PWS 2.0_ee_FAA Order_8300.16A_CHG_1.pdf

Distribution: Electronic Only Initiated By: AIR-100/AFS-300

CHANGE U.S. DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION 8300.16A CHG 1

National Policy Effective Date:

8/17/20

SUBJ: Major Repair and Alteration Data Approval

1. Purpose of This Order. This order provides guidance applicable to the data approval process for major repairs and alterations, including field approvals. The source basis for this order is Title 14 of the Code of Federal Regulations (14 CFR) part 43.

2. Audience. The audience for this order is responsible Flight Standards offices, aviation safety inspectors (ASI), Aircraft Certification Offices (ACO), Aviation Safety Engineers (ASE), designees (Designated Engineering Representatives (DER), Organization Designation Authorizations (ODA), and Designated Airworthiness Representatives (DAR)), and others engaged in the approval process for major repairs, major alterations, and the data associated with each. For the purpose of this order, the use of the term “ASI” includes DARs authorized to approve data in support of major repairs or alterations when performing work in accordance with Federal Aviation Administration (FAA) Order 8000.95, Designee Management Policy.

3. Where You Can Find This Order. You can find this order on the MyFAA employee website at https://employees.faa.gov/tools_resources/orders_notices. Inspectors can access this order through the Flight Standards Information Management System (FSIMS) at https://fsims.avs.faa.gov. Air carriers (operators) can find this order on the Federal Aviation Administration’s (FAA) website at https://fsims.faa.gov. This order is available to the public at https://www.faa.gov/regulations_policies/orders_notices.

4. Explanation of Policy Changes. This change updates information in Chapter 4, Figure 4-1, Possible Resources for Approved Data Relevant to Major Repairs or Major Alterations, to clarify a use of FAA Form 337.

5. Disposition of Transmittal Paragraph. This change will remain in FSIMS until superseded by a revision to this order.

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ORIGINAL SIGNED by

/s/ Ali Bahrami Associate Administrator for Aviation Safety

12/11/18 8300.16A

Distribution: Electronic Only Initiated By: AIR-100/AFS-300

U.S. DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

National Policy

ORDER

8300.16A

Effective Date:

12/11/18

SUBJ: Major Repair and Alteration Data Approval

This order provides guidance on the responsibilities and requirements for the approval of technical data associated with major repairs or alterations. Types and sources of technical data are discussed. Considerations that must be addressed in the development of technical data to substantiate major repairs or alterations are also addressed. This order does not provide guidance for making decisions on major or minor changes in type design.

8/17/20 8300.16A CHG 1

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Table of Contents

Paragraph Page

Chapter 1. General Information ................................................................................................... 1-1

1. Purpose of This Order ...................................................................................................... 1-1

2. Audience .......................................................................................................................... 1-1

3. Where You Can Find This Order ..................................................................................... 1-1

4. What This Order Cancels ................................................................................................. 1-1

5. Scope ................................................................................................................................ 1-1

6. Major Repair and Alteration Data Approval Job Aid ...................................................... 1-1

7. Directive Feedback Information ...................................................................................... 1-2

Chapter 2. Field Approval Eligibility .......................................................................................... 2-1

1. Eligibility ......................................................................................................................... 2-1

Chapter 3. Field Approval Process and Data Approval ............................................................... 3-1

1. General Information ......................................................................................................... 3-1

2. Initial Review ................................................................................................................... 3-3

3. Data Evaluation ................................................................................................................ 3-3

4. ACO Coordination Determination ................................................................................... 3-5

5. Data Package Approved/Denied for Field Approval ....................................................... 3-6

6. Variations to the Field Approval Process ........................................................................ 3-7

Chapter 4. Data ............................................................................................................................ 4-1

1. Introduction ...................................................................................................................... 4-1

2. Types of Technical Data .................................................................................................. 4-1

Chapter 5. Maintenance Information and Instructions for Continued Airworthiness ................. 5-1

1. Repair or Alteration Data Package .................................................................................. 5-1

2. Data Approval of Major Alterations Under the Civil Air Regulations (CARs) .............. 5-1

3. Maintenance Instruction Requirements ........................................................................... 5-3

4. Changes to Maintenance Information After Approval .................................................... 5-3

5. Maintenance Information Procedures .............................................................................. 5-3

6. Develop the Maintenance Information ............................................................................ 5-4

Chapter 6. Airplane and Rotorcraft Flight Manual Supplements ................................................ 6-1

1. General Information ......................................................................................................... 6-1

2. AFMs/RFMs .................................................................................................................... 6-1

3. Manual Supplements ........................................................................................................ 6-1

4. Supplement Approval ...................................................................................................... 6-1

5. ACO Approval Process .................................................................................................... 6-3

6. Format and Content.......................................................................................................... 6-4

7. Online Job Aid ................................................................................................................. 6-4 iv

Chapter 7. Flight Evaluation and Flight Test ............................................................................... 7-1

1. Introduction ...................................................................................................................... 7-1

2. Flight Evaluation .............................................................................................................. 7-1

3. Flight Test ........................................................................................................................ 7-1

Chapter 8. Technical Considerations ........................................................................................... 8-1

1. Introduction ...................................................................................................................... 8-1

2. Powerplant ....................................................................................................................... 8-1

3. Propeller ........................................................................................................................... 8-1

4. Rotorcraft ......................................................................................................................... 8-1

5. System Failure Modes and Effects .................................................................................. 8-3

6. Structure ........................................................................................................................... 8-3

7. Systems ............................................................................................................................ 8-3

8. Avionics General ............................................................................................................. 8-4

9. Circuit Protection ............................................................................................................. 8-6

10. Commercial Off-the-Shelf (COTS) and Other Articles Not Produced Under § 21.9 ...... 8-7

11. Commercial Parts ............................................................................................................. 8-7

12. Enhanced Airworthiness Program for Airplane Systems (EAPAS) ................................ 8-8

13. Lightning, HIRF, and Electromagnetic Compatibility (EMC) ........................................ 8-8

14. Electrical Load Analysis (ELA)....................................................................................... 8-9

15. Software Considerations .................................................................................................. 8-9

16. Human Factors (HF) ...................................................................................................... 8-10

Chapter 9. Roles and Responsibilities ......................................................................................... 9-1

1. General Information ......................................................................................................... 9-1

2. Applicant .......................................................................................................................... 9-1

3. ASI ................................................................................................................................... 9-1

4. Responsible Flight Standards Offices .............................................................................. 9-3

5. DER.................................................................................................................................. 9-3

6. ODA ................................................................................................................................. 9-4

7. ACO ................................................................................................................................. 9-4

8. DAR ................................................................................................................................. 9-4

Chapter 10. Recording and Reporting ....................................................................................... 10-1

1. Disposition of FAA Form 337 (Other Than Additional Fuel Tank Installations) ......... 10-1

2. Disposition of FAA Form 337 for Extended-Range Fuel Tank Installations ................ 10-2

Appendix A. Definitions ............................................................................................................. A-1 Appendix B. Related Publications and References ......................................................................B-1 Appendix C. Acronyms ...............................................................................................................C-1

List of Figures Figure Page

3-1. Repair and Alteration Data Approval Process Overview .................................................. 3-2 4-1. Possible Resources for Approved Data Relevant to Major Repairs or Major

Alterations ......................................................................................................................... 4-3 5-1. Major Repair or Major Alteration Maintenance Information Checklist ........................... 5-2

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Chapter 1. General Information

1. Purpose of This Order. This order provides guidance applicable to the data approval process for major repairs and alterations, including field approvals. The source basis for this order is Title 14 of the Code of Federal Regulations (14 CFR) part 43.

2. Audience. The audience for this order is responsible Flight Standards offices, aviation safety inspectors (ASI), Aircraft Certification Offices (ACO), Aviation Safety Engineers (ASE), designees (Designated Engineering Representatives (DER), Organization Designation Authorizations (ODA), and Designated Airworthiness Representatives (DAR)), and others engaged in the approval process for major repairs, major alterations, and the data associated with each. For the purpose of this order, the use of the term “ASI” includes DARs authorized to approve data in support of major repairs or alterations when performing work in accordance with Federal Aviation Administration (FAA) Order 8000.95, Designee Management Policy.

3. Where You Can Find This Order. You can find this order on the MyFAA employee website at https://employees.faa.gov/tools_resources/orders_notices. Inspectors can access this order through the Flight Standards Information Management System (FSIMS) at https://fsims.avs.faa.gov. Air carriers (operators) can find this order on the FAA’s website at https://fsims.faa.gov. This order is available to the public at https://www.faa.gov/regulations_policies/orders_notices.

4. What This Order Cancels. FAA Order 8300.16 CHG 1, Major Repair and Alteration Data Approval, dated December 7, 2015, is canceled.

5. Scope.

a. Process. This order defines the process for the approval of technical data for major repairs and major alterations. This order does not provide guidance for making decisions on major or minor changes in type design.

b. Definitions. The use of the terms “major” and “minor” are sometimes inappropriately applied or misunderstood. A major change in type design can be approved only by an ACO or an ODA holder with Supplemental Type Certificate (STC) or type certificate (TC) authorization.

A major alteration requires the use of FAA-approved technical data. Minor alterations only require data that is acceptable to the FAA. During an evaluation, an anticipated major alteration may be subsequently classified as a major change in type design, and thus would require application for an amended TC or STC.

c. Job Aid. In order to assist the applicant, the Major Repair and Alteration Data Approval Job Aid associated with this order may be used. The job aid lists those alterations that fall within the authority of this order and those that the FAA has determined must be processed as major changes in type design. The job aid includes description of a reclassification request process applicants may use if they believe a specific change does not warrant the STC process.

6. Major Repair and Alteration Data Approval Job Aid. A job aid associated with this order provides current Aviation Safety (AVS) organization policy for approval methods for specific major repairs and alterations. You may access it from FSIMS—Publications—Other—Job Aids

1-2 or via the Aircraft Maintenance Division’s (AFS-300) web page at https://www.faa.gov/about/office_org/headquarters_offices/avs/offices/afx/afs/afs300/.

7. Directive Feedback Information. Direct questions or comments to AFS-300 at 202-267-1675. For your convenience, FAA Form 1320-19, Directive Feedback Information, is the last page of this order. Note any deficiencies found, clarifications needed, or suggested improvements regarding the contents of this order on FAA Form 1320-19.

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Chapter 2. Field Approval Eligibility

1. Eligibility.

a. Review. ASIs must review the data packages submitted for approval in order to ensure that a field approval is necessary and appropriate. ASIs who deny field approval requests to applicants for alterations or repairs that do not need or qualify for field approvals must explain to the applicant the reason for the denial and, if requested, provide the reason(s) in writing or electronically.

b. Consideration. When determining the basic eligibility of a proposed major repair or major alteration for field approval, the ASI must consider whether the repair or alteration is major or minor. Refer to 14 CFR part 1, § 1.1 and part 43 appendix A.

c. Minor Alterations or Repairs. Minor alterations or repairs do not require FAA-approved data and therefore typically do not receive field approval.

d. Repairs and Alterations. Repairs and alterations that have all the necessary FAA-approved data also do not require field approval.

e. Major Changes. Data supporting major changes in type design are not eligible for approval using the field approval process. Refer to the Major Repair and Alteration Data Approval Job Aid to determine if a reclassification of the change might be justified.

f. Maintenance Program. Data associated with major repairs and alterations to Title 14 CFR part 121-operated aircraft are typically not eligible for approval using the field approval process since owners/operators are required by part 121, § 121.367 to follow their own maintenance program, which includes repairs and alterations. See Chapter 3, Field Approval Process and Data Approval, paragraph 6a, for details.

g. Approved Technical Data. Major alterations and major repairs that have all the necessary DER- or ODA-approved technical data should not require further approval.

h. Field Approval. The field approval process is not authorized for data associated with installation of auxiliary fuel tanks or any other fuel system alterations to which § 121.1117, 14 CFR part 125, § 125.509, and 14 CFR part 129, § 129.117 apply. In addition, data approval using the field approval process is not to be performed for installation of auxiliary fuel tanks or any other fuel system alterations to which 14 CFR part 91, § 91.1507 and §§ 121.1113, 125.507, and 129.113 apply.

i. Limitations. When determining the basic eligibility of a proposed major repair or major alteration for data approval using the field approval process, the ASI must consider limitations that are imposed at aircraft certification and noted on the Type Certificate Data Sheet (TCDS), or that may be the result of issues related to those systems or equipment that have been discovered during the service life of the aircraft and the limitations are mandated by the FAA (e.g., an Airworthiness Directive (AD)).

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Chapter 3. Field Approval Process and Data Approval

1. General Information.

a. Data Approval Authority. One of the means used by the FAA to approve technical data that is used to accomplish a major repair or major alteration is through an authorized ASI or other delegated authority. Technical data, when so approved, becomes data approved by the FAA, but it does not constitute a “type design change approval.”

Note: A No Technical Objection (NTO) letter or statement that a particular maintenance or alteration action is “DER approvable” does not constitute FAA approval. However, such a statement when supported along with other technical information may provide the basis for a field inspector or delegate approval.

When evaluating the compliance of data representing a particular maintenance or alteration action or continue-in-service condition, the data must include substantiated data to support the approval.

b. Field Approval. Field approvals are a method by which the FAA approves technical data used to accomplish a major repair or a major alteration on a single aircraft. A field approval is a one-time approval limited in application to the product or appliance to which it applies. The overall repair and alteration process is illustrated in Figure 3-1, Repair and Alteration Data Approval Process Overview. Paragraphs 2 through 5 below provide further details on the process contained in Figure 3-1. An authorized FAA ASI or appropriately rated DAR signs block 3 of FAA Form 337, Major Repair and Alteration (Airframe, Powerplant, Propeller, or Appliance), in order to approve the data referenced on the form (refer to Order 8000.95). An ASI may approve the data package only or approve the technical data by physical inspection. See paragraph 5 for details. Appropriately rated designees are limited to data approval only.

Note: The information and process steps are provided in Figure 3-1 in a specific order to give a logical representation of progression through the major repair or alteration process. This is not meant to imply that one step must follow another in the order presented. Indeed, several actions may take place concurrently or in a different order. Within the limitations described in this order, the field approval process may be one method of data approval associated with this process.

Note: The paragraph numbers next to the blocks in Figure 3-1 correspond to associated paragraph numbers in this order, which provide information in more detail.

Note: An ASI (or an appropriately rated DAR) approves data on FAA Form 337 for a major repair or alteration to a specific aircraft, powerplant, propeller, or appliance. Prior to September 2002, the FAA permitted approval of data on a single FAA Form 337 for use on multiple aircraft. This practice is no longer permitted. However, past multiple approvals can still be used on identical aircraft by the original modifier.

c. Coordination. A field approval may or may not require engineering assistance or coordination with an ACO.

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Figure 3-1. Repair and Alteration Data Approval Process Overview

d. Alternative to Field Approval. An alternative to a field approval is approval of all the data by a DER or an ODA. In some cases, multiple DERs may be required when the repair or

3-3 alteration deals with several disciplines, such as systems and structures. A DER or ODA that is approving data for a major repair or major alteration must follow paragraphs 2 and 3 of this chapter, as well as Chapters 4 through 8, in making their approvals.

2. Initial Review.

a. Overview. This paragraph presents an overview of the actions an applicant may take when preparing the data package to support a major repair or alteration and the involvement of an ASI when field approval of data is requested.

b. Define the Scope. The applicant may use Advisory Circular (AC) 43-210, Standardized Procedures for Obtaining Approval of Data Used in the Performance of Major Repairs and Major Alterations, or another method acceptable to the FAA, to define the scope of the repair or alteration and develop the associated data.

c. Review and Confirm. The ASI or appropriately authorized designee will review the applicant’s package and confirm that the repair or alteration qualifies as a major repair or alteration. The ASI or designee will:

(1) Refer to the Major Repair and Alteration Data Approval Job Aid to confirm that the project is within the scope of a field approval. If it is determined that the alteration requires an STC, inform the applicant to apply for an STC or amended TC (if the applicant is the design approval holder (DAH)).

(2) Confirm that the applicant, in accordance with § 1.1 and part 43 appendix A, properly determined that the repair or alteration is major. Minor alterations and repairs do not need approved data and therefore do not require approval.

(3) When examining the data for the repair or alteration field approval, determine if all of the data for the project has been approved. If all the required data is approved, then a field approval is not required. If all of the required technical data is not approved, then additional approvals (i.e., DER-approved data) or a field approval are necessary. The compliance checklist in AC 43-210 may be used.

d. Explanation of Denial. ASIs or designees who deny data approval requests for alterations or repairs that do not need or qualify for approval must explain to the applicant the reason for the denial and, if requested, provide the reason(s) in hardcopy or electronic form.

3. Data Evaluation.

a. Considerations. This paragraph addresses several general factors that must be considered when evaluating a data package for major repairs and alterations. The following is a summary of considerations:

(1) Determine the certification basis of product repaired/altered.

(2) Does the data meet the applicable airworthiness requirements?

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(3) Does the installation meet the requirements of the applicable rules?

(4) Are there any model-specific issues that would affect accomplishment of the proposed major repair or alteration (e.g., an AD or a limitation contained in the TCDS that requires ACO consultation for alteration of specific systems)?

(5) Do the installation instructions provide adequate detail to complete the installation on the aircraft?

(6) Is the intended function described and appropriate for the aircraft? If based on previously approved data, is the intended function the same as was approved by the original data?

(7) Are the current or proposed instructions for continued airworthiness (ICA) or maintenance instructions adequate for the proposed repair or alteration? (See Chapter 5, Maintenance Information and Instructions for Continued Airworthiness.)

(8) Is the equipment being installed required under 14 CFR parts 23, 25, 26, 27, 29, 31, 121, and/or 135?

(9) Is the equipment approved per 14 CFR part 21, § 21.8?

Note: Any installed equipment must still meet the airworthiness requirements of the product on which it is installed.

(10) Has adequate substantiating data been provided?

(11) Is an Aircraft Flight Manual Supplement (AFMS)/Rotorcraft Flight Manual Supplement (RFMS) required? If so, is it provided? (See Chapter 6, Airplane and Rotorcraft Flight Manual Supplements.)

(12) Will a flight evaluation be performed? Has it been addressed in the documentation?

(See Chapter 7, Flight Evaluation and Flight Test.)

(13) Have applicable, specific considerations been addressed? (See Chapter 8, Technical Considerations.)

(14) Does the installation or repair affect any special conditions or equivalent level of safety (ELOS) findings? Are those conditions and findings addressed within the supporting data?

Note: This list is not all-inclusive.

b. Aircraft Airworthiness. The applicant must have conducted an evaluation in order to ensure that a proposed repair or alteration will not impact the airworthiness of the aircraft. The applicant will provide verification that the aircraft has been inspected and any aircraft records have been reviewed in order to ensure compatibility of this repair or alteration with previously approved changes to the aircraft.

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c. Effect. The technical data that a major repair or alteration may require must be determined based on the specifics of each application. Installation of equipment or a system that does not have a primary function in flight operation, and whose failure would have no adverse effect on the ability of the flightcrew to properly perform their duties and does not involve complex interface, still requires sufficient data to show compliance with the certification basis and all applicable requirements. In contrast, an alteration that, if it failed, would have more serious consequences would require more extensive substantiation and supporting technical data.

d. Compliance with Airworthiness Standards. The repair or alteration data must show compliance with the pertinent certification basis for the aircraft in question. This will include the basic airworthiness standards and, in addition, any special conditions or ELOS findings that may be applicable, including previously accomplished STCs or major alterations.

e. Operational and Equipment Requirements. An alteration’s effect on required equipment and the aircraft’s operational capability must be considered in the evaluation of the data package. It is important to ensure that an alteration does not inadvertently reduce the operational capability of the aircraft.

4. ACO Coordination Determination.

a. Considerations. This paragraph presents an overview of necessary considerations to determine if engineering assistance is required.

(1) Review the applicant’s data package and consult the Major Repair and Alteration Data Approval Job Aid for the approval path to be followed.

(2) The job aid describes methods of approval for typical major alterations. The job aid is not all-inclusive. The ASI must evaluate each project on a case-by-case basis.

(3) Items not listed in the job aid must be independently evaluated.

b. Necessary Data. If the repair or alteration requires additional engineering-approved data, but does not necessitate ACO involvement, the ASI identifies the data necessary to complete the substantiation of the repair or alteration. The ASI will direct the applicant to use AC 21-47, Submittal of Data to an ACO, a DER, or an ODA for a Major Repair or a Major Alteration, for guidance. The applicant must obtain the approved data on FAA Form 8100-9, Statement of Compliance with Airworthiness Standards, or FAA Form 8110-3, Statement of Compliance with Airworthiness Standards, as necessary.

c. ACO-Coordinated Field Approval.

(1) A coordinated field approval is one in which an ASI requests FAA engineering to provide an evaluation of the proposed repair or alteration and accompanying technical data. The ASI requests a concurrence or nonconcurrence for approval of the technical data.

(2) A coordinated field approval is initiated when it is determined that a proposed repair or alteration (project) may, because of its scope and complexity, be beyond the expertise of an ASI to approve data. The ASI “coordinates” the field approval with an ACO. Alterations

3-6 requiring an AFMS/RFMS may have to be coordinated with the ACO unless ASIs have been specifically authorized to sign the document(s).

(3) An ASI requests ACO engineering assistance following the responsible Flight Standards office’s or Technical Aircraft Maintenance Branch’s procedure. The ASI should submit a copy of the entire package and identify the elements of the project that require ACO participation. A designee must coordinate with their appropriate FAA managing advisor for the procedures to communicate with other lines of business.

(4) If the ACO determines that the intended alteration introduces a major change to the type design requiring application for an STC, the ASI must officially notify the applicant that the field approval request is no longer appropriate and direct the applicant to contact the ACO directly.

(5) If the repair or alteration requires additional engineering-approved data, the ACO will identify the needed information to the ASI who will then coordinate with the applicant to obtain that data.

(6) If ACO coordination is necessary, the written ACO concurrence (e.g., memo or email) becomes an attachment to FAA Form 337.

5. Data Package Approved/Denied for Field Approval.

a. Approval for Data Package Only. If the repair or alteration data substantiates that the repaired or altered product will comply with the applicable airworthiness regulations, record data approval by entering the appropriate statement and signing block 3 of FAA Form 337; then return both copies to the applicant. When recording FAA approval in block 3, the following statement from AC 43.9-1, Instructions for Completion of FAA Form 337, should be used:

“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 section 43.7.”

b. Approval of Technical Data by Physical Inspection. ASIs may schedule a physical inspection with the applicant in order to verify workmanship and conformance to the data submitted. If the repair or alteration complies with regulations, record the repair or alteration approval by entering the appropriate statement and signing block 3 of FAA Form 337; then, return copies to the applicant. When recording FAA approval in block 3, the following statement from AC 43.9-1 should be used:

“Approval by Physical Inspection, Demonstration, Testing, etc.—One Aircraft: The alteration or repair 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 section 43.7.”

Note: An ASI (or an appropriately rated DAR) approves data on FAA Form 337 for a major repair or alteration to a specific aircraft, powerplant, propeller, or appliance. Prior to September 2002, the FAA permitted approval of data on a

3-7 single FAA Form 337 for use on multiple aircraft. This practice is no longer permitted. However, multiple approvals can still be used on identical aircraft by the original modifier.

c. Denial of Proposed Repair or Alteration Approval. If the applicant is unwilling or unable to comply with the requirements to obtain the requested field approval, terminate the process by notification in writing to the applicant. This notification must include the reason for denial. The applicant may be given the opportunity to make necessary corrections within a reasonable amount of time from receipt of notification.

6. Variations to the Field Approval Process.

a. Airplanes TC’d Under Part 23 or Part 25—Operated Under Part 121.

(1) Field Approval Eligibility. These aircraft, although not specifically prohibited from having data approved by field approvals, are not generally eligible, since owners/operators are required by § 121.367 to follow their own maintenance program, which includes repairs and alterations. Field approval of data may be performed on these aircraft for extenuating circumstances, and each request must be evaluated on a case-by-case basis. If an ASI from responsible Flight Standards office believes that a field approval request is appropriate, the responsible Flight Standards office will obtain concurrence from the appropriate Air Carrier Safety Assurance Office prior to performing the approval. Designated Airworthiness Representatives-Maintenance (DAR-T) are prohibited from performing these types of approvals.

(2) Field Approval Database. The cognizant Air Carrier Safety Assurance Office will maintain a database of field approvals accomplished on aircraft operated under part 121 for which it either concurred or nonconcurred. This database will contain:

(a) A unique control number for each instance;

(b) The date of concurrence or nonconcurrence;

(c) The name of the ASI assigned to field approve the data;

(d) The responsible Flight Standards office’s routing symbol;

(e) An indication of concurrence or nonconcurrence;

(f) The air carrier identifier;

(g) The make and model (M/M) of the aircraft; and

(h) A brief description of the requested approval.

b. Commercial Derivative Aircraft (Military). TC’d aircraft operated by or for the U.S.

military require special consideration when approving data by field approvals due to the complexity of the aircraft and systems. Coordinate any request for field approval of data through the FAA Military Certification Office (MCO). The MCO must provide a concurrence that the

3-8 proposed data is compatible with previously installed systems or design criteria. In general, the MCO discourages the use of field approval of data on military aircraft.

c. Incomplete or Incremental Installations.

(1) Conditions and Limitations. If the applicant intends that the aircraft operate for an unspecified period of time (per § 91.213) or without complete equipment or system functionality, then installations of such equipment or components are considered incomplete or incremental.

Installation of equipment or components, such as racks, wiring, circuit breakers, hard-points, etc., may be accomplished and may be eligible for field approval of data if it is determined that the installation is a major alteration to an aircraft. Such aircraft having been altered may receive approval for return to service only if the following have been accomplished:

(a) All applicable technical data was FAA-approved prior to performance of the installation;

(b) The determination that the incomplete or incremental installation does not adversely affect safe operation of the aircraft;

(c) The equipment or components as installed remain deactivated and appropriate placards have been affixed to prohibit use of such equipment or components;

(d) Aircraft Weight and Balance (W&B) data reflects the incomplete installation; and

(e) The aircraft maintenance records and FAA Form 337 for the work that was actually accomplished is complete and signed.

Note: In order to maintain a current airworthiness certificate, the approval for return to service must be accomplished by a person authorized in part 43, § 43.7.

(2) Conformity Inspection. The applicant must conduct a conformity inspection on the completed alteration and submit an FAA Form 337 with complete installation description in block 8. FAA approval of the incremental installation data may provide for use of installed equipment if the FAA can determine that such equipment can be used safely (e.g., may require placards, AFMS/RFMS, or crew training).

d. Transport Canada. Transport Canada Civil Aviation (TCCA) or TCCA designee-approved repair data is considered FAA-approved for use on aircraft registered in the United States, or on engines, propellers, or articles used on U.S.-registered aircraft. Refer to FAA Order 8110.53, Reciprocal Acceptance of Repair Design Data Approvals Between FAA and TCCA, for more information.

e. Reversal of STC or Major Alteration. Occasionally, a request to remove an installed STC or major alteration may be made. When the alteration was originally accomplished, an FAA Form 337 and accompanying data was submitted to record the configuration change.

Similarly, the restoration must be recorded via FAA Form 337, including consideration of any accompanying documentation used in the original alteration. If the original FAA Form 337 data included restoration instructions, then a new FAA Form 337 would not be required. In some

3-9 cases, the original FAA Form 337 may have been submitted only to record approval of an AFMS/RFMS. The removal of the supplement must be recorded via FAA Form 337 and may require ACO or ASI approval.

Note: For removal of a major alteration, whether installed by the manufacturer in production or post-production by an STC, removal of the alteration requires an FAA Form 337 unless the removal instructions are provided with the STC or as part of the production.

f. Major Repairs and Alterations for Engines and Propellers. Major repairs and alterations can also be performed on engines and propellers. The repair or alteration is documented on FAA Form 337, but it is not recorded until the engine or propeller is installed on an aircraft. Refer to AC 43.9-1.

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Chapter 4. Data

1. Introduction. This chapter provides guidance related to the sources, use, and approval of data used to substantiate an aircraft major repair or major alteration.

2. Types of Technical Data. In the context of this order, technical data means the drawings, specifications, and other material that provide the description and substantiation of an aircraft repair or alteration. There are several ways in which data may be labeled and described.

a. Descriptive Data. Descriptive data describes the design of the repair or alteration.

Descriptive data should include reference to installation methods, materials, fabrication processes, dimensions, and tolerances. It may also include intended function and how the alteration is appropriate to the aircraft.

b. Substantiating Data. Substantiating data shows that the design complies with the applicable regulations and that all appropriate technical considerations have been addressed.

c. Acceptable Data. Acceptable data means data acceptable to the FAA. The terms “acceptable to the Administrator” and “acceptable to the FAA” appear numerous times in the maintenance regulations. They refer to any item addressed in the regulation (e.g., data; methods, techniques, and practices; manual contents; tools; materials; equipment, etc.) that must meet regulatory standards. If the regulation requires only that an item must be “acceptable to,” it does not necessarily follow that the FAA requires the item to have specific FAA review and acceptance before it may be used. A person making a determination of whether an item is “acceptable to” the agency must ensure the item addresses specific applicable section(s) of the regulations.

d. Approved Data. Approved data means data approved by the FAA. The term “approved” is based on § 1.1, which states, “Approved, unless used with reference to another person, means approved by the FAA or any person to whom the FAA has delegated its authority in the matter concerned, or approved under the provisions of a bilateral agreement between the United States and a foreign country or jurisdiction.” For the FAA ASI, “approved” or “approved by” means the item (e.g., data; methods, techniques, and practices; manual contents; tools; materials;

equipment, etc.) is required to be and has been reviewed and formally approved by the FAA (or appropriate Civil Aviation Authority (CAA)). Approvals are granted only by letter, by a stamp of approval, by the issuance of operations specifications (OpSpecs), or by other official means. All data used to substantiate a major repair or alteration, regardless of the source, must be approved before being used.

e. Previously Approved. This term refers to data that was approved for a specific purpose, such as an STC or major alteration on an aircraft, powerplant, propeller, or appliance. All previously approved data has to be applicable to the requested major repair or alteration. All differences, deviations, inclusions, and exclusions between the original use of the data and the current one must be considered before the data can be approved for use. Figure 4-1, Possible Resources for Approved Data Relevant to Major Repairs or Major Alterations, identifies possible sources of previously approved data that may be relevant to a major repair or major alteration.

Figure 4-1 is not all-inclusive.

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(1) Previously approved data on FAA Form 337 for a single product identified in block 1 may be used to substantiate a similar repair or alteration on a different product or article, but it must be evaluated for each new application to determine if, and how much of, the data can be directly approved. Reference to the previous FAA Form 337 itself does not constitute substantiation; the actual data must be available if requested.

(2) Previously approved data may also refer to data that has been approved for use on multiple products or articles. In this case, further review or approval of that data would not be necessary for the products or articles identified in the approval.

(a) An example of this would be data approved by a DER on FAA Form 8110-3 that is applicable to more than one specific serial number aircraft.

(b) Another example would be technical data contained in a repair specification (RS).

RS provide an alternative to major repair technical data. Approval as an RS is required for multiple-use major repairs that do not come from the DAH and do not specifically identify serial numbers of all the products or parts currently in need of repair to which the RS applies. Refer to FAA Order 8110.37, Designated Engineering Representative (DER) Handbook, and FAA Order 8300.13, Repair Assessment Program, for more details on RS.

f. Multiple Use Data. An ASI (or an appropriately rated DAR) approves data on FAA Form 337 for a major repair or alteration to a specific aircraft, powerplant, propeller, or appliance. Prior to September 2002, the FAA permitted approval of data on a single FAA Form 337 for use on multiple aircraft. This practice is no longer permitted. However, existing multiple approvals can still be used on identical aircraft by the original modifier.

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Figure 4-1. Possible Resources for Approved Data Relevant to Major Repairs or Major Alterations

TCDS. Refer to FAA Order 8620.2, Applicability and Enforcement of Manufacturer’s Data, for guidance.

Repair data from AC 43.13-1, Acceptable Methods, Techniques, and Practices—Aircraft Inspection and Repair, may also be used as approved data, and the AC chapter, page, and paragraph listed in block 8 of FAA Form 337 when the user has determined that it is:

• Appropriate to the product that receives repairs;

• Directly applicable to the repair being made; and

• Not contrary to the airframe, engine, propeller, or appliance manufacturer’s repair data or instructions.

Alteration data from AC 43.13-2, Acceptable Methods, Techniques, and Practices—Aircraft Alterations, may be used as approved data for major alterations when the AC chapter, page, and paragraph are listed in block 8 of FAA Form 337 when the user has determined that it is:

• Appropriate to the product being altered;

• Directly applicable to the alteration being made; and

• Not contrary to the airframe, engine, propeller, product, or appliance manufacturer’s data.

ADs.

Appliance manufacturer’s manuals or instructions, unless specifically not approved by the FAA, may be used as approved data for major repairs.

Data describing an article used in an alteration which is FAA-approved under a Parts Manufacturer Approval (PMA).

Data developed during the FAA authorization of an article for production under a Technical Standard Order (TSO) when applicable to the repair or alteration intended.

Data in the form of an appliance type approval issued by the Minister of Transport Canada for those parts or appliances for which there is no current TSO available. The installation manual provided with the appliance includes the environmental performance qualification statement.

DER-approved data, including repair specifications, within the limitations listed on the DER’s authorization (see chapter 9, paragraph 5).

ODA-approved data, within the limitations of the ODA holder’s procedures manual (see chapter 9, paragraph 6).

FAA-approved portions of Structural Repair Manuals (SRM).

FAA-approved Service Bulletins (SB) and Service Letters (SL) or similar documents as documented in AC 20-77, Use of Manufacturers’ Maintenance Manuals.

Foreign bulletins, for use on U.S.-certificated foreign-designed aircraft, when approved by the foreign authority within the provisions of a bilateral agreement with the United States or as listed in the TCDS notes.

Original aircraft manufacturer’s service and repair data in accordance with current regulations, for major repairs on nonpressurized elements of aircraft that are 12,500 pounds or less maximum certificated takeoff weight provided the person intending to perform such repair determines that:

• Data is appropriate for the specific M/M aircraft being repaired;

• Data is applicable to the specific M/M aircraft being repaired; and

• The repair does not deviate from the manufacturer’s methods, techniques, and practices.

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Figure 4-1. Possible Resources for Approved Data Relevant to Major Repairs or Major Alterations (Continued)

United States Department of Commerce (DOC) Form ACA-337, Major Repair and Alteration, dated prior to October 1, 1955, provided the data is appropriate, directly applicable, and not contrary to regulatory requirements.

STC data, including that for approved model list (AML) STCs, may be used, if applicable, to substantiate a major alteration on a different aircraft.

FAA Form 337, previously approved for use on multiple identical aircraft (see subparagraph 2f) when used by the original alterer.

Note: Maintenance manuals issued by DAHs, Production Approval Holders (PAH), and certain supplier manuals (i.e., those for which the supplier is the actual designer and producer of an article that is approved under 14 CFR part 21) were developed using part 21 approved technical data. This technical data remains FAA-approved provided the design change requirements of part 21 are followed. Therefore, it does not require reapproval when a major repair or major alteration is performed in accordance with these maintenance manuals.

(3) Previously approved data may not be directly applicable to repair or alteration of certain products or appliances. For example, such data may identify a location to which an appliance or component part cannot be located due to a mounting conflict or configuration differences. Relocation may be considered a deviation from the previously approved data. In these instances, the ASI must consider the deviation and, if appropriate, may consult with the cognizant ACO responsible for issuance of the TC or STC. Consideration for field approval may occur provided that the applicant can show that the alteration meets the certificated characteristics with regard to aerodynamic function, structural strength, resistance to vibration, and deterioration, and that other qualities affecting airworthiness are not adversely affected.

Minor deviations from previously approved data do not require reapproval. The aircraft records must identify and include such deviations.

(4) Data that was approved for alteration of a particular product type (e.g., part 25 aircraft) may be used to provide substantiation for a similar alteration on a different product type (e.g., part 23 aircraft).