B737-3/4/5 CFM56 MAINTENANCE PRACTICE TRAINING MANUAL B1/B2 LEVEL

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1 MAINTENANCE PRACTICE TRAINING MANUAL LEVEL DERICHEBOURG ATIS Aéronautique - ATIS Aviation, 17, Avenue Didier Daurat Blagnac : : DOC.FOR.14 Ed3 1/38

2 TRAINEE SURNAME: Forename: Licence number: Experience on an aircraft with similar technology: YES NO Signature: : / / ON JOB TRAINING Type: B1 B2 Starting date : / / Ending : / / Performed at : DERICHEBOURG ATIS AÉRONAUTIQUE STAMP : Licence number/stamp PRACTICAL ASSESSORS NAME Signature Validation by Quality Department: : Name: Signature: DOC.FOR.14 Ed3 2/38

3 SUBJECT The aim of this document is to record all the practical tasks performed by engineers within ATIS Aviation, PART 145 FR approved maintenance organisation, in order to comply with the requirements of Appendix III of PART 66 to have the rating on aircraft. Any task performed in the frame of this On Job Training (OJT) will have to be signed by the trainee engineer and validated by assessors. This OJT will be performed under the responsibility of one or more qualified engineers. (See PRE-REQUISIT on page 4/38) After this training, the engineer will be able to: - perform verifications of systems, engines, components and operational functions such as specified in the maintenance manual, - analyse all information in order to make decisions regarding trouble shooting and corrective actions as per maintenance manual, - describe the component replacement procedures specific to aircraft type. DURATION - Engineer with rating and six month experience on an aircraft with a similar technology: 70 hours (1), - Engineer with rating and less than six month experience on an aircraft with a similar technology: 140 hours (1), - Engineer with no rating on an aircraft with a similar technology: four months. (1) The 70/140 hours do not have to be necessarily performed in a row, but can be extended on a period adapted to operational configuration (availability of aircraft, trainee and assessors). CLASSIFICATION Classifies the importance of a task for the completion of the practical training record. Following classifications are used: - Mandatory (M): This indicates that the related task is required for completion of the practical training record. - Optional (O): This indicates that the related task is optional. It is recommended to perform at least 70% of those tasks in each ATA chapter. TASKS CODES - FOT: Functional Operational Test (*) - LOC: Location and identification of system components - MEL: Minimum Equipment List items requiring a maintenance procedure - RIA: Removal Installation Activation - SGH: Servicing Ground Handling - TPR: Thorough Procedural Review - TVC: Carry out Thorough Visual Check (*) If ground power or other applicable systems are unavailable a TPR will be carried out in place of a FOT. DOC.FOR.14 Ed3 3/38

4 SIGNING OFF THE TASKS Part 66 Appendix 3 paragraph 2.2 requires that the practical training element must consist of the performance of representative tasks and their assessment, in order to meet the following objectives: a) Ensure safe performance of maintenance, inspections and routine work according to the maintenance manual and other relevant instructions and tasks as appropriate for the type of aircraft, for example troubleshooting, repairs, adjustments, replacements, rigging and functional checks such as engine run, etc, if required, b) Correctly use all technical literature and documentation for the aircraft, c) Correctly use specialist/special tooling and test equipment, perform removal and replacement of components The nominated trainer/assessor will sign off each task when satisfied that the trainee has attained the demonstrable level of understanding that is required. PRE-REQUISIT The trainee must have participated and succeeded in a PART 147 theoretical type rating training (T1/T2 training). The assessors must have an experience of five years in the line maintenance and two years in the qualification of type. For any OJT, the assessors will have to make a request by at the Quality Department for validation of pre-requisit. ADDITIONAL PRACTICE At least one trouble shooting among the major ATA (*) must be performed. To be added in the additional practice from page 35. (*) ATA major: 21 to 80. DOC.FOR.14 Ed3 4/38

5 ATA 00 - Introduction Identify aircraft manuals and documentation M X X / Cockpit familiarisation M X X LOC Servicing M X X TVC External power points M X X TVC Hydraulic servicing M X X TVC Fuelling panel M X X TVC Defuelling M X X TVC Toilet servicing M X X TVC Water servicing M X X TVC ATA 05 - Time Limits/Maintenance Checks Aircraft Technical Logbook M X X TPR Walk around, Daily, Weekly checks M X X TVC Unscheduled maintenance checks (after abnormal events: hard or overweight landing, lightning strike, bird strike, etc. ) M X X TPR ATA 06 Dimentions and areas Principe dimensions and areas M X X LOC DOC.FOR.14 Ed3 5/38

6 ATA 07 Lifting and shoring Jack Airplane O X TPR Primary/secondary jacking points O X TPR Jack axles O X TPR Shoring O X TPR ATA 09 - Towing and Taxiing Towing maintenance practices M X TPR Tow Airplane with Flat Tires O X TPR ATA 10 - Parking and Mooring Normal Parking M X TPR High wind conditions parking O X TPR DOC.FOR.14 Ed3 6/38

7 ATA 12 - Servicing Fuelling and defuelling M X SGH Fuel system drainage O X SGH Hydraulic reservoir servicing M X SGH Engine servicing M X SGH IDG servicing M X SGH APU Servicing M X SGH Engine starter servicing M X SGH Potable water servicing M X LOC Landing gear fluid servicing O X SGH Hydraulic Brake accumulator servicing O X SGH Oxygen servicing O X LOC Main landing gear gas servicing O X TPR Nose landing gear gas servicing O X TPR Landing gear tires servicing M X SGH Toilet M X LOC Access doors and panels M X LOC DOC.FOR.14 Ed3 7/38

8 ATA 20 Standard Practices Electrical bonding M X X TVC ESDS Devices/Procedures M X X SGH ATA 21 - Air Conditioning Cockpit and control indications M X TVC External source M X LOC Pack operation M X SGH Distribution M X LOC Main distribution manifold M X TVC Recirculation fan filter O X SGH Equip cooling low flow detector bite test M X TPR Equip cooling air filter O X LOC Pressurization control M X LOC Operational test (auto-standby-manual) of Pressurization control system Pressurization control system System test AC or DC manual mode M X FOT M X MEL Cabin altitude/differential pressure indicator O X TVC Control and passenger heating O X LOC Door area heating O X LOC Cargo compartment heating O X LOC Cooling O X LOC Cooling Air cycle system O X LOC Air conditioning Pack valve O X RIA Water Separator Coalescer Bag Replacement O X SGH Ram air inlet deflector door O X LOC Ram Air system O X LOC EFIS supply cooling system M X LOC Temperature control M X LOC Pack/zone temperature controller Bite test M X FOT Duct sensor O X SGH Cabin sensor O X SGH DOC.FOR.14 Ed3 8/38

9 Temperature indicating system M X LOC / Air conditioning and pressurisation MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 9/38

10 ATA 22 - Auto flight Auto Flight System controls and indications in cockpit M X X TVC Auto Flight System components M X X LOC DFCS BITE test Line Maintenance Quick test, Operational test M X X FOT Digital Flight Control System rigging test M X X FOT Mach trim actuator O X X TPR Elevator neutral shift sensor rigging O X X TPR Autopilot actuator rigging M X X TPR Spoiler position sensor ringing M X X TPR Aileron position sensor rigging procedure M X X TPR Elevator position sensor rigging procedure M X X TPR Stabiliser position sensor rigging M X X TPR Auto flight status annunciator O X X LOC Flight control computer O X X LOC DFCS Mode control panel: maintenance practices M X X TVC Integrated flight system accessory unit O X X LOC Toga switch removal installation O X X FOT Hydraulic pressure switch REM/INS O X X FOT Autopilot disengage switch REM/INS O X X FOT Yaw damper system components M X X LOC Stall management & yaw damper computers 1 & 2 test M X X FOT Auto-throttle system components M X X LOC Auto-throttle computer bite test & ground test M X X FOT / Auto Flight MEL maintenance procedures M X X MEL DOC.FOR.14 Ed3 10/38

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12 ATA 23 - Communication Communication system components M X X TVC Communication system controls and indications in the cockpit M X X LOC HF operation test O X X TPR HF Transceiver bite test O X X TPR HF Vertical fin antenna O X X LOC HF Antenna coupler O X X LOC VHF communication system M X X LOC VHF operational test M X X FOT ELT Test O X X FOT Selcal system O X X LOC Passenger address amplifier test O X X TPR Video system control unit test O X X FOT Audio entertainment player bite test O X X FOT Boarding music player test O X X FOT Service interphone test O X X FOT Flight and ground call test M X X FOT Audio control panel test M X X FOT Static discharger inspection O X X SGH Static discharger replacement O X X RIA Voice recorder system O X X FOT / Communication MEL maintenance procedures M X X MEL DOC.FOR.14 Ed3 12/38

13 ATA 24 - Electrical power Electrical system controls and indications in the cockpit M X X TVC Components location M X X LOC Precautions Electrical power Maintenance practices Standard wiring practices ATA 20 M X X TPR IDG functional and operational test M X X FOT VSCF: Fault history messages O X X SGH CSD: Disconnect reset T handle O X X SGH AC Generation system components M X X LOC APU AC Generator test M X X FOT Power system test module M400 M X X LOC GCU APU test M X X FOT DC Generation system components M X X LOC DC Generation system test M X X FOT Battery M X X LOC Main battery replacement M X X RIA Battery charger test M X X FOT Auxiliary battery charger O X X TPR Dual battery remote control CB O X X FOT Stand by power control unit test M X X FOT AC External Power operational test M X X FOT Electrical load distribution components M X X LOC Main 115 volt AC power M X X LOC volt AC power distribution M X X LOC Standby power system components M X X LOC Standby power system operational test M X X FOT / Electrical system MEL procedures M X X MEL DOC.FOR.14 Ed3 13/38

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15 ATA 25 - Equipment & Furnishing Equipment / Furnishings components location M X LOC Crew seat adjustment M X SGH Passenger seats O X SGH Passenger cabin panels O X RIA Cabin attendant seats O X LOC Galleys O X LOC Lavatories O X LOC Cargo compartments Blowout panels Pressure equalization valve O X LOC Emergency equipment O X LOC Escapes ropes / Straps and Lanyards O X TVC Escape slides check O X SGH / Emergency evacuation signal system operational test Equipment and furnishing MEL maintenance procedures M X FOT M X MEL DOC.FOR.14 Ed3 15/38

16 ATA 26 - Fire protection Fire protection controls and indications in the cockpit M X X TVC Fire detection system components M X X LOC APU and Engine fire detection system operational test M X X FOT Lavatory smoke detection system test O X X FOT Cargo bay smoke detection test M X X FOT Cargo electric unit M X X FOT Wheel well overheat detection O X X FOT Wing and lower AFT Body overheat O X X LOC Wing and lower AFT Body overheat Built in test procedures O X X FOT Engine fire extinguishing system O X X LOC Engine fire extinguishing system test O X X FOT Engine fire bottle replacement O X X RIA APU fire extinguishing system M X X SGH CARGO compartment fire extinguishing system O X X SGH Lavatory fire extinguishing system O X X FOT / Fire protection MEL maintenance procedures M X X MEL DOC.FOR.14 Ed3 16/38

17 ATA 27 - Flight Controls Flight controls :controls and indications in the cockpit M X X TVC Flight control components location M X X LOC Flight controls hydraulic modular O X LOC Aileron and aileron trim components location O X LOC Aileron and aileron trim control system test O X FOT Rudder and rudder trim control system O X LOC Rudder and rudder trim control system test O X FOT Elevator and elevator tab control system M X LOC Elevator and elevator tab control system test M X FOT Pitot static system drainage Inspection O X SGH Stall warning system components location M X LOC Stall warning system operational check M X FOT Horizontal stabilizer trim control system M X LOC Horizontal stabilizer trim control system test M X FOT Trailing edge flaps system components location M X LOC Trailing edge flaps system test M X FOT Flap/slats electronic unit bite test O X FOT Trailing edge Flaps position indicating system components location Trailing edge Flaps position indicating system test Trailing edge Flaps position indicator replacement M X LOC M X FOT M X RIA Flap skew detection system test M X FOT Flap skew sensors location M X LOC Flight spoiler system components location M X LOC Flight spoiler system test M X FOT Auto speed brake control system components location O X LOC Auto speed brake control system test O X FOT Leading edge flap and slat control system components location Leading edge flap and slat control system test O X LOC O X FOT DOC.FOR.14 Ed3 17/38

18 Leading edge slat actuator replacement O X RIA Leading edge Auto slat control system components location O X LOC Leading edge Auto slat control system test O X FOT Leading edge flaps and slats position indicating system components location Leading edge flaps and slats position indicating system test O X LOC O X FOT / Flight controls MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 18/38

19 ATA 28 - Fuel Fuel controls and indications in the cockpit M X TVC Fuel tanks components location M X LOC Fuel vent system O X SGH Centre tank scavenge system O X FOT Pressure fuelling system M X LOC Engine fuel feed system O X LOC Engine fuel spar valve battery M X TPR Fuel boost pump replacement O X RIA Defuelling maintenance practices O X TPR Transfer fuel from tank to tank O X SGH Fuel quantity indicating system M X LOC Fuel quantity indicating system test M X FOT Fuel temperature bulb O X FOT / Fuel tank safety / CDCCL awareness M X TPR / Fuel system MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 19/38

20 ATA 29 - Hydraulic power Hydraulic power controls and indications in the cockpit O X TVC A hydraulic system components O X LOC B hydraulic system components O X LOC Stand-by hydraulic system components M X LOC Hydraulic reservoir pressurization system O X LOC Pressurize the hydraulic reservoirs ( APU ) and release the pressure from hydraulic reservoirs O X FOT Pressurize the Standby hydraulic system M X FOT Pressurize A or B hydraulic system with Electric motor driven pump (EMDP) M X FOT Power Transfer Unit O X LOC Power Transfer Unit operational test O X FOT Hydraulic pressure indicating system O X LOC Hydraulic fluid overheat warning O X LOC Hydraulic fluid quantity indicating system O X LOC Pump low pressure warning system O X LOC / Hydraulic power MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 20/38

21 ATA 30 - Ice & rain protection Ice and rain protection controls and indicators in the cockpit M X X TVC Wing thermal anti icing system O X X LOC Wing thermal anti icing shutoff valve O X X RIA Wing anti ice control: module P5-11 M X X LOC Inlet cowl anti icing system M X X LOC Pitot static tubes,temperature probe, and AOA probe anti icing system Pitot static tubes,temperature probe, and AOA probe anti icing system Test P5-9 O X X LOC O X X FOT Control cabin window anti icing system O X X LOC Window heat control unit operational test O X X FOT Windshield wiper system O X X LOC Windshield wiper replacement M X X RIA Hydrophobic coating O X X FOT Water and Toilet drain anti icing system O X X LOC / Ice and rain protection MEL maintenance procedures M X X MEL DOC.FOR.14 Ed3 21/38

22 ATA 31 - Indicating & recording system Indicating and recording system controls and indicators in the cockpit M X X TVC Indicating and recording system components O X X LOC Emergency Locator Transmitter O X X LOC Clocks test O X X FOT Aural warning system operational test O X X FOT Aural warning Module bite test O X X FOT Flight data recorder system test and download O X X FOT Digital flight data acquisition unit bite test O X X FOT Master caution system O X X FOT Rudder position transmitter O X X FOT Display electronic unit M X X FOT / Indicating and recording system MEL maintenance procedures M X X MEL DOC.FOR.14 Ed3 22/38

23 ATA 32 - Landing Gear Landing gear controls and indicators in the cockpit M X TVC Ground lock assemblies maintenance pratices M X RIA Landing gear safety sensors M X LOC Proximity switch electronics unit bite test O X FOT Main gear components location O X LOC Main gear wheel well seal system O X SGH Main gear shock strut doors O X SGH Nose landing gear components location O X LOC Nose gear doors ground opening and closing O X SGH Main gear extension and retraction O X TVC Nose gear extension and retraction O X TVC Main gear manual extension O X TVC Maint landing gear brakes O X TVC Antiskid autobrake control unit bite test O X FOT Main wheel replacement M X RIA Nose wheel replacement M X RIA Nose wheel steering operation O X FOT Landing gear position indicating and warning system M X FOT Sensor, main gear up lock O X FOT / Landing gear MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 23/38

24 ATA 33 - Lights Lights controls and indicators in the cockpit M X X TVC Flight compartment lighting operational test M X X FOT Master warning and caution lights operational test M X X FOT Passenger compartment lighting test O X X FOT Passenger signs operational test O X X FOT Call lights operational test O X X FOT Lavatory lights O X X LOC Galley lights O X X LOC Passenger reading lights M X X LOC Passenger reading lights M X X RIA Cargo and service compartment lights O X X LOC Exterior lighting O X X LOC Fixed landing lamp replacement M X X RIA Retractable landing lamp replacement M X X RIA Emergency lighting test M X X FOT / Lights MEL maintenance procedures M X X MEL DOC.FOR.14 Ed3 24/38

25 ATA 34 - Navigation Navigation controls and indicators in the cockpit M X X TVC Standby altimeter and airspeed indicators M X X FOT Mach airspeed warning system O X X FOT ADIRU component location O X X LOC ADIRU CDU, bite test O X X FOT Standby horizon system operational test O X X FOT ILS receivers bite test O X X FOT ILS glide slope antenna O X X LOC VOR test O X X FOT Multimode receiver bite test O X X TPR Radio alti bite test O X X TPR Marker Beacon system components O X X LOC Weather Radar system components location O X X LOC FOT from weather radar control panel O X X FOT Enhanced Ground Proximity Warning System components location O X X LOC EGPWS bite test O X X TPR TCAS system component location O X X LOC TCAS computer bite test O X X TPR ATC SYSTEM component location O X X LOC DME system component location O X X LOC ADF system component location O X X LOC GPS components location O X X LOC GPS bite test O X X TPR Flight Management Computer system O X X LOC FMCS database loading O X X TPR FMCS bite test O X X TPR / Navigation MEL maintenance procedures M X X MEL DOC.FOR.14 Ed3 25/38

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27 ATA 35 - Oxygen Oxygen systems controls and indicators in the cockpit M X TVC Oxygen system pressure indication-check M X FOT Flight crew oxygen system components location Flight crew mask/regulator in the stowed condition test O X LOC O X FOT Replace oxygen bottle transducer O X RIA Passenger oxygen system components location O X LOC Portable oxygen equipment O X TVC Inspection of passenger oxygen generator for firing mech and heat sensitive band O X TVC / Oxygen MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 27/38

28 ATA 36 - Pneumatic Pneumatic system controls and indicators in the cockpit M X TVC Pneumatic system components O X LOC Engine bleed air distribution O X LOC Bleed air control system operational test with APU O X FOT Wing to Body overheat operational test O X FOT Replacement of 5th stage check valve O X RIA High stage valve O X LOC Bleed air precooler system test M X FOT APU bleed air system test O X LOC Engine bleed pressure indicating system O X TPR Duct pressure transmitter O X SGH / Pneumatic MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 28/38

29 ATA 38 Water and waste Water and waste components M X LOC Potable water system O X TVC Waste water system O X TVC Toilet system maintenance practices O X TPR Water tank point level sensor replacement M X RIA Water tank pressurization system O X FOT / Water and waste MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 29/38

30 ATA 49 - APU APU controls and indicators in the cockpit M X X TVC APU troubleshooting procedures O X X TPR APU maintenance practices O X X TPR APU power plant bite test M X X FOT APU air inlet M X X FOT APU shroud drains O X X SGH APU fuel system test O X X LOC APU ignitor plug replacement M X X RIA Cooling air shutoff valve O X X FOT APU surge bleed air valve O X X FOT APU CDU bite test O X X TPR Exhaust gas temperature indicating system M X X FOT APU EGT temperature probes M X X FOT APU oil pump O X X FOT / APU MEL maintenance procedures M X X MEL DOC.FOR.14 Ed3 30/38

31 ATA 52 - Doors Doors indications in the cockpit M X TVC Forward entry door open/close operations M X FOT Emergency exits M X LOC Emergency exit hatch open/close operations M X TPR Cargo compartment doors open/close operations Air conditioning access doors open/close operations O X FOT O X FOT APU access door open/close operations M X FOT Electronic equipment compartment external access door open/close operations M X FOT Miscellaneous exterior service doors O X LOC Control cabin door: operational test door lock O X FOT Forward AIRSTAIR and door operational test M X FOT Door warning system test O X FOT / Doors MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 31/38

32 ATA 56 - Windows Flight compartment Windows M X TVC Operation of cockpit sliding windows O X FOT Cabin sliding windows Emergency exit release mechanism O X TVC Passengers cabin windows O X SGH Emergency exit hatch windows O X SGH Door mounted windows O X TVC Viewers and observation windows O X TVC / Windows MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 32/38

33 ATA 71 to 80 - Engine Power Plant components Precaution /Engine ground safety M X LOC Engine cowling M X LOC Fan cowl panels: opening and closing M X X SGH Engine vents and drains O X LOC Engine M X LOC Fan blade replacement O X RIA Fuel distribution system M X LOC Fuel control system, system test M X FOT Fuel flow indicating O X X LOC Fuel filter bypass warning system O X LOC Ignition system location O X LOC Engine ignition control O X LOC Air O X LOC Engine indicating system O X X LOC Exhaust gas temperature (EGT) O X LOC Airborne vibration monitoring O X LOC Thrust reverser deactivation and activation for flight dispatch Thrust reverser deactivation /activation for ground maintenance Open/ close the fan duct cowl Thrust reverser (manual procedure) Thrust reverser sleeve translation (manual procedure ) M X MEL M X SGH M X SGH M X SGH Thrust reverser indicating system M X LOC OIL :Inspection check // Magnetic chip detector Engine oil chip detector inspection remove and refit M X LOC O X RIA Oil quantity indicating system M X LOC Oil quantity indicating system Operational test M X FOT Oil pressure indicating system M X LOC Low oil pressure indicating system M X LOC Oil filter bypass warning system M X FOT Engine starting system M X LOC DOC.FOR.14 Ed3 33/38

34 ATA Subject Class X B2 Opening for start valve manual operative drive M X SGH 71 to 80 / Engine MEL maintenance procedures M X MEL DOC.FOR.14 Ed3 34/38

35 ADDITIONAL PRACTICAL EXPERIENCE ATA reference Work experience DOC.FOR.14 Ed3 35/38

36 ADDITIONAL PRACTICAL EXPERIENCE ATA reference Work experience DOC.FOR.14 Ed3 36/38

37 ADDITIONAL PRACTICAL EXPERIENCE ATA reference Work experience DOC.FOR.14 Ed3 37/38

38 DOC.FOR.14 Ed3 38/38

BOEING AIRCRAFT WEIGH WORKSHEET

BOEING AIRCRAFT WEIGH WORKSHEET WEIGHING FACILITIES AND EQUIPMENT ITEM MECH INSP The airplane should be weighed inside a closed facility that will: Exclude all wind and drafts. Permit shutdown of air conditioning during the weighing