Airworthiness Presented to: Upper Cumberland EAA Chapter By: Pam Charles Date: 6/17/2017
Who am I? Pam Charles i ti Safety Program Manager, Airworthiness Nashville FSDO 615-324-1314 Pamela.k.charles@faa.gov A little about me
Why am I here? The FAAST Program Training Outreach Education Reducing Accidents
Maintenance related Accidents Improper p Maintenance. Inadequate Maintenance.
Failure to Follow Procedures Virtually all maintenance errors are a result of the failure to follow procedures because of a human factors issue. Human Factors is the most important safety issue in the performance of maintenance.
The Dirty Dozen Communication Complacency Lack of Knowledge Distraction ti Teamwork Fatigue Lack of Resources Pressure Assertiveness Stress Lack of Awareness Norms
A Little About the Regulations Part 43 does it apply? Part 91 Operating Limitations Minimum i Equipment Requirements 7
Performance Rules (general) (43.13) 43.13 a) use the methods, techniques, and practices prescribed in the current manufacturer s maintenance manual or Instructions ti for Continued Airworthiness prepared by its manufacturer or other methods, techniques, and practices acceptable to the Administrator.
Performance Rules (general) (43.13 a) Cont d use the tools, equipment, and test equipment so the work is done in accordance with accepted industry practices. Must use special tools or test t equipment recommended by the manufacturer involved, or its equivalent acceptable to the Administrator.
Performance Rules (general) 43.13 (cont d) 43.13 b) shall do that work and use materials that the condition will be at least equal to its original or properly altered condition (with regard to aerodynamic function, structural strength, resistance to vibration and deterioration, and other qualities affecting airworthiness).
Maintenance Record Entries (43.9) 1) A description of work performed. 2) The date of completion of the work performed. 3) The name of the person performing the work if other than the person approving return to service. 4) Upon satisfactory performance of the work, the signature, certificate number, and kind of certificate held by the person approving the work.
Maintenance Record Entries (43.11) Recording of Inspections and aircraft total t time.
Bonus Question Incorrectly substituted with hobbs or tach time when making a maintenance record entry required by FAR Part 43.11 13
Answer What is AIRCRAFT TOTAL TIME IN SERVICE. AC 43-9 14
Bonus Question An Alteration other than a major alteration ti 15
Answer 3 on Defining Moments What is a MINOR ALTERATION. 16
What about a major alteration? Recording. Flight Testing. Operating Limitations. 17
What about a maintaining my aircraft? Resources other than the manufacturer. Contacting the FAA. Contacting industry groups. 18
What about a maintaining my aircraft? Be ecaeu careful of the internet. et Just because you read it there doesn t make it true. 19
PPPP U.S. Department of Transportation ADVISORY CIRCULAR AC 43.13-1B ACCEPTABLE METHODS, TECHNIQUES, AND PRACTICES AIRCRAFT INSPECTION AND REPAIR CONSOLIDATED REPRINT Incorporates change 1 September 8, 1998 DEPARTMENT OF TRANSPORTATION FEDERAL AVIATION ADMINISTRATION Flight Standard Service Regulatory Support Division, AFS-600 For sale by the Superintendent of Documents; U.S. Government Printing Office; Washington, DC 20402
Mechanics Handbooks 21
Advisory Circular 65-15A 22
Advisory Circular 65-15A 23
Advisory Circular 65-15A -Tire Care - Tire Maintenance - Tire Inspection 24
Bonus Question The most necessary maintenance function for safe, long-lasting service from aircraft tires 25
Answer Proper inflation 26
Bonus Question The tire pressure check interval recommended by the FAA in Advisory Circular 65-15 27
Answer At least once a week or before each flight. 28
Bonus Question Are much more likely to creep or slip on landing or when brakes are applied 29
Answer 3 on Tires Under-Inflated Tires. 30
Bonus Question Maximum allowable loss of pressure over a twenty four hour period for a non- newly mounted tire 31
Answer What is 5 percent. 32
Bonus Question How much of a pressure drop may be expected over an initial 24-hour period of a newly mounted tire 33
Answer What is 5 to 10 percent. 34
. Wheel Bearings - 35
Wheel Bearings - When cleaning be sure to use proper cleaning agent. Do not use gasoline or jet fuel. Dry the bearing by directing a blast of dry air between the rollers. Do not direct the air so that it spins the bearing as without lubrication, this could cause the bearing to fly apart resulting in injury. Be sure the grease you use is the type recommended by the manufacturer as well as the manufacturer s instructions on properly examining the bearings for serviceability? Lacking that, refer to the Technician Handbook. 36
Wheel Bearings - What about re-packing the bearing? Do you know how to properly do that? t? Bottom line is follow the procedures and heed to all manufacturer instructions, notes, cautions and warnings. Lacking that, refer to the Technician Handbook. 37
Wheel Bearings - When inspecting the bearing, check for defects that would render it unserviceable, such as cracks, flaking, broken bearing surfaces, roughness due to impact pressure or surface wear, corrosion or pitting, discoloration from excessive heat, cracked or broken bearing cages, and scored or loose bearing cups or cones that would affect proper seating on the axle or wheel. If any discrepancies are found, replace the bearing with a serviceable unit. Bearings should be lubricated immediately after cleaning and inspection to prevent corrosion. 38
Are you Properly Lubricating your aircraft? Don t assume this is the right tool for every application! 39
Lets Talk about Engine Oil It creates a slippery gap between moving metal parts in the engine and reduces friction, heat and wear. It coats all of the surfaces within the engine, so even when the motor is not running, it is protected from corrosion. It disperses the heat that is naturally created by the combustion process within an engine. It absorbs and suspends particulate matter like carbon and transports it to the oil filter so it can be trapped and removed before it causes any major damage. It neutralizes acids that would otherwise build up in the engine and cause scarring and pitting on smooth, polished surfaces It prevents the accumulation of sludge. Cheap oils or oil that is way overdue for changing will not only fail to remove sludge and other contaminants, but will begin to break down and actually become sludge. It stays thin enough to keep mobile in cold weather and thick enough to still coat surfaces in hot weather - protecting the inside of your engine, no matter what conditions are like on the outside. 40
Bonus Question Why should you always get your engine up to operational temperature every time you start it 41
Answer To eliminate water that can break down your oil and cause corrosion. 42
Taking care of fabric and patching. UV Damage Correct Fabric Correct adhesives 43
Bonus Question FAA recommendations for when Can You use an Unsewed (Doped-On) Fabric Repair 44
Answer When the VNE for the aircraft is below 150 mph and the damage does not exceed 16 inches in any direction. How could exceeding this affect a condition inspection sign-off? 45
The Importance of Aircraft Finishes..
A good intact paint finish is one of the most effective barriers available for placement between metal surfaces and corrosive media. Touching up the existing gpaint finish and keeping it in good condition will eliminate most general corrosion problems. 47
Bonus Question All Corrosive Attacks Begin Here 48
Answer The SURFACE of the metal. 49
Bonus Question This can mask the initial stages of corrosion 50
Answer What is Paint. When you see a working rivet, replace and repaint. Working rivets can lead to inter-granular corrosion that can go undetected. 51
Bonus Question The metal used in Aircraft construction most highly susceptible to corrosion 52
Answer What is Magnesium. 53
Bonus Question One of two basic methods of corrosion removal 54
Answer 4 What is chemical or mechanical. Know when to use which one. 55
Do burn certs matter?
Drag and proper air flow.
Hardware Selection. Commercial grade hardware found in hardware or automotive stores is legal l to use on an experimental airplane but is not recommended by the FAA. Common steel bolts purchased from a hardware store are made of low carbon steel that has a low tensile strength usually in the neighborhood of 50,000 to 60,000 psi. They also bend easily and have little corrosion protection. ti In contrast, aircraft bolts are made from corrosion resistant steel and are heat treated to a strength in excess of 125,000 psi. The same comparison applies to most hardware items.
Hardware Selection. AC43-13 presents a table of torque values for nuts and bolts. It shows fine thread and coarse thread series with a minimum and maximum torque limit it in inch pounds. Use a torque wrench whenever possible. Critical installations should definitely be torqued to proper values.
Rules for hardware also apply to Fasteners!
Hardware Selection. Do not assume the engineer role by using hardware or fastener types or sizes that are contrary to your plans or assembly manual. A torque wrench is not that expensive and will be a worthwhile investment for a custom builder.
Torque and Tool Calibration Be absolutely sure your measuring tools are accurate. 62
Bonus Question The amount of torque applied upon a bolt is dependent on what two things 63
Answer What is Length of Wrench and Amount of Force. What is that formula? 64
Bonus Question Torque wrenches should always be stored this way 65
Answer At it s LOWEST SETTING or with NO TORQUE 66
Safety belts
A word about the 4 point harness system. For this reporting period (FY2017Q2) there was one (1) accident reported. The one (1) Q1 accident occurred during 14 CFR Part 91 operations. * A Maule MX7 suffered a loss of control while attempting to land with a tailwind gusting to 23 kts. Pilot received non-fatal injuries. For this reporting period (FY2017Q2) there were two (2) incidents reported. One Q2 incident occurred during 14 CFR Part 91 operations, and one during CFR Part 135. *A Cirrus with a frosted over windscreen taxied into an Experimental airplane on the ramp. The airplane was being operated under CFR 135. *An 8KCAB (Decathlon) suffered blown tire on touchdown. 68
Wiring selection -
When troubleshoot and repairing wiring circuits use caution when choosing the proper wire type and size for a repair. It is important to use proper tools, quality materials. The chart on the previous slide is a chart found in AC 43.13. 70
Spark plugs and setting of spark plug gap clearance.
Anytime you replace or reinstall a spark plug you must be certain it has the proper gap clearance. Improper gap may affect fuel burn efficiency or cause misfire. Use the correct tool to clean and gap the spark plug. Plugs also require specific torque. 72
Bonus Question 1 on Spark Plugs Do you or do you not apply anti seize compound on the spark plug threads? When was the last time your torque wrench was calibrated? What would you do if you drop a spark plug on the floor? It is wise to discard it for new. Are you sure the right plugs were previously installed? DO NOT assume anything and always check manufacture recommendations and parts requirements!! 73
Bonus Question The distance from the plug gasket to the end of the threaded portion of the plug 74
Answer REACH. It is essential to install a spark plug with the correctly required reach. 75
Bonus Question Prevents Radio Frequency (RF) produce by the ignition system of a piston engine from interfering with Avionics Equipment 76
Answer Shielding. 77
Bonus Question Carbon deposits on a plug are an indication of engine operation with what type mixture 78
Answer Too RICH. 79
Bonus Question 4 on Spark Plugs Who determines the choice of Spark Plug to be used in an Aircraft Engine 80
Answer 4 on Spark Plugs The ENGINE MANUFACTURER. 81
Bonus Question An Under-torqued spark plug can cause poor heat conduction which may lead to 82
Answer What is a HOT SPOT and/or PRE-IGNITION 83
Bonus Question Black Oily deposits on a plug and missing at lower power settings indicates 84
Answer What is OIL FOULING. Oil on spark plugs can be caused by failing valve stem guides and bad stem seals. As pressure builds up in the crankcase, excessive oil enters the combustion chamber through wornout piston rings or cylinder walls and forces its way to spark plugs. The most common sign of spark plug fouling is engine misfires. Oil blocks the electrical current needed to create sparks that combust fuel, leading to poor performance, higher fuel consumption and bad emissions. Misfiring engines can shake badly during idling and can cause engine mounts eventually ent to fail. 85
Bonus Question Can you remove a data plate from a type certificated engine? 86
Answer What is Yes, with permission from the FAA. 87
Bonus Question Do Airworthiness Directives Apply to Experimental Aircraft? 88
Answer Yes, if listed in the applicability section. 89
A Word About Condition Inspections Applicability to Part 43 performance rules Operating limitations. Knowing the requirements to protect your investment! 90
A Word About Condition Inspections Appendix D vs. Recommended Condition inspection in AC 90-89A and the Mechanics Handbook. 91
Questions? 92