- AC 29-2C, Chg 1 2/12/03 (MANUAL IDENTIFICATION) CHAPTER 1 INTRODUCTION (continued)
12. SYMBOLS. Symbols used in the ICA should be listed with explanations in the Introduction of the ICA.
13. PRECAUTIONS. Precaution means a measure taken beforehand to prevent harm.
a. Any necessary precautions to be taken must be included in the ICA. Reference Appendix A, A29.3 (b)(3).
b. The following examples of precautions will differ due to the seriousness of the hazard or condition:
(1) WARNING: Could be a maintenance procedure, practice, condition, etc. that could result in personal injury or loss of life.
(2) CAUTION: Could be a maintenance procedure, practice, condition, etc. that could result in damage or destruction of equipment.
(3) NOTE: Could be a maintenance procedure, practice, condition, etc., or a statement which needs to be highlighted.
14. UNITS OF MEASUREMENT
a. The ICA contains units of measurements. These measurements could be instrument readings, temperatures, pressures, tolerances, limits, or torque values.
b. It is recommended the ICA contains both United States standard measurements and Metric measurement, for each measurement, tolerance, or torque value. A general conversion chart is not acceptable.
15. ICA FOR EACH ENGINE
a. The ICA must include ICA for each engine. Reference Appendix A, A29.1 (b).
b. ICA for type certificated engines are accepted by the FAA/AUTHORITY responsible for engines and could be included by reference in the applicant’s ICA.
c. ICA for non-type certificated engines are prepared by the applicant and submitted to appropriate FAA/AUTHORITY for review and evaluation.
16. ICA FOR EACH ROTOR
a. The ICA must include ICA for each rotor. Reference Appendix A, A29.1 (b).
b. ICA for rotors is normally included in the rotorcraft ICA.
17. ICA FOR EACH APPLIANCE REQUIRED BY THIS CHAPTER
a. The ICA must include ICA for each appliance required by FAR/JAR.
Reference Appendix A, A29.1 (b).
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(MANUAL IDENTIFICATION) CHAPTER 1 INTRODUCTION (continued)
b. FAA/AUTHORITY-accepted ICA for an appliance could be included by reference in the applicant’s ICA.
c. When an appliance is required to be installed by a TDC, or the appliance is required by FAR/JAR and the applicant must prepare ICA that is acceptable to the FAA/ AUTHORITY.
d. The FAA/AUTHORITY-accepted appliance ICA normally does not address interface information. The applicant should prepare information on how that appliance interfaces with the rotorcraft. Interface information should include appliance location, appliance attachment, if applicable the system(s) from which the appliance receives it electrical power, fluid (fuel, oil, hydraulic, etc.), vacuum, pneumatic, etc., and how the appliance is controlled.
e. When the ICA for an appliance is not FAA/AUTHORITY accepted, the applicant should prepare the ICA for that appliance which meets the requirements specified in Appendix A to FAR/JAR Part 29. The ICA for each appliance could be a stand-alone document or could be included in the applicant’s ICA document for that TDC.
f. When an original appliance is replaced with a different appliance as part of the TDC, the applicant should prepare the ICA for that appliance which meets the requirements specified in Appendix A to FAR/JAR Part 29. A different appliance is one that has a different part number, or model number, or is made by the same manufacturer or different manufacturer.
g. As defined in FAR/JAR Part 1, Appliance means any instrument, mechanism, equipment, part, apparatus, appurtenance, or accessory, including communications equipment, that is used or intended to be used in operating or controlling an aircraft in flight, is installed in or attached to the aircraft, and is not part of an airframe, engine, or propeller. Avionics equipment is an appliance.
NOTE: Some applicants may wish to include Amendment 20 to FAR/JAR Part 29 in the certification basis for their TDC and prepare the ICA for their TDC even though the certification basis for the rotorcraft does not require acceptance of the ICA by the FAA/AUTHORITY. These applicants will be required to obtain FAA/AUTHORITY acceptance for their ICA.
18. INFORMATION ESSENTIAL TO THE CONTINUED AIRWORTHINESS OF THE
ROTORCRAFT
a. If ICA are not supplied by the manufacturer of an appliance or product (engine or rotor), the ICA must include the information essential to the continued airworthiness of the rotorcraft. Reference Appendix A, A29.1(b).
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AC 29-2C, Chg 1 2/12/03 (MANUAL IDENTIFICATION) CHAPTER 1 INTRODUCTION (continued)
b. The applicant should include in their ICA the information necessary to service, maintain, and inspect the rotorcraft, its engines, rotors, and appliances, in an airworthy condition and ensure they meet type design. Appendix A to FAR/JAR Part 29 specifies minimum requirements. The applicant determines the information essential to the continued airworthiness.
c. The information essential to the continued airworthiness of the rotorcraft its engines, rotors and appliances could be contained in the applicant’s ICA, engine ICA, appliance ICA or other applicant-associated publications, i.e., overhaul manuals, illustrated parts catalog, or flight manual. Those ICA’s and associated publications that are listed in the applicant’s List of Applicable Publications (LOAP) constitute the information essential for continued airworthiness for that rotorcraft, its engines, rotors, and appliances or that TDC. The LOAP is contained in the Introduction section of the applicant’s ICA. The LOAP should contain one of the following statements: “The publications listed in the LOAP constitute the information essential for continued airworthiness for the rotorcraft” or “The publications listed in the LOAP constitute the information essential for continued airworthiness for the TDC.”
19. REFERENCED INFORMATION
a. Appendix A to FAR/JAR Part 29 allows an applicant to refer to an accessory, instrument, or equipment manufacturer as the source of this information if the applicant shows that the item has an exceptional high degree of complexity requiring specialized maintenance techniques, test equipment, or expertise.
b. When the applicant has shown that the accessory, instrument, or equipment meets the requirements of 19a above, the manufacturer’s information could be referred to as the source of the information. The information refers to those specified in Appendix A, Section A29.3, Contents, Paragraph (b)(1). The applicant has responsibility for securing authorization to use that information in their ICA.
c. The information is limited to scheduling for each of the accessories, instruments, and equipment that provides the recommended periods at which they should be cleaned, inspected, adjusted, tested, and lubricated. In addition, they could be the source of information for the degree of inspection, applicable wear tolerances, and work recommended at these periods.
d. The FAR/JAR allows an applicant to refer to Engine ICA and Appliance ICA, which are FAA/AUTHORITY-accepted, and the applicant’s associated publications in the applicant’s ICA.
See Introduction Section, Paragraph’s 15, 16, and 17.
e. Any ICA or associated publications referenced in the applicant’s ICA should be submitted with the applicant’s ICA.
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(MANUAL IDENTIFICATION) CHAPTER 1
INTRODUCTION (Continued)
20. DISTRIBUTION
a. The ICA must include a program to show:
(1) Distribution of changes to the ICA made by the applicant.
(2) Distribution of changes to the ICA made by the manufacturer of the engine or engines, rotor or rotors, and appliances installed on the rotorcraft.
Reference Appendix A, A29.1 (c).
b. The introduction of the applicant’s ICA should contain the procedure used to distribute changes to persons who maintain the rotorcraft or who have incorporated the TDC.
c. When the applicant has referenced FAA/AUTHORITY accepted publications in their ICA, the procedure used to ensure changes to those referenced publications are distributed to persons who maintain the rotorcraft or who have incorporated the TDC. The procedures should be explained in the introduction of the applicant’s ICA.
d. ICA normally includes a procedure for making changes to the applicant’s ICA. The introduction should include a description of the revision procedure. The procedure should contain information on the type of revisions, composition of the revision, revision control procedure, revision log page, updating procedure, and procedure for purchase of revisions and renewal of subscription.
21. ROTORCRAFT FEATURES
a. The ICA must include introduction information that includes:
(1) An explanation of the rotorcraft’s features; and,
(2) Data to the extent necessary for maintenance and preventive maintenance.
Reference Appendix A, A29.3 (a)(1).
b. The ICA normally contain a description which includes:
(1) The explanation of the rotorcraft’s features:
(a) General information about the rotorcraft features.
(b) Exterior features.
(c) Interior features including cockpit, and cabin.
(d) Other features.
c. A figure showing the features is helpful and does not require detailed explanation.
d. The data necessary for maintenance and preventive maintenance is normally described in the applicable chapter and is determined by the applicant.
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AC 29-2C, Chg 1 2/12/03 (MANUAL IDENTIFICATION) CHAPTER 1
INTRODUCTION (Continued)
22. CORRECTIONS TO ORIGINAL INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
a. Any correction made to Draft Instructions for Continued Airworthiness prior to FAA/AUTHORITY acceptance should have the same revision number and date as the draft page originally submitted.
b. Changes or corrections made to ICA after FAA/AUTHORITY acceptance of ICA are considered to be a revision.
23. INDICATING CHANGES TO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS The applicant could use any means to indicate changes to their ICA. The following is an example used in the ICA Template.
a. Any change to the ICA should be indicated as follows:
(1) Changes made to a line should be indicated by a vertical bar in the left margin next to the line.
(2) Changes made to a paragraph should be indicated by a vertical bar in the left margin next to the paragraph letter or number.
(3) Changes made to a complete page should be indicated by a vertical bar to the right of the page number.
b. Only revisions should contain change bars. Change bars are used to indicate changes for that revision. Previous change bars should be removed at the next revision.
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- (MANUAL IDENTIFICATION) CHAPTER 4
AIRWORTHINESS LIMITATION SECTION
1. AIRWORTHINESS LIMITATIONS INFORMATION
a. The ICA must have in the principal manual a section titled “Airworthiness Limitations.” This section should be segregated and clearly distinguishable from the rest of the maintenance manual and contain:
(1) Each mandatory replacement time.
(2) Each structural inspection interval and related structural inspection procedure approved under §§ 29.571.
(3) A legible statement in a prominent location indicating that the Airworthiness Limitations section is FAA/AUTHORITY approved and specifies required maintenance and/or inspections. The exact, required wording of this statement is found in the FAR/JAR. Reference Appendix A, A29.4
b. The Airworthiness Limitations Section will be evaluated and approved by FAA/AUTHORITY.
2. NO AIRWORTHINESS LIMITATIONS INFORMATION REQUIRED:
When the applicant’s type design has no airworthiness limitations, the Airworthiness Limitations Section of the ICA should contain the following statement:
“No airworthiness limitations associated with this type design change.”
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AC 29-2C, Chg 1 2/12/03 (MANUAL IDENTIFICATION)
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- (MANUAL IDENTIFICATION) CHAPTER 5
INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE
1. INSPECTION REQUIREMENTS
a. The ICA must include:
(1) The recommended period at which each part of the rotorcraft and its engine(s), auxiliary power unit, rotor(s), accessories, instruments and equipment shall be inspected. Reference Appendix A, A29.3 (b)(1).
(2) The degree (scope) of the inspection for each part of the rotorcraft and its engine(s), auxiliary power unit, rotor(s), accessories, instruments and equipment.
Reference Appendix A, A29.3 (b)(1).
(3) An inspection program that includes the frequency and extent of the inspection necessary to provide for the continued airworthiness of the rotorcraft. Reference Appendix A, A29.3 (b)(1).
b. This chapter should contain a schedule of the interval for all inspections. The inspection intervals may be in cycles, hours, and/or calendar time.
c. In the introduction of this chapter, it should explain all required inspections and should include:
(1) The different type of inspections.
(a) Scheduled Inspections.
(b) Special Inspections.
(c) Conditional Inspections.
(2) An explanation of each inspection.
(3) A list of all inspections (daily, 300-hour, 600-hour, annual, special inspection, etc.).
d. This chapter should contain the scope of the inspection(s). It should also describe the intent of the inspection and should address at least the following:
(1) What the inspector should be looking for when inspecting the product or appliance.
(cracks, corrosion, delamination, dents, bends, wear, etc.)
(2) Location of the product or appliance to be inspected.
(3) Any special techniques required to inspect the product or appliance.
(4) Instructions to be followed when inspecting the product or appliance.
(5) Any tools or equipment required to accomplish the inspection of the product or appliance.
(6) The wear tolerances for a product or appliance when the inspection requires the product or appliance to meet a standard.
e. This chapter should contain an inspection program which contains an outline of the order of the inspections and instructions to be followed during the inspection and should include:
(1) General information such as:
(a) The title of the inspection.
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AC 29-2C, Chg 1 2/12/03 (MANUAL IDENTIFICATION) CHAPTER 5
INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE (continued)
(b) Aircraft information (registration number, serial number, total time in service).
(c) General information about the inspection.
(d) Provide a block for the inspector or maintenance personnel to initial when each item has been inspected or action taken.
(e) Provide a signature line for the inspector and maintenance personnel to sign when the inspection has been accomplished.
(f) Provide a place to enter the date the inspection was completed.
(2) Pre-Inspection activities such as:
(a) Maintenance records review.
(b) Airworthiness Directive review.
(c) Overhaul and Life Limits requirements review.
(3) Maintenance Practices are associated with an inspection such as:
(a) Removal of cowling, panels, plates and covers to access items being inspected.
(b) Cleaning of the item to be inspected. Specify type and number of cleaning material.
(c) Specify tools and/or equipment required for the particular inspection, i.e., Torque wrench, Hydraulic unit, etc.
(4) The Inspection should include:
(a) Locate the item(s) to be inspected.
(b) Identify what the inspector should be inspecting for (security, wear, damage, corrosion, etc.)
(c) Instructions specified for that inspection.
(d) Using the required Inspection techniques.
(e) Using tools and equipment specified for that inspection.
(f) Determine that the item(s) being inspected meet the airworthiness standard established for that product or appliance.
(g) Recording of inspection findings.
# NOTE: Most of the above information is normally contained in an inspection form which inspection personnel could copy and use.
(5)Type of action to be taken when inspected item is unsatisfactory.
(6 Post Inspection actions such as:
(a) Application of protective coatings removed for inspection.
(b) Servicing and lubrication requirements
(c) Installation of cowling, panels, plates and covers removed for inspection.
(d) Post inspection run up and system operation.
(e) Maintenance record entry.
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(MANUAL IDENTIFICATION) CHAPTER 5
INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE (continued)
f. If applicable this chapter should include any Special Inspection Techniques such as:
(1) Radiographic
(2) Ultrasonic
g. Inspection interval extension statement in the ICA is not acceptable to the FAA. For those airworthiness authorities that allow extensions, the following statement should be included in this chapter:
“Inspection interval extension may be used if approved by the airworthiness authority.”
2. COMPONENT OVERHAUL SCHEDULE
a. The ICA must include:
(1) The recommended overhaul periods.
(2) Necessary cross-references to the Airworthiness Limitations Section.
Reference Appendix A, A29.3 (b)(1).
b. The Component Overhaul Schedule normally includes:
(1) Component’s Part Number.
(2) Component’s Nomenclature.
(3) Time Between Overhaul Interval in Hours or Calendar time.
c. Notes may be used to provide information about the requirements.
3. NO OVERHAUL REQUIREMENTS
a. When there are no overhaul requirements, the following statement should be included in Chapter 5 of the ICA.
“No component overhaul required for this type design.”
4. INSPECTION EXAMPLE
a. To assist in preparing an inspection program, an Inspection Example is provided on the next page. We recommend making the Inspection Example an Appendix and last page of the ICA, so maintenance personnel can copy the Inspection Program, add the STC inspection to the rotorcraft’s inspections, and use it to inspect the appliance.
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AC 29-2C, Chg 1 2/12/03 (MANUAL IDENTIFICATION) INSPECTION EXAMPLE: 100-Hour Inspection N________ Serial Number ______________ Aircraft Hours_________ Total Time __________ The 100-Hour Inspection shall be accomplished each 100 hours time-in-service.
Initial each item after accomplishing the inspection.
Record all findings and attach a copy to this inspection form.
After correction of all findings, make maintenance record entry.
PRE-INSPECTION INITIAL EACH ITEM AFTER ACCOMPLISHMENT INITIAL
1. Describe pre-inspection actions Example: 1. Review Rotorcraft and Engine Maintenance Records.
Example: 2. Review Airworthiness Directives.
MAINTENANCE PRACTICES INITIAL EACH ITEM AFTER ACCOMPLISHMENT INITIAL
1. Describe access panel to be removed and door to be opened.
Example: 1. Remove access panel P3, P4, P5, P6, P7, P8, D1, D5, D10, D15 etc.
2. Describe maintenance action required to accomplish the inspection.
Example: 1. Clean (appliance) using Arro ACR-223 solvent.
Example: 2 Lubricate (appliance) in accordance with Chapter 12.
3. Describe Special tool and equipment required for the inspection.
Example: 1. Place jacks under helicopter and jack up aircraft.
Example: 2. Use a 10-power magnifying glass and bright light required for inspection.
INSPECTION INITIAL EACH ITEM AFTER ACCOMPLISHMENT INITIAL
1. Describe the item being inspected, its location, and what the item is being inspected for.
Provide any special instructions or technique to be used, identify special tool required, and provide information on the standard that the item should meet.
Example: 1. (Appliance) Inspect (appliance) for cleanliness, corrosion and security.
Example: 2. (Appliance) Inspect (appliance) for scratches, dent, delamination and cracks. Cracks up to .040 may be repaired. Appliance with cracks longer than .040 part should be replaced.
Example: 3. (Appliance) Inspect (appliance) for due dates and expiration.
Example: 4. (Appliance) Inspect (appliance) for security, lack of lubrication, and freedom of movement, and wear. Acceptable wear is .003 to .005.
Example: 5. (Appliance) Inspect (Appliance) attachment nuts for correct torque. Set torque wrench to 22-inch lbs.
and torque nut. If nut moves, replace (appliance).
Example: 6. (Appliance) Inspect (Appliance) for correct operations, etc.
POST INSPECTION INITIAL EACH ITEM AFTER ACCOMPLISHMENT INITIAL Describe post actions such as protective coating, servicing or lubrication appliances, installation of access panels and doors, run up and system operations.
Example: 1 Complete maintenance practices for the inspection, i.e., install access panels and close doors opened for the inspection, remove aircraft form jacks, etc.
Example: 2 Perform run up or system operation and verify correct function and operation.
Example: 3 Complete and sign aircraft’s maintenance record entry Mechanic Name _________________________ Signature_______________________ # ______________ Inspector Name _________________________ Signature_______________________ # ______________ REVISION: (PAGE NUMBER) Revision 4 05-00-00 Page 4 Page Apdx A - 26
(MANUAL IDENTIFICATION) CHAPTER 6
DIMENSIONS AND ACCESS
1. AN EXPLANATION OF THE ROTORCRAFT FEATURES
a. The ICA must include the features of the rotorcraft.
Reference Appendix A, A29.3 (a)(1).
b. The dimensions are part of the rotorcraft’s features and normally include:
(1) Principal dimensions of the rotorcraft.
(2) Dimensions of the rotorcraft.
(a) Exterior dimensions.
(b) Interior dimensions.
(3) Layout of the rotorcraft.
(4) Divisions of the structure - zones and zonal groups.
(5) Airframe reference lines.
(a) Stations lines.
(b) Water Lines.
(c) Buttocks Lines.
2. LOCATION OF ACCESS PANELS
a. The ICA must include the location of access panels for inspection and servicing.
Reference Appendix A, A29.3 (a)(4).
b. Access information normally includes:
(1) Descriptions of access panel, plates, doors and cowlings.
(2) Location of access panels plates, doors, and cowlings.
(3) Procedure for removing and installing access panels and doors.
(4) Figures showing dimensions and locations of access panels and doors.
c. To prevent removal of all access panels, plates, doors, and cowling for each inspection, the access panels, plates, doors, and cowling should be identified. Only those identified would need to be removed for each inspection. The use of a figure to identify those access panels, plates, doors, and cowling is recommended.
3. DIAGRAM OF STRUCTURAL ACCESS PLATES AND INFORMATION NEEDED TO GAIN ACCESS FOR INSPECTION WHEN ACCESS PLATES ARE NOT PROVIDED.
a. The ICA must include structural access plate information.
Reference Appendix A, A29.3 (c).
b. If applicable, the ICA should identify those structural access plates.
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