AC 27-1B, Chg 1 2/12/03
MANUAL IDENTIFICATION) ATTACHMENT 2
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PROCEDURES INFORMATION The procedures information in this appendix is not a requirement. It is intended as guidance to assist the applicant in preparing procedures for Instructions for Continued Airworthiness (ICA).
An ICA is required when field maintenance personnel are authorized to remove, disassemble, assemble, clean, inspect, check, repair, replace, install, service, lubricate, test, troubleshoot, adjust, or apply a protect treatment to a rotorcraft, its engine(s), rotor(s), or appliances.
The following topics should be considered when preparing procedures for an ICA.
1. Provide general information about the appliance.
2. Provide a description of the appliance in the procedures.
3. Specify any necessary precautions to be taken during the procedures and include them in Notes, Cautions, and Warnings.
4. Specify tool(s), special tool(s), or equipment required for the procedures.
5. Specify torque value(s) for the appliances and attaching hardware.
6. Provide information to gain access to the appliance.
7. Consumable Materials should be identified by specification/part number, product name, or manufacturer.
8. Identify the appliance that is to be removed, disassembled, cleaned, inspected, checked, repaired, replaced, assembled, checked, serviced, tested, adjusted, or operated.
9. Develop order and method procedures for removing, and/or replacing the appliance, including a procedure to protect opening, lines, and hoses, etc., from contamination.
10. Develop order and method procedures for disassembly and assembly of the appliance, including any special process required and safety precautions.
11. Develop order and method procedures for cleaning the appliance, including any special process(es) to be used during cleaning. Identify type of cleaning materials.
12. Specify what inspections or checks are required and their interval. Develop order and method for inspecting the appliance, including special inspection techniques, standards and limits. Describe what actions are to be taken when appliance is found unacceptable.
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(MANUAL IDENTIFICATION) ATTACHMENT 2
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
PROCEDURES INFORMATION (Continued)
13. Develop order and method procedures for making the repair. Identify the type of damage and limits that can be repaired and specify inspection required before the repair can be made. Specify special process(es) to be used to make the repair and acceptable repair materials.
14. Develop order and method procedures for applying protective treatment to the appliance, including any special process(es) to be used during treatment. Specify the type of protective material to be used.
15. Develop order and method procedures for installation of the appliance. Specify special procedure and process(es) to be used. Specify measurements, clearances, and torques for the appliance being installed.
16. Develop order and method procedures for servicing, lubricating, or draining the appliance. Specify the type of servicing material, the quantity, and limits. Specify safety equipment and safety precautions.
17. Develop order and method procedures for testing the part. Specify the type of test and equipment required for the test, including location of connection points. Specify test standards and limits for the appliance being tested. Describe what action should be taken when the test results are unacceptable.
18. Develop order and method procedures for troubleshooting the appliance. Provide troubleshooting information, problem malfunction, and remedial actions.
19. Develop order and method procedures for adjusting the appliance. Specify location for adjusting, and the standards and limits of adjustments. Specify special tool(s) or equipment required to make adjustments. Describe actions to be taken when adjustment is past limits.
Provide safety precautions and safety equipment required for adjustment.
20. Develop order and method for safetying or securing the appliances and specify the types of safetying devices.
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AC 27-1B, Chg 1 2/12/03 (MANUAL IDENTIFICATION) ATTACHMENT 3
ATA CHAPTER LISTINGS Listed below are the ATA chapters and their titles.
AIRCRAFT GENERAL STRUCTURAL Chapter 4 Airworthiness Limitations Chapter 51 Standard Practices - Structure Chapter 5 Inspection Requirements Chapter 52 Doors Overhaul Requirements Chapter 53 Fuselage Chapter 6 Principal Dimension Chapter 54 Nacelles and Pylons Chapter 7 Lifting and Shoring Chapter 55 Stabilizers Chapter 8 Leveling and Weighing Chapter 56 Windows Chapter 9 Towing and Taxing Chapter 10 Parking and Mooring Chapter 11 Placards and Markings Chapter 12 Servicing
AIRFRAME SYSTEMS Chapter 20 Standard Practices - Airframe Chapter 21 Air Conditioning Chapter 22 Autoflight Chapter 23 Communications Chapter 22 Autoflight Chapter 23 Communications ROTORS Chapter 60 Standard Practices -Rotors Chapter 62 Main Rotor Chapter 63 Main Rotor Drive Chapter 64 Anti Torque Chapter 65 Anti Torque Drive Chapter 66 Folding Blades Chapter 67 Rotor Flight Controls Chapter 24 Electrical power Chapter 25 Equipment and Furnishings POWERPLANT Chapter 26 Fire Detection Chapter 70 Standard Practice Engines Chapter 28 Fuel Chapter 71 Powerplant Chapter 29 Hydraulic Power Chapter 72 Engine Chapter 30 Ice and Rain Protection Chapter 73 Engine Fuel and Control Chapter 31 Indicating and Recording Chapter 74 Ignition Chapter 32 Landing Gear Chapter 75 Engine Air Chapter 33 Lights Chapter 76 Engine Controls Chapter 34 Navigation Chapter 77 Indicating Chapter 35 Oxygen Chapter 78 Exhaust Chapter 36 Pneumatics Chapter 79 Oil Chapter 37 Vacuum Chapter 80 Starting Chapter 45 Centralized Maintenance Sys Chapter 83 Gear Boxes Chapter 49 Airborne Auxiliary Power REVISION: (DATE) Revision 3 Page 1 Page Apdx A - 60
(MANUAL IDENTIFICATION)
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AC 27-1B, Chg 1 2/12/03 (MANUAL IDENTIFICATION) ATTACHMENT 4
TYPE DESIGN CHANGE
ICA RECOMMENDED PROCEDURES The following information is intended for guidance to assist the applicant in preparing an ICA.
For this sample, we will use a twidget, which is a sounder attached to an extendible cable assembly connected to a pivoting arm, which is mounted to the side of the fuselage structure at the right cabin door forward frame.
NOTE: The twidget manufacturer's ICA does not meet the requirements of Appendix A and cannot be referenced.
The following step-by-step procedure in this sample can be used to prepare an ICA for that appliance:
1. Determine the following:
a. What modifications to the rotorcraft will be required.
b. Determine what appliances will be replaced or added to the rotorcraft.
c. Determine which ATA chapters of the original rotorcraft manufacturer's maintenance manual will be affected by this TDC and which additional ATA chapters will be affected.
2. Review Appendix A, Part 27. Using the information derived in paragraph 1, determine which paragraphs are applicable and which are not applicable. As defined in Figure 2, provide the status of each requirement on the applicable paragraph. If the requirement is not applicable, place an NIA within the parentheses ( ). Address the remaining requirements in the ICA. A completed document for the twidget installation (see Figure 2) is included.
3. Prepare the ICA, which includes the applicable requirements specified in Appendix A to Part 27. This can be done by using the information provided in the Instructions for Continued Airworthiness Template. The regulatory requirements in the sample manual are in bold type.
Information to be copied is in normal type. Information in italics is for information only and should not be copied. See Instructions for Continued Airworthiness sample manual.
4. Ensure that the ICA includes the following:
a. A Cover Page, which will readily identify the publication as the applicant's ICA for that make and model rotorcraft.
b. A List of Effective Pages, which lists each page in the ICA and its revision number and revision date.
c. A Record of Revisions Page for listing the revisions which have been inserted in the ICA.
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(MANUAL IDENTIFICATION) ATTACHMENT 4
TYPE DESIGN CHANGE
ICA RECOMMENDED PROCEDURES (Continued)
5. Table of Contents is not required, but we recommend that it be included in the ICA.
6. Audit the proposed ICA to ensure the applicable requirements have been included. Edit the ICA document to ensure it does not contain incorrect terminology or incorrect references and determine it does contain correct spelling, proper grammar, and accurate information.
7. When referring to another publication, ensure the information in the referenced publication meets the requirements of Appendix A, Part 27. It is the responsibility of the applicant to obtain authorization to use the information contained in the referenced publication. Submit a copy of each publication referenced in the applicant's ICA.
8. Submit two complete copies of the proposed ICA in binders, a copy of the completed Figure 1 document, and a copy of any referenced publication to the FAA/AUTHORITY in sufficient time to allow for evaluation prior to the date acceptance is needed. The average turnaround time is 20 to 30 days depending on the workload at that time.
9. When FAA/AUTHORITY receives the applicant's proposed ICA, the applicant and the appropriate FAA/AUTHORITY are notified. FAA/AUTHORITY reviews and evaluates the ICA in the order they are received.
10. • If FAA/AUTHORITY finds the applicant's ICA does not meet the requirements, the review will be discontinued, and the applicant will be notified.
11. When the proposed ICA document, excluding the Airworthiness Limitations Section, is determined to be acceptable, the FAA/AUTHORITY will stamp, sign, and date the ICA. The applicant will be notified of the acceptance.
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AC 27-1B, Chg 1 2/12/03 (MANUAL IDENTIFICATION) ATTACHMENT 4
TYPE DESIGN CHANGE
ICA RECOMMENDED PROCEDURES (Continued) Twidget Type Design Change Attachment 2
1. Use the list of appliances and modifications required for that Type Design Change (TDC) to determine which ATA chapters of the original rotorcraft manufacturer's maintenance manual the TDC will affect and which additional ATA chapters will be affected.
2. The following are component and systems that will be affected by the Twidget TDC:
a. Fuselage structure will be modified to mount twidget arm assembly.
b. Cabin door will be modified.
C. Electrical power will be required for electrical motor.
d. Hydraulic power source will be required for deploying and storing twidget arm.
e. Twidget control assembly will be installed in the cabin.
f. Control will be mounted in cockpit for emergency release of the twidget..
g. An Instrument will be installed in instrument panel indicating twidget's position.
h. Iwidget recording equipment and monitor will be mounted in cabin.
i. Twidget antenna will be mounted on belly of fuselage.
j. . Cables and wiring will be routed through rotorcraft.
k. Two-way communication will be required between the pilot and twidget operator.
1. Twidget gearbox requires servicing to full mark on site gage every 50 hours.
m. Twidget arm assemblies and clutch requires lubrication every 100 hours.
n. Iwidget installation requires an inspection every 300 hours.
o. Twidget arm assembly requires an ultrasonic test every 600 hours.
p. Clutch has a wear tolerance of 1.56 mm.
q. Clutch is life-limited to be replaced every 1,000 hours time in service.
r. Twidget gearbox is required to be overhauled every 1,000 hours time in service.
s. Iwidget gearbox attach bolt torque is 75-ft lb. and twidget arm assembly torque is 110 in Ib.
t. Warning: Twidget should be retracted during takeoff, landing, and cruise above 85 knots.
u. Caution: Do not tow or taxi the rotorcraft with the twidget arm deployed.
v. Placards are required on the twidget unit and in the cockpit.
3. This example TDC will affect ATA-100 chapters: 4 Airworthiness Limitations, 5 Inspection, 6 Dimensions, 9 Towing and Taxiing, 10 Parking and Mooring, 11 Placards, 12 Servicing, 23 Communication, 24 Electrical, 25 Furnishings, 29 Hydraulic, 31 Indication and Recording, 52 Doors, and 53 Fuselage. A Chapter 1 Introduction is also needed.
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(MANUAL IDENTIFICATION) ATTACHMENT 4
TYPE DESIGN CHANGE
ICA RECOMMENDED PROCEDURES (Continued) INFORMATION:
Attachment 4 includes a Figure 2 for Thomas Copter Mods TDC to affix a Twidget installation on Thomas Copter model T-97J helicopter.
Figure 2 is intended to assist in determining which requirements are applicable to this certification project. The document contains each requirement with a set of parentheses, the appropriate regulation, and the location of information in the applicant's ICA.
Information obtained from Attachment 4 can be used to determine which requirements are applicable. For requirements that are not applicable, place an NIA in the parentheses. All other requirements would be applicable to the certification project. Place a Y if the required information is included in ICA. Figure 2 has been completed for the sample Twidget TDC.
Applicant that uses and completes Figure 1 and indicates the location of that information in the applicant's proposed ICA will reduce the time required to evaluate the ICA.
It is important that the applicant include the project number or numbers associated with the ICA, the name of the appropriate FAA/AUTHORITY office, the name of the project engineer, the applicant's company name, the make and model of rotorcraft being modified, and the date.
The completed Figure 1 should be submitted to FAA/AUTHORITY with the applicant's ICA.
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AC 27-1B, Chg 1 2/12/03 (MANUAL IDENTIFICATION) ATTACHMENT 4
TYPE DESIGN CHANGE
ICA RECOMMENDED PROCEDURES (Continued) APPENDIX A PART 27 REQUIREMENTS The following is a breakdown of Appendix A to FAR/JAR Part 27 and is intended to provide guidance to assist an applicant for a Type Design Change under a Type Certificate (TC), Supplemental Type Certificate (STC), or Field Approval (FA) requiring Instructions for Continued Airworthiness (ICA). The breakdown is intended to provide guidance to assist an applicant in understanding the ICA requirements of FAR/JAR § 27.1529. An applicant may use the guidance to prepare the ICA. Completion of this appendix will provide information needed for the evaluation and will reduce the time required for evaluation of the proposed ICA.
() Status of ICA: Y = Yes included; N/A = non-applicable. The Location Column lists the page number in the Applicant's ICA that contains the information.
Project Number(s) ST01998RC-R ACO/FSDO: Rotorcraft ACO Project Engineer: Data Mastermine Applicant: Thomas Copter Mods Make: Thomas Copter Model: T97-J Date June 18, 1998 Requirement Regulation Location (NIA) ICA for each engine A27.1(b) N/A (NIA) ICA for each rotor A27.1(b) N/A (Y) ICA for each appliance required by this chapter A27.1(b) * All (Y) Any required information relating to the interface of the A27.1(b) See (Y) appliances, (N/A) engines and (N/A) rotors with the rotorcraft. NOTE 1 (Y ) If ICA are not supplied by the manufacturer of an A27.1 * All (NA) appliance, (NA) engine or (NIA) rotor installed in the rotorcraft, the ICA for the rotorcraft must include (Y ) the information essential to the continued airworthiness of the rotorcraft.
(Y ) A program showing how changes to the applicant's ICA will be A27.1(c) ATA O distributed.
(NIA) A program showing how changes to the ICA of the A27.1(c) N/A manufacture of the engine(s), rotor(s) and appliances installed in the rotorcraft will be distributed, if referenced in applicant's ICA (Y ) ICA that must be in a form of a manual or manuals as A27.2(a) * All appropriate for the quantity of data.
(Y ) A format of the manual or manuals which must provide for a A27.2(b) * All practical arrangement.
(Y) Content prepared in the English language. A27.3 * A11 Figure 2 REVISION: (DATE) Revision 4 Page 5 Page Apdx A - 66
( MANUAL IDENTIFICATION) ATTACHMENT 4
TYPE DESIGN CHANGE
ICA RECOMMENDED PROCEDURES (Continued) Requirement Regulation Location (Y ) Introduction information that includes (Y ) an explanation of A27.3(a)(1) ATA O the rotorcraft's features and (Y) data to the extent necessary for maintenance and preventive maintenance.
(Y ) A description of the (IN/A) rotorcraft and its systems and A27.3(a) (2) ATA 25 installations, (N/A) engines and its systems and installations, (NA) rotors and its systems and installations, (Y ) appliances and its systems and installations.
(Y) Basic control and operating information describing (Y A27.3(a) (3) ATA 25 ) how the rotorcraft components and systems are controlled and (Y ) how the rotorcraft components and systems are operated including (Y) any special procedure and limitations.
(Y ) Servicing information that covers details regarding (Y A27.3(a) (4) ATA 12 ) servicing points, (NA) capacities of tanks, (Y ) capacities of reservoirs, (Y ) types of fluids to be used, (Y ) pressures applicable to the various systems.
(Y ) Location of access panels for (Y ) inspection and (Y A27.3 (a) (4) See ) servicing. NOTE 2 (Y) Servicing information that covers details regarding (Y A27.3(a) (4) ATA 12 ) locations of lubrication points, (Y ) the lubricant to be used.
(Y) Equipment required for servicing. A27.3(a) (4) ATA 12 (Y ) Tow instructions and limitations. A27.3(a) (4) ATA 9 (Y) Mooring information A27.3(a)(4) ATA 10 (NA) Jacking information A27.3(a) (4) N/A (NA) Leveling information A27.3(a) (4) NA (Y ) Scheduling information for each part of the (Y ) rotorcraft A27.3(b)(1) See that, provides the recommended periods at which they should (Y) NOTE 3 cleaned, (Y) inspected, (Y ) adjusted, (Y ) tested, lubricated and (Y) the work recommended at these periods.
(NA) Scheduling information for the (NA) rotorcraft's engine(s) A27.3(b)(1) N/A that provides the recommended periods at which they should be (IN/A) cleaned, (IN/A) inspected, (IN/A) adjusted, (N/A) tested, (N/A) lubricated and (N/A) the work recommended at these periods.
NOTE: This information may be in the FAA/AUTHORITY accepted engine ICA.
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AC 27-1B, Chg 1 2/12/03 (MANUAL IDENTIFICATION) ATTACHMENT 4
TYPE DESIGN CHANGE
ICA RECOMMENDED PROCEDURES (Continued) Requirement Regulation Location (NA) Scheduling information for the (N/A) rotorcraft's auxiliary A27.3(b)(1) N/A power unit(s) (APU) that provides the recommended periods at which they should be (NA) cleaned, (N/A) inspected, (N/A) adjusted, (N/A) tested, (N/A) lubricated and (N/A) the work recommended at these periods.
(N/A) Scheduling information for the (N/A) rotorcraft's rotor(s) that A27.3(b)(1) N/A provides the recommended periods at which they should be (N/A) cleaned, (N/A) inspected, (N/A) adjusted, (N/A) tested, (NA) lubricated and (IN/A) the work recommended at these periods.
(Y ) Scheduling information for the (Y ) rotorcraft's accessories A27.3(b)(1) See that provides the recommended periods at which they should be (Y ) NOTE 3 cleaned, (Y) inspected, (Y ) adjusted, (Y ) tested, (Y ) lubricated and (Y) the work recommended at these periods.
(Y) Scheduling information for the (Y ) rotorcraft's instruments A27.3(b)(1) See that provides the recommended periods at which they should be (Y ) NOTE 3 cleaned, (Y ) inspected, (Y ) adjusted, (Y ) tested, (Y ) lubricated and (Y) the work recommended at these periods.
(Y ) Scheduling information for the (Y ) rotorcraft's equipment A27.3(b)(1) See that provides the recommended periods at which they should be (Y NOTE 3 ) cleaned, (Y) inspected, (Y) adjusted, (Y ) tested, (X) lubricated and (Y) the work recommended at these periods.
(1) The degree of inspection for each part of the (NA) rotorcraft A27.3(b)(1) ATA 5 and its (N/A) engine(s), (N/A) auxiliary power unit, (INVA) rotor(s), (Y ) accessories, (Y ) Instruments and (Y ) equipment.
(Y) The applicable wear tolerances A27.3(b)(1) ATA 25 The applicant may refer to an (NA)accessory, (NA) instrument, or A27.3(b)(1) N/A (NA) equipment manufacturer as the source of this information if the applicant shows (NIA) that the item has an exceptionally high degree of complexity requiring specialized maintenance techniques, test equipment, or expertise.
(1) The recommended overhaul periods and necessary cross A27.3(b)(1) ATA 5 references to the Airworthiness Limitation Section.
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(MANUAL IDENTIFICATION) ATTACHMENT 4
TYPE DESIGN CHANGE
ICA RECOMMENDED PROCEDURES (Continued) Requirement Regulation Location (Y) An inspection program that includes (Y ) the frequency and ( 427.3(b)(1) ATA 5
1) extent of the inspection necessary to provide for the continued airworthiness of the rotorcraft.
(Y) Troubleshooting information describing (Y ) problem A27.3(b)(2) See malfunctions, (Y) how to recognize those malfunctions and (Y NOTE 4 ) the remedial action for those malfunctions.
(N/A) Information describing the order and method of A27.3(b)(3) N/A (NA) removing and (NA) replacing engine(s) with any necessary precautions to be taken.
(NA) Information describing the order and method of A27.3(b)(3) N/A (NA) removing and (NA) replacing rotor(s) with any necessary precautions to be taken.
(Y) Information describing the order and method of (Y A27.3(b)(3) ATA 25 ) removing and (Y ) replacing parts with any necessary precautions to be taken.
(Y) Other general procedural instructions including (NA) storage A27.3(b)(4) ATA 8 limitations and procedures for (NIA) testing system during ground running, (N/A) making symmetry checks, (Y ) weighing and determining the center of gravity, (IN/A) lifting, (IN/A) shoring.
(NA) Diagrams of structural access plates and information needed A27.3(c) N/A to gain access for inspections when access plates are not provided.
(NA) Details for the application of special inspection techniques A27.3(d) N/A including radiographic and ultrasonic testing where such process are specified.
(NA) Information needed to apply protective treatment to structure A27.3(e) N/A after inspection.
(Y) All data relative to structural fasteners such as (Y A27.3(Đ) ATA25 ) identification, (Y) discarded recommendations, and (X) torque values.
(Y) A list of special tools needed A27.3(g) NOTE 5 (Y) The Instructions for Continued Airworthiness must contain a A27.4 ATA 4 section, titled Airworthiness Limitations that is (X) segregated and (Y ) clearly distinguishable from the rest of the document. NOTE: The Airworthiness Limitations Section in the applicant's ICA will be evaluated by the appropriate FAA/AUTHORITY.
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