Maintenance and Manufacturing Staff Instructions (MSI) No. 53: Appendix B

From: Transport Canada

Appendix B - Sample manual content descriptions

The following sections summarize the required contents of the ICA for initial certification. They are listed here only to assist the applicant and reviewer in assessing the kind of information to be considered for inclusion in supplemental ICA. The specific items listed need only be included in the supplemental ICA where the change to the approved design requires an amendment to the relevant section of the ICA.

B1. Aeroplane / rotorcraft manual.

1.1 This manual must explain the aircraft features, and include maintenance or preventive maintenance information, including:

  1. Description of all systems and installations, including engines, propellers, and appliances (for aircraft/rotorcraft); and accessories (for engines);
  2. Removal and installation instructions for parts, including all required equipment and precautions;
  3. Description of how the system operates and is controlled, including special procedures and limitations;
  4. Description of how to adjust and test the system, plus required equipment and precautions;
  5. Description of probable malfunctions, and how to recognize and correct them;
  6. Servicing procedures, including servicing points (location and access), capacities of tanks and reservoirs, types of fluid used, required equipment and precautions;
  7. Aircraft/rotorcraft towing instructions, including required equipment and precautions;
  8. Aircraft/rotorcraft jacking, mooring, and leveling instructions (including required equipment and precautions);
  9. Lifting and shoring instructions, including required equipment and precautions;
  10. Weight and balance instructions to determine the center of gravity;
  11. List of equipment required to complete all work. There may be several lists, each in the sections of the ICA where the work is described. CAR Standards: Appendix H: H525.3: (g) specifies special tools to be used during maintenance.
  12. The applicant’s inspection program with the frequency and extent of the inspections necessary to sustain continued airworthiness.

1.2 See CAR Standards 523.1529: Appendix G; G23.3(a); 525.1529: Appendix H; H525.3(a); 527.1529: Appendix A; A527.3(a); 529.1529; Appendix A; A529.3(a) for regulatory requirements.

B2. Balloon manual.

2.1 This manual must explain the balloon’s features and describe maintenance or preventive maintenance, including;

  1. Description of the balloon, its systems, and installations. This should include, but is not limited to, the controls, basket structure, fuel systems, and heating assembly.
  2. Removal and installation instructions for parts, including all required equipment and necessary precautions.
  3. Description of how the system operates and is controlled, including special procedures and limitations.
  4. How to adjust and test the system, including all required equipment and precautions.
  5. Description of probable malfunctions, how to recognize and correct them.
  6. Servicing procedures that include balloon components, including burner nozzles, fuel tanks, valves during operation, and any required equipment and precautions.
  7. Hard landing inspection items and procedures.
  8. Balloon storage preparation and limits.
  9. How to repair the balloon envelope, its basket or trapeze.
  10. The applicant’s inspection program with the frequency and extent of the inspections necessary to sustain continued airworthiness.

2.2 Reference CAR Standards 531.82: Appendix A: A531.3 for the regulatory requirement.

B3. Engine maintenance manual.

3.1 This manual or section must cover the engine’s features and what is necessary for engine maintenance or preventive maintenance, including the following:

  1. Description of engine features, systems, and installations.
  2. Removal and installation instructions for parts and accessories with warnings,cautions, and notes that are part of the engine type design.
  3. Description of how the engine components, systems, and installations operate; how to start, run, test, and stop the engine and its parts, including any special procedures and limitations.
  4. How to adjust and test a system, including all required equipment and precautions.
  5. Description of probable malfunctions, how to recognize and correct them.
  6. Servicing procedures with servicing points (location and access), capacities of tanks and reservoirs, types of fluid used, and any required equipment and precautions. Procedures must cover both engine type design parts and systems or components either installed integrally or dependent on the engine.
  7. List of required equipment to complete all work. There may be several lists, each in the ICA sections where the work is described. CAR Standards 533.4: Appendix A: A533.3. (a) (9) specifies special tools to be used during maintenance.
  8. Schedule for each part of the engine with the recommended times for cleaning, inspecting, adjusting, testing, and lubricating. Applicants should add the depth of inspection required, applicable wear tolerances, and tasks at those times.
  9. Schedule for part removal, replacement, or overhaul, cross-referenced to the ALS. If the ICA shows overhaul time for a part, then the ICA must include an overhaul manual for that part.
  10. The applicant’s inspection program with the frequency and extent of the inspections necessary to sustain continued airworthiness.
    See CAR Standards 533.4: Appendix A: A533.3(a) for regulatory reference.

B4. Engine overhaul manual.

4.1 This manual must cover engine disassembly, overhaul, and reassembly. It must include necessary cautions or warnings, and:

  1. Cleaning and inspection instructions with inspection criteria for each part of the engine, subassembly, assembly, module, systems, and components. The inspection criteria should identify the tasks at each level, such as part replacement, repair, or more detailed inspection.
  2. Details on all fits and clearances of the engine and components, and structural integrity and functionality for new and worn parts.
  3. Repair methods for worn or otherwise substandard parts that do not meet the inspection limits. The ICA does not need repair information for all engine parts, but should identify when and why a part must be replaced or repaired.
  4. Instructions for testing an engine after overhaul, including test acceptance criteria.
  5. Instructions for storage that identify special containers and required equipment or tools. The ICA should also include environmental restrictions for storage and storage limits.
  6. List of required tools to complete all work. There may be several lists, each in the ICA section where the work is described. The list of overhaul tools should be in the front of the manual or section so it’s easy to find the list and order the tools. CAR Standards 533.4: Appendix A: A533.3. (a) (9) specifies special tools to be used during maintenance.

4.2 See CAR Standards 533.4: Appendix A; A533.3(b) for the regulatory requirement.

B5. Propeller maintenance manual.

5.1 The manual or section must cover both the propeller features and maintenance or preventive maintenance, including:

  1. Description of propeller features, systems, and installations.
  2. Instructions for uncrating, acceptance checking, lifting, installing, and removing the propeller, and any warnings, cautions, and notes that are part of the propeller type design.
  3. Description of the propeller components and systems, how they operate, and how they are controlled, including any special procedures and limitations.
  4. Description of how to adjust and test propellers, including required equipment and precautions.
  5. Description of probable malfunctions, and how to recognize and correct them.
  6. Order and method of removing and replacing propeller parts, with any necessary precautions to take.
  7. List of required equipment to complete all work. There may be several lists, each in the ICA section where the work is described. CAR Standards 535.4: Appendix A: A535.3 (a) (9) specifies special tools to be used during maintenance.Maintenance schedule for each part of the propeller, including recommended periods for cleaning, inspecting, adjusting, testing, and lubricating; the depth of inspection required; the wear tolerances; and tasks at those intervals.
  8. The recommended replacement/overhaul schedule – with the necessary cross reference to the ALS – that shows when to remove, replace, or overhaul a specific part. If the ICA shows an overhaul time for a part, then the ICA must include the overhaul manual for that part. The product design approval holder is responsible for controlling the content and changes, not the part manufacturer.
  9. Expect an applicant to include an inspection program detailing the frequency and extent of the inspections necessary to sustain continued airworthiness.

5.2 See CAR 535.4: Appendix A: A535.3.(a) for the regulatory requirement.

B6. Propeller overhaul manual.

6.1 This manual must cover propeller disassembly, overhaul, and reassembly. It must include any necessary cautions or warnings, plus:

  1. Cleaning and inspection instructions with inspection criteria for each part of the propeller. The criteria should identify the tasks at each level, such as part replacement, repair, or more detailed inspection.
  2. Details on all fits and clearances for the propeller and components, and structural
  3. integrity and functionality for new and worn parts.
  4. Repair methods for worn or otherwise substandard parts that do not meet the inspection limits. The ICA does not need to cover repairs on all propeller parts, but should identify when and why a part must be replaced or repaired.
  5. Description of how to test the propeller after overhaul, including test acceptance criteria.
  6. Instructions for storage that identify special containers and required equipment or tools. The ICA should also include the environmental restrictions for storage and storage limits.
  7. List of required tools to complete all work. The list may actually be several lists, each in the ICA section where the work is described. The tools list should be in front of the manual or section so it’s easy to find the list and order the tools. CAR Standards 535.4: Appendix A: A535.3 (b) (8) specifies special tools to be used during maintenance.

6.2 See CAR Standards 535.4: Appendix A: 3.(b) for the regulatory requirement.

B7. System wiring diagram.

For aircraft and engines, this section covers the aircraft’s electrical or electronic circuits. The diagrams must be detailed enough to enable maintenance personnel to troubleshoot and service the electrical system. This section must include wiring diagrams for the installation in sufficient detail for the purposes of troubleshooting. In addition, the wiring diagram section must include a method of determining connector type, wire type and wire size. We consider system wiring diagrams as descriptive data of the systems used on the product, and a part of the ICA.

B8. Component overhaul / maintenance manuals.

For aircraft, engines and propellers, these manuals cover overhauling and repairing components or appliances not covered under the maintenance manual (such as “black boxes.”). If the ICA refer to the manuals or set overhaul times as a requirement to maintain the continued airworthiness, those instructions are incorporated by reference and now become part of the complete ICA, and must be provided to the owner by the design approval holder. The component manuals must contain the following:

  1. Cleaning and inspection instructions with criteria for each part. The inspection requirements should identify the tasks at each level, such as part replacement, repair, or more detailed inspection.
  2. Details on all fits and clearances of the component, and structural integrity and functionality for new and worn parts.
  3. Repair methods for worn or otherwise substandard parts that do not meet the inspection limits.
  4. Instructions for testing after overhaul, including test acceptance criteria.
  5. Instructions for storage, identifying special containers and any equipment or tools. The ICA should also include environmental restrictions for storage and storage limits.
  6. List of required tools to complete all work. There may be several lists, each in the ICA section where the work is described. The tools list should be in front of the manual or section so it’s easy to find and order the tools.

B9. Non-Destructive Testing and Inspection manual or section

For aircraft, engines, and propellers, this manual or section covers testing techniques, instructions, and required equipment for all required NDT and inspections.

B10. Maintenance Review Board (MRB) Report (Transport Category Aircraft).

Design Approval Holders for Transport Category aircraft are required to develop their initial scheduled maintenance recommendations following the Maintenance Review Board process, and utilizing the MSG-3 methodology. This process results in a MRB Report, which contains the initial minimum scheduled maintenance and inspection requirements for the aircraft type. Air Operators may use the MRB Report as the basis for their maintenance schedules. See TP 13850, Scheduled Maintenance Instruction Development Processes, available on the TC website for additional information.

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