10 can obtain approval from a DER, an ODA, or by requesting a field approval.
3.3.1.3.2 After the ASI has reviewed the data package and/or inspected the aircraft, and can approve the repair/alteration, the ASI may (1) approve the data package only, or (2) approve the repair/alteration on FAA Form 337 by physical inspection. The ASI will sign and date block 3 indicating approval. The ASI enters one of two statements:
1. First statement: “The data identified herein complies with the applicable airworthiness requirements and is approved for the above described aircraft, subject to conformity inspection by a person authorized in § 43.7.”
Note: This statement is entered on block 3 of FAA Form 337 when the ASI reviews a data package and completes data approval.
2. Second statement: “Approval by Physical Inspection, Demonstration, Testing, etc. One Aircraft: The repair or alteration identified herein complies with the applicable airworthiness requirements and is approved for the above described aircraft, subject to conformity inspection by a person authorized in § 43.7.”
Note: This statement is entered on block 3 of FAA Form 337 when the ASI makes a physical inspection of the aircraft, or the applicant satisfactorily performs a demonstration or other type of test and the ASI completes an installation or repair approval.
3.3.2 DER Data Approval.
3.3.2.1 A properly authorized DER is a designee of the FAA whom an applicant may employ to provide approved technical data to support a major repair/major alteration. A DER’s authority is limited to specific functions, and data from more than one DER may be necessary. If an applicant has determined that a single DER has, or multiple DERs have, provided necessary approved data for the repair/alteration before involving the ASI, then no field approval is required.
3.3.2.2 We have referenced DER authorizations and limitations in the current edition of FAA Order 8110.37, Designated Engineering Representative (DER) Handbook. This reference includes Repair Specification DER (RS-DER) authorizations and limitations, and general guidance on approving data for major repairs/major alterations. A list of current DERs and their appointed functions and authorizations is available at http://www.faa.gov/other_visit/aviation_industry/designees_delegations/desig nee_types/media/DERDirectory.pdf.
11 Note: Although DERs are not authorized to approve block 3 of FAA Form 337, you may use DER-approved data as a basis for a repair/alteration in support of FAA Form 337. However, when you have obtained sufficient DER-approved data that addresses requirements in parts 21 and 43, the approval process applicable to the alteration is complete. The person performing the alteration, not the DER, is then responsible for a conformity inspection and for return to service approval of the installation.
3.3.3 ODA Data Approval. You may employ an ODA holder to provide approved technical data to support a major repair/major alteration. If the applicant employs a DER or ODA to provide approved technical data to support a major repair or major alteration, then the applicant is responsible for ensuring that the DER or ODA is authorized to approve such technical data, as applicable to the repair or alteration. If the data, as approved, addresses the entire repair or alteration, and all of the requirements of parts 21 and 43 are met, there is no requirement for any further approval by the ASI. If the repair or alteration data is approved solely by the DER, ODA, or DAR, but necessitates maintenance instructions, the maintenance instructions should be prepared by the applicant and recorded in block 8 of FAA Form 337.
3.3.3.1 TC/STC ODA Holder with Specific Authority. A TC/STC ODA holder with specific authority for major repairs/major alterations may approve data within its authority and limitations. The data approved by an ODA holder may not adequately cover every aspect of the repair/alteration.
1. If a major repair, alteration, and airworthiness (MRA) ODA holder approves all aspects of the major repair/major alteration data, then no field approval is necessary.
2. If an MRA ODA holder (or holders) does not approve all aspects of the major repair/major alteration data, then a field approval is necessary.
3.3.3.2 ODA Authorizations and Limitations. For ODA authorizations and limitations, and general guidance on approving data for major repairs/major alterations, refer to the current edition of FAA Order 8100.15, Organization Designation Authorization Procedures. A list of authorized ODA holders is available on the FAA Designees and Delegations Web page:
https://www.faa.gov/other_visit/aviation_industry/designees_delegations/desi gnee_types/media/ODADirectory.pdf.
Note: The person performing the alteration, not the ODA, must conform and approve the installation from ODA-approved data. ODA data does not constitute a field approval, but is approved data that, like other approved data, can be used for major repairs/major alterations without further approval if the data addresses the entire repair/alteration. In this case, the applicant does not need to request a field approval.
3.4 Perform Repair or Alteration. After the repair or alteration data is approved, an applicant can alter or repair the aircraft or one of its components. When the work is complete, you should review the requirements of 14 CFR part 91, § 91.407, and determine if a flight check is required. Complete FAA Form 337 and follow procedures in part 43 appendix B.
Figure 3-1. Field Approval Process Applicant determines need for repair or alteration
3.2.1.
Is this Repair a repair or alteration?
Alteration the scope of the alteration sufficient to process No as a major change in type design?
(14 CFR 3.2.2.3
21.93) Yes See Consider as a minor repair or alteration and Applicant performs Figure 3-2 repair or minor documents in alteration Consider as a major maintenance records change in type design 3.2.2.1 Applicant applies for STC or TC amendment Does additional data No No field approval need to be required STC or TC amendment, After FAA approves approved? 3.3 applicant performs repair or alteration and Yes records it per Appendix B of Part 43 Applicant prepares data package
3.2.4 Applicant submits data package to FAA ASI
3.3.1.2 Applicant may make necessary corrections and resubmit FAA approves No ASI notifies applicant in data package? writing / 3.3.1.3.2 Yes ASI approves data and signs block 3 of FAA Form 337
3.3.1.3.2 Applicant performs repair or alteration and records it per Appendix B of Part 43 Aircraft is returned to service 13
Figure 3-2. Determination of Major or Minor Alteration or Repair From Figure 3-1 Repair or alteration listed in Yes •C Figure 3-1 product's specifications?
To No Figure 3-1 Could the repair or alteration have an practices or Accepted No appreciable affect on elementary operations?
Yes Yes Weight? If Repair improperly No Repair or done would Yes alteration? appreciably affect airworthiness?
Yes Balance?
Alteration No No Structural Yes strength?
No Yes Performance?
No Powerplant Yes operation?
No Flight Yes characteristics?
No Other qualities affecting Yes airworthiness?
No 14
15 4 FLIGHT MANUAL SUPPLEMENTS.
4.1 General Information. Alterations that result in a change to limitations, procedures, performance, or loading information from a current Aircraft Flight Manual (AFM) or placards, require an applicant to develop revised or supplemental information as addressed in paragraph 4.3 of this AC.
4.2 Aircraft Flight Manuals. Aircraft operating procedures and performance limitations are typically provided as:
1. AFMs, including either Airplane Flight Manuals or Rotorcraft Flight Manuals;
2. Markings or placards; or
3. Combinations of the above.
4.3 Manual Supplements. Supplemental information should be provided by one of the following methods:
1. If the aircraft has an AFM, the supplemental information must appear in an AFMS or RFMS.
2. If the aircraft does not have an AFM, the applicant should create a SAFM so necessary information is available to the pilot. A SAFM complements a pilot’s operating handbook (POH), which may not have specific FAA approval. Procedures for creating and approving a SAFM are the same as those for an AFMS.
3. You may present the supplemental information either as modified, or as additional markings and placards in aircraft type-certificated before AFMs were required.
4.3.1 If you substantiate a major alteration based on data from a previous approval, you must include a flight manual supplement if the previous approval had one. For the purposes of this guidance, AFMSs include RFMSs and SAFMs, as well.
4.4 Format and Content. The AFMS or placards must contain any new or changed limitations, emergency or abnormal operating procedures, normal operating procedures, performance, and system operating instructions. The supplement must be consistent with the format of the basic AFM and applicable to the specific installation configuration for the installed equipment and systems. ASI approvals of AFMS should not contain conditional operation descriptions and need to be explicit for the configuration of the targeted aircraft. The current editions of AC 23-8, Flight Test Guide for Certification of Part 23 Airplanes, and AC 25.1581-1, Airplane Flight Manual, provide guidance on what is recommended in an AFMS for aircraft.
4.4.1 The AFMS should include:
1. The aircraft manufacturer’s name;
2. Model number;
3. Serial number; and
4. Registration number.
4.4.2 You should include the following information, as applicable to the altered conditions:
1. Abnormal or emergency procedures;
2. Normal operating procedures;
3. Aircraft performance;
4. Aircraft Weight and Balance (W&B); and
5. Loading information.
4.4.3 You must install placards in clear view of the pilot and, as applicable, in proximity to affected equipment. Refer to 14 CFR part 23, § 23.1541; part 25, § 25.1541; part 27, § 27.1541; or part 29, § 29.1541.
4.5 Supplement Information Approval. Approval of the supplement (including placards):
1. Alterations that change the operating limits of the aircraft, aircraft engine, or propeller. These alterations would require coordination with an appropriate ACO for approval of the supplement or placard that stipulates limitations to the operation of the aircraft. See paragraph 4.6 for details.
2. ASIs with field approval authorization, and (1) authorized specifically by Flight Standards (AFS) policy, or (2) delegated by an ACO to review and approve certain AFMSs.
3. An authorized DER/ODA who can approve an AFMS or placards.
4.5.1 Repairs or alterations that do not result in a change to limitations, procedures, performance, or loading information may not require a supplement, or the supplemental information may consist of system operating instructions only.
4.5.2 An ASI with field approval authorization may review and grant field approval of an appropriately affixed placard characterizing operating limitations or information about certain equipment and systems. Refer to § 23.1541, 25.1541, 27.1541, or 29.1541. For examples of such placards—“Not For IFR” or “VFR Only"—refer to the “Kinds of Operations” paragraph in § 23.1525, 25.1525, 27.1525, or 29.1525.
4.6 Aircraft Certification Office Approval Process.
1. If an ASI or designee is not authorized to approve the AFMS, the ASI must forward the alteration data package, including proposed AFMS, to the ACO.
2. The ASI may route the AFMS to ACO flight-test personnel for review.
3. After review and approval of the AFMS/RFMS/SAFM, or limitations placard, the applicant must record the approval date, document name, and number on FAA Form 337, block 8, Description of Work Accomplished. Such entry must indicate that the AFMS/RFMS/SAFM is inserted or affixed to the AFM or POH.
4. The ASI will advise you that equipment upgrades, such as changes to the operating system software or hardware, may invalidate the existing FAA-approved AFMS and trigger a subsequent review and approval of the AFMS.
4.7 Additional AFMS Considerations.
4.7.1 Operating procedures for a newly-installed appliance or system are frequently provided in an AFMS. Alternatively, you may incorporate equipment manufacturer operating manuals by reference into the AFMS.
4.7.2 Manufacturer operating instructions included/referenced in the AFMS for systems or equipment, such as those for navigation systems, do not require specific approval; but if included in an AFMS, the AFMS itself must be approved.
4.7.3 If all of the following conditions are met, an AFMS is not required:
1. Does not restrict, displace, or limit the use of required equipment;
2. All new limitations can be addressed via placards;
3. The aircraft performance is not negatively affected;
4. Does not require a placard per TC or STC;
5. VFR use only; and
6. Is nonrequired equipment.
4.7.4 For equipment limited to VFR, you must install a readable placard, in clear view of the pilot, stating that the equipment is only for VFR operations. If the equipment automatically displays this message on start-up and the pilot must clear the message, an AFMS or RFMS is unnecessary, since the placard or display contains the equipment limitation.
18 5 MAINTENANCE INFORMATION.
5.1 Purpose of Maintenance Information for a Major Repair or Major Alteration.
Maintenance information provides adequate instructions to maintain the repaired or altered product in an airworthy condition. For this AC, major repair and major alteration maintenance information can include:
1. Additional maintenance instructions;
2. Supplemental information for the product’s maintenance manual or illustrated parts catalog;
3. Supplemental information for the product’s ICAs;
4. Supplemental information for articles or appliance maintenance manuals or illustrated parts catalog; and
5. Any other information required to maintain the product in an airworthy condition.
5.2 Benefits of Providing Maintenance Information for a Major Repair or Major Alteration.
5.2.1 When the owner/operator references maintenance information in block 8 of FAA Form 337, this gives the aircraft owner or operator the following advantages:
1. One document can reference or contain maintenance information about a major repair/major alteration;
2. The maintenance information becomes a permanent aircraft record as required by § 91.417(a)(2)(vi); and
3. The owner or operator can contact the FAA registry for a replacement FAA Form 337 if the maintenance information is lost or destroyed.
Note: The owner or operator may also forward a previously-completed FAA Form 337 and associated maintenance information if the FAA Form 337 is not currently in the registry.
5.2.2 The additional reference to maintenance information as part of a major repair/major alteration in the aircraft’s maintenance entry will ensure that maintenance personnel appropriately address maintenance of the major repair/major alteration during future inspections.
5.3 Maintenance Information as Part of the Major Repair or Major Alteration Data Package. We have determined that a major repair/major alteration data package must address how the major repair or major alteration affects continued airworthiness. You must develop maintenance information if a major repair/major alteration affects the continued airworthiness, or must also state that a major repair or major alteration doesn’t affect continued airworthiness. If a major repair or major alteration affects the airworthiness limitations section (ALS) of the ICA or a part of the ICA that requires FAA
19 approval, such as described in part 26 ICA requirements, you must obtain approval of that maintenance information from an ACO/ODA for the major repair/major alteration.
The maintenance information checklist is a guide for an applicant to develop maintenance information using methods, techniques, and practices acceptable to the FAA. See Figure 5-1, Major Repair or Major Alteration Maintenance Information Checklist.
5.4 Maintenance Information Under the Civil Air Regulations (CAR). For field-approved major alterations to CAR-certificated aircraft, engines, and propellers, maintenance information must meet the requirements of the original certification basis. In cases where the major alteration adds new items the CAR requirements didn’t address, the major alteration must meet applicable 14 CFR requirements. Figure 5-1 lists acceptable guidance for these installations, and also for inspections not covered by the original equipment manufacturer’s instructions.
5.5 Maintenance Information Development.
5.5.1 Major alterations needing maintenance or inspections not covered by original equipment manufacturer’s instructions must have maintenance information prepared in accordance with methods, techniques, and practices acceptable to the FAA. You should reference maintenance information as an attachment on block 8 of FAA Form 337. The entry— required by 14 CFR part 43, §43.9—must refer to the maintenance information and be identified by the approval date of the FAA Form 337. You must keep the form in the aircraft’s permanent records per § 91.417(a)(2)(vi).
Maintenance information referenced in block 8 of FAA Form 337 is considered acceptable to the FAA and will not be approved unless specifically required by regulation, as with changes to the ALS or part 26 requirements. Applicants should use Figure 5-1 as a guide to help ensure they meet all applicable requirements.
Note: Maintenance information is required to be acceptable to the FAA; therefore, should be referenced as a separate document on block 8 of FAA Form 337. Block 8 of FAA Form 337 is for data that is approved by the FAA.
5.5.2 If the repair or alteration data is approved solely by the DER, ODA, or DAR, but necessitates maintenance instructions, the maintenance instructions should be prepared by the applicant and referenced in block 8 of FAA Form 337.
5.6 Maintenance Information Content. Maintenance information must include specific instructions describing how to maintain affected areas for continued airworthiness. For example, maintenance information might include a new requirement for a special inspection during 100-hour or annual inspections. Such maintenance information must also include installed appliances that may impact maintainability of the product, or require periodic maintenance to ensure continued performance. When appropriate, maintenance information must also include specific instructions for determining excessive wear or deterioration, troubleshooting information, installation and removal procedures, and functional checks. You must also include servicing requirements, such as recommended fluid change intervals or lubrication schedules. In the instances that a
20 repair/alteration must meet part 26 requirements, only the ACO may approve the maintenance information developed. The maintenance information must contain:
1. Inspection tasks and task intervals;
2. Instructions and procedures in the aircraft maintenance manual to accomplish the tasks; and
3. Precautions, protective procedures, and information in the standard wiring practices manual.
21 Figure 5-1. Major Repair or Major Alteration Maintenance Information Checklist A/C Make_____________ Model____________ S/N____________ Reg. #N__________ Revision:_______________ Date:____________ System:_______________ Item Subject
1. Introduction: This section briefly describes the aircraft, engine, propeller, or component that has been altered. Include any other information on the content, scope, purpose, arrangement, applicability, definitions, abbreviations, precautions, units of measurement, referenced publications, and distribution of the maintenance information, as applicable.
2. Description: Describe the major alteration and its functions, if any.
including an explanation of its interface with other systems,
3. Control, operation information or special procedures, if any.
4. Servicing information, such as types of fluids used, servicing points, and location of access panels, as appropriate.
5. Maintenance instructions, such as recommended inspection/maintenance periods in which each of the major alteration components are inspected, cleaned, lubricated, adjusted, and tested, including applicable wear tolerances and work recommended at each scheduled maintenance period. This section can refer to the manufacturer’s instructions for the equipment installed where appropriate, such as functional checks, repairs, and inspections. It should also include any special notes, cautions, or warnings, as applicable.
6. Troubleshooting information: Information describing probable malfunctions, how to recognize those malfunctions, and remedial actions to be taken.
7. Removal and replacement information: This section describes the order and method of removing and replacing products, parts, and any necessary precautions. This section should also describe or refer to such items as manufacturer’s instructions to make required tests, trim checks, alignment, calibrations, center of gravity (CG) changes, lifting or shoring, if any.
8. Diagrams: Access plates and information, if needed, to gain access for inspection.
9. Special inspection requirements, such as X-ray, ultrasonic testing, or magnetic particle inspection, if required.
10. Application of protective treatments to the affected area after inspection and/or maintenance, if any.
11. Data: Relative to structural fasteners such as type, torque, and installation requirements, if any.
12. List of special tools: Special tools required, if any.
13. For commuter category aircraft: The following additional A. Electrical loads.
B. Methods of balancing flight controls.
C. Identification of primary and secondary structures.
D. Special repair methods applicable to the aircraft.
information must be furnished, as applicable:
14. Recommended overhaul periods must be noted on maintenance information when an overhaul period has been set by the manufacturer of a component or equipment. If there is no overhaul period, the maintenance information for item 14 should state: “No additional overhaul time limitations.”
15. Airworthiness limitation (AL) section: Include any approved ALs identified by the manufacturer or Federal Aviation Administration (FAA) Certificate Management ACO (CMACO). Example: An STC incorporated in a larger field-approved major alteration may have an AL. The FAA inspector will not establish, alter, or cancel ALs without coordinating with the appropriate FAA CMACO. If there are no changes to ALs, maintenance information should state for item 15: “No additional ALs” or “Not applicable.”
16. Maintenance information must be acceptable to the FAA. As such, changes should be documented by submitting the revised maintenance information along with the original Form 337 to the Aircraft Registration Branch (AFS -750) in Oklahoma City. An entry in the aircraft records should indicate the current revision.