle can include more than one
crew or maintenance personnel which is documented and supersonic cycle.
requires maintenance action.
DE-RATING
PIREPS (Pilot Reports)
The intentional reduction of the stress/strength ratio in the
Suspected or known malfunctions or unsatisfactory conditions application of an item, usually for the purpose of reducing the
entered by the flight crew into the aircraft log and which require occurrence of stress-related failures.
maintenance action.
DOWNTIME
COMPONENT
The time during which an aircraft is not available for flight for
Any self-contained part, combination of parts, sub-assemblies technical reasons.
or units which perform a distinctive function necessary to the
operation of a system. FLIGHT OR TRIP
AIRCRAFT OPERATING CYCLE OR FLIGHT CYCLE The entire passage consisting of one or more flight legs, from
leaving the airport of origin to arrival at the airport of final
A completed take-off and landing sequence. destination and operated under one flight number.
NOTE: Touch and go landings are counted as Aircraft
Operating Cycles.

7.20 - 18 Mar 2014
EXTRA SECTION (XSEC) EXPENDABLE ITEM
Any flight made to accommodate passengers or cargo not Items for which no authorized repair procedure exists, and for
handled by the regular flight schedule. which cost of repair would normally exceed that of replacement.
CHARTER FLIGHT REPAIRABLE ITEM
A revenue flight that is not listed in the published time-table, but An item comprising or including replaceable parts, commonly
is booked for a specified purpose. economical to repair, and subject to being rehabilitated to a fully
serviceable condition over a period less than the life of the flight
FERRY FLIGHT equipment to which it is related.
A non-revenue flight made to position an aircraft for any reason. ROTABLE ITEM
FLIGHT SECTOR or FLIGHT LEG An item that can be economically restored to a serviceable
condition and, in the normal course of operations, can be
Any of the sequential aircraft operating cycles which together repeatedly rehabilitated to a fully serviceable condition over a
constitute a flight. period approximating the life of the flight equipment to which it is
related.
WALK AROUND CHECK
LINE REPLACEABLE UNIT
A visual check conducted from ground level to detect obvious
discrepancies. A unit which can be readily changed on an aircraft during line
maintenance operations.
ITEM
PARTS POOL
Any level of hardware assembly i.e., system, subsystem,
module, accessory component, unit, part, etc.) An arrangement whereby participants are entitled to draw items
from the agreed stock held by any participant.
CONSUMABLE ITEM
An item that is used only once.

7.20 - 19 Mar 2014
CANNIBALIZATION REMOVAL
The removal of an item to satisfy the needs of another aircraft or

item. Also called as ROBBERY.

7.20 - 20 Mar 2014

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PIA TRAINING CENTRE (PTC) Module 7 - MAINTENANCE PRACTICES

Category – A/B1 Sub Module 7.20 - Maintenance Procedures

ISO 9001:2008 Certified For Training Purpose Only

MAINTENANCE PROCEDURES --------------------------------------------------- 1

ISO 9001:2008 Certified For Training Purpose Only

ISO 9001:2008 Certified For Training Purpose Only

When a modification is being designed, a decision has to be STORES PROCEDURES

3. An office or administration centre, which keeps adequate

CERTIFICATION PROCEDURES INTERFACE WITH AIRCRAFT OPERATION

ISO 9001:2008 Certified For Training Purpose Only

An approved company has to introduce a Quality Assurance

ISO 9001:2008 Certified For Training Purpose Only

ADDITIONAL MAINTENANCE PROCEDURES

ISO 9001:2008 Certified For Training Purpose Only

ISO 9001:2008 Certified For Training Purpose Only

REQUIRED INSPECTIONS CHECKLIST

c. Windows and windshields–for deterioration and

d. Instrument–for condition, mounting, marking, and (where

ISO 9001:2008 Certified For Training Purpose Only

f. Batteries–for proper installation, and charge. i. Accessories–for apparent defects in security of

c. Internal engine–for cylinder compression and for metal

ISO 9001:2008 Certified For Training Purpose Only

g. Wheels–for cracks defects, and condition of bearings. 6. Empennage group

a. All components–for condition and security. 7. Propeller group

b. Wiring and conduits–for proper routing, secure

ISO 9001:2008 Certified For Training Purpose Only

c. Bonding and shielding–for proper installation and AIRCRAFT LOGS

Aeronautical publications are the sources of information for

ISO 9001:2008 Certified For Training Purpose Only

Bulletins particles inspection; and (11) a list of special tools.

ISO 9001:2008 Certified For Training Purpose Only

Maintenance Schedule Base Maintenance

Preventive Maintenance or Scheduled Maintenance or 1. Service Checks

 They have lesser frequency as compared to service

ISO 9001:2008 Certified For Training Purpose Only

ISO 9001:2008 Certified For Training Purpose Only

2. Condition Monitoring 4. Hard Time

ISO 9001:2008 Certified For Training Purpose Only

ISO 9001:2008 Certified For Training Purpose Only

APPROVED STORES MODIFICATIONS

Quarantine Store It is an alteration to an aircraft, its component units, introduced

5. DEFERRED: Deferred for a given period of time to

6. INFORMATION: For record propose only.

ISO 9001:2008 Certified For Training Purpose Only

TEST FLIGHT Note: Removal / installation of same component will also be

A management system for programming and coordinating the

2. Major repair subsequent to damage. QUALITY ASSURANCE

Overall authority for the supervision of quality standard enabling

ISO 9001:2008 Certified For Training Purpose Only

AIRCRAFT ON GROUND (AOG) ENGINE OPERATING CYCLE

SNAG A completed supersonic flight sequence comprising

ISO 9001:2008 Certified For Training Purpose Only

EXTRA SECTION (XSEC) EXPENDABLE ITEM

CHARTER FLIGHT REPAIRABLE ITEM

An item that is used only once.

ISO 9001:2008 Certified For Training Purpose Only

The removal of an item to satisfy the needs of another aircraft or

ISO 9001:2008 Certified For Training Purpose Only

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