Avionics Shop Manual: Uncontrolled Document

UNCONTROLLED DOCUMENT
Avionics Shop Manual
Address: KF Aerospace
5655 Airport Way
Kelowna, BC
V1V 1S1
Telephone: (250) 491-5500

Fax: (250) 765-1489
Manual Owner: Vinny Sharma
MANUAL NUMBER: __________
Page: i
Revision: 3 Re-issue
Date: 2018 Feb 09
RECORD OF REVISIONS
REVISION NO. AFFECTED PAGES ISSUE DATE

0 All pages – Reissue 23 Feb 00
1 Form QA-712; Certification, pg. ii; Table of Contents, pg. iv-viii; 13 Apr 00
Effective Pages, pg. ix-x; Index, xiii-xv; Section 1-0; Section 2-0;
Section 5-2;
2 Form QA-712; Certification; Table of Contents; Effective Pages; 1 Aug 00
Distribution; Description; Index; Section 4-2; Section 4-12; Section 4-
13; Section 7-2
3 Form QA-712; Certification; Table of Contents; Effective Pages; Index; 1 Dec 00
Section 1-0; Section 2-0; Section 4-13; Section 5-0; Section 5-1;
Section 5-2; Section 8-0
4 Form QA-712; Certification; Table of Contents; Effective Pages; Index; 1 Mar 01
Section 1-0; Section 5-1; Section 8-1; Section 8-2; Appendix A; Form
MTC-155
5 Form QA-712; Certification; Effective Pages; Section 8-2 1 Apr 01
0 Re-issue All pages - Reissue 13 Feb 04
1 Form QA-712, Certification, Contents; Effective Pages; Objectives; 27 Apr 04
Section 4-3; Section 4-6;Section 5-0; Section 6-0; Section 8-2
0 Re-issue All Pages - Reissue 10 Nov 2009

1 Record of Revisions; Certification Page (deleted); Statement of 2013 Jul 18
Compliance; Table of Contents; List of Effective Pages; Distribution;
Index; Objectives (deleted); Section 1-0; Section 2-0; Section 3-0;
Section 4-5; Section 4-7; Section 4-8; Section 5-0; Section 7-0; Section
8-0; Section 8-1; Section 8-2; Appendix A
2 Cover Page; Record of Revisions; Table of Contents; List of Effective 2016 Nov 07
Pages; Distribution; Description; Index; Section 1-0; Section 2-0;
Section 3-0; Section 5-0; Section 5-1; Section 5-2; Section 7-0; Section
8-1; Section 8-2
3 Reissue All Pages - Reissue 2018 Feb 09
Page: ii
REVISIONS Revision: 3 Re-issue
Date: 2018 Feb 09
TABLE OF CONTENTS
RECORD OF REVISIONS
STATEMENT OF COMPLIANCE
TABLE OF CONTENTS
LIST OF EFFECTIVE PAGES
DISTRIBUTION LIST
DESCRIPTION
INDEX
SECTION 1-0 AVIONICS PERSONNEL

1. Titles and Responsibilities
A. Description
B. Avionics Shop Supervisor
C. Avionics Assembly and Radio Shop Lead
D. Avionics Assembly Shop Lead Hand
E. Wire Harness Assemblers
F. Avionics Radio Shop Lead Hand
G. Lab Technician
SECTION 2-0 AVIONICS ORGANIZATIONAL CHART

1. Organization Chart
A. Distribution of Responsibilities
SECTION 3-0 MANUAL REVISION

1. Procedures
A. General
SECTION 4-0 PROCESS CONTROL

1. General
SECTION 4-1 USE OF IRIDITE 14-2 AND ISOPREP 188

1. Process
A. General
2. Safety & Handling
A. General
Page: iv
CONTENTS Revision: 3 Re-issue
Date: 2018 Feb 09
3. Typical Process Cycle

A. Clean (as recommended)
B. Iridite
SECTION 4-2 WIRE MARKING

1. Process
A. Industry Standards
2. Procedure
A. Wiring Inspection Procedure
SECTION 4-3 WIRING HARNESS

1. Preparation
A. Standards
2. Wire Stripping
A. General
3. Crimping
A. Verification
B. Completed unmated connectors
SECTION 4-4 ELECTRICAL HARDWARE, TRAYS, ETC. RADIO RACK SHELVES OFF
AIRCRAFT
1. Preparation and Assembly
A. Standards
B. Verification
C. Testing
2. Work Cards or Work Orders
A. Completion of Work
SECTION 4-5 AVIONICS TOOLING REFERENCE

1. Procedure
A. Proper Use guidelines
SECTION 4-6 CONTROL OF INSPECTION MEASURING AND TEST EQUIPMENT

1. General
A. Calibration of Crimping Equipment Go/No-Go Gauges (24 months)
B. Crimping Tool Calibration
C. Calibration of Linaire Panels
Page: v
Date: 2018 Feb 09
SECTION 4-7 SOLDERING OF ELECTRICAL CONNECTIONS

1. Procedures
A. General
B. Solder Practices
SECTION 4-8 INTENTIONALLY LEFT BLANK
SECTION 4-10 WIRING MAINTENANCE PRACTICES

1. Process Control
A. General
B. Particular Points of Installation
C. Lug Termination
D. Bonding
E. Power Checks, Ground Checks and Continuity Checks
F. Power Checks and Ground Checks
G. Continuity Checks
2. Wire Inspection
A. General
3. Possible Wire Degradations
A. Causes
4. Wiring Inspections
A. Special Attention Installations
SECTION 5-0 CONTROL OF WORK ORDER (FORM NO. M3MTC-M255)

1. Control Process of the Work Order (M3)
A. Initiating Work Order
B. Controlling Work Order
C. Moving the final product
Page: vi
Date: 2018 Feb 09
SECTION 5-2 WARRANTY WORK

1. Production Control
A. Process
B. Procedure
C. Original Equipment Manufacture (OEM) Warranty
SECTION 7-0 TRAINING

1. Training
A. General
B. Avionics Department Supervisor
C. Avionics Crew Chief
D. Avionics AME
E. Avionics Apprentice/Technician
F. Wire Harness Assembler
G. Lab Lead/Technician
H. Avionics Assembly Shop Lead Hand
SECTION 8-0 AVIONICS LABORATORY OPERATIONS

1. General
A. Approved dealerships
2. Laboratory Technicians
A. Responsibilities
SECTION 8-1 LABORATORY PRODUCTION

1. Process
A. General
2. Line Maintenance Stations
A. Parts & LRUs
3. External Customers
A. Parts & LRUs
Page: vii
Date: 2018 Feb 09
SECTION 8-2 LABORATORY REPORT (FORM MTC-155)

1. Avionics Laboratory Report
A. General
B. Use
C. Procedure
D. Initiating the form
E. Customer Approves Quote
F. Customer Refuses Quote
G. Beyond Economical Repair (BER)
SECTION 9-0 NON-CONFORMING PRODUCT

1. Control
A. Procedure
B. Non-Conformance and General Action
C. Rejected / Beyond Economic Repair or Scrapped Product.
SECTION 10-0 ELECTROSTATIC SENSITIVE DEVISE (ESD) - HANDLING

1. Handling
A. Policy / Procedures
B. ESD Components
C. Line Replaceable Unit (LRU) Handling
D. ESD Handling
APPENDIX A FORMS
1. Forms List
A. General
Page: viii
Date: 2018 Feb 09
LIST OF EFFECTIVE PAGES
Page No. Page Date Revision Page No. Page Date Revision
Cover page i 2018 Feb 09 3 Reissue 2 2018 Feb 09 3 Reissue
Revisions ii 2018 Feb 09 3 Reissue Section 4-5 1 2018 Feb 09 3 Reissue
Compliance iii 2018 Feb 09 3 Reissue Section 4-6 1 2018 Feb 09 3 Reissue
Contents iv 2018 Feb 09 3 Reissue 2 2018 Feb 09 3 Reissue
v 2018 Feb 09 3 Reissue Section 4-7 1 2018 Feb 09 3 Reissue
vi 2018 Feb 09 3 Reissue Section 4-8 1 2018 Feb 09 3 Reissue
vii 2018 Feb 09 3 Reissue Section 4-9 1 2018 Feb 09 3 Reissue
viii 2018 Feb 09 3 Reissue Section 4-10 1 2018 Feb 09 3 Reissue
LEP ix 2018 Feb 09 3 Reissue 2 2018 Feb 09 3 Reissue
x 2018 Feb 09 3 Reissue 3 2018 Feb 09 3 Reissue
Distribution xi 2018 Feb 09 3 Reissue 4 2018 Feb 09 3 Reissue
Description xii 2018 Feb 09 3 Reissue Section 5-0 1 2018 Feb 09 3 Reissue
Index xiii 2018 Feb 09 3 Reissue Section 5-1 1 2018 Feb 09 3 Reissue
Section 1-0 1 2018 Feb 09 3 Reissue Section 5-2 1 2018 Feb 09 3 Reissue
2 2018 Feb 09 3 Reissue Section 6-0 1 2018 Feb 09 3 Reissue
4 2018 Feb 09 3 Reissue 2 2018 Feb 09 3 Reissue
Section 4-0 1 2018 Feb 09 3 Reissue 2 2018 Feb 09 3 Reissue
2 2018 Feb 09 3 Reissue
Section 4-2 1 2018 Feb 09 3 Reissue
2 2018 Feb 09 3 Reissue
Page: ix
LEP Revision: 3 Re-issue
Date: 2018 Feb 09
DISTRIBUTION LIST
The Quality Assurance Department is responsible for maintaining a master controlled circulation list of
this manual in order to facilitate positive revision/recall action.
Manuals distributed in support of technical proposals or marketing projects shall not be registered or
subject to revision follow-up or recall action.
Copy No. Holder of Copy
1. Avionics Library
2. QA Department
3. KF Intranet
Page: xi
DISTRIBUTION Revision: 3 Re-issue
Date: 2018 Feb 09
DESCRIPTION
Kelowna Flightcraft Ltd. Avionics Department is a Transport Canada approved organization operating
under Approval Number 16-82 and is authorized to perform Work I.A.W. MPM 1-0.
Page: xii
DESCRIPTION Revision: 3 Re-issue
Date: 2018 Feb 09
INDEX
APPENDIX A – FORMS .................................................................................................... APPENDIX A
AVIONICS LABORATORY OPERATIONS ....................................................................... SECTION 8-0
Avionics Laboratory Report ................................................................................................ Section 8-2,1
AVIONICS ORGANIZATIONAL CHART ........................................................................... SECTION 2-0
AVIONICS PERSONNEL .................................................................................................. SECTION 1-0
AVIONICS TOOLING REFERENCE ................................................................................. SECTION 4-5
CONTROL OF INSPECTION Measuring and Test Equipment .......................................... SECTION 4-6
CONTROL OF WORK ORDER (FORM NO. M3MTC-M255) ............................................ SECTION 5-0
Crimping ............................................................................................................................ Section 4-3,3
ELECTRICAL HARDWARE, TRAYS, ETC. RADIO RACK SHELVES OFF AIRCRAFT ... SECTION 4-4
ELECTROSTATIC SENSITIVE DEVISE (ESD) – HANDLING .........................................SECTION 10-0
External Customers ........................................................................................................... Section 8-1,3
LABORATORY PRODUCTION ........................................................................................ SECTION 8-1
LABORATORY REPORT (FORM MTC-155) .................................................................... SECTION 8-2
Line Maintenance Stations ................................................................................................. Section 8-1,2
MANUAL REVISION ......................................................................................................... SECTION 3-0
NON-CONFORMING PRODUCT ..................................................................................... SECTION 9-0
Possible Wire Degradations ............................................................................................. Section 4-10,3
PROCESS CONTROL ...................................................................................................... SECTION 4-0
Safety & Handling .............................................................................................................. Section 4-1,2
SOLDERING OF ELECTRICAL CONNECTIONS ............................................................. SECTION 4-7
Titles and Responsibilities ................................................................................................. Section 1-0,1
TRAINING ........................................................................................................................ SECTION 7-0
Typical Process Cycle ........................................................................................................ Section 4-1,3
USE OF IRIDITE 14-2 AND ISOPREP 188 ....................................................................... SECTION 4-1
WARRANTY WORK ......................................................................................................... SECTION 5-2
Wire Inspection ................................................................................................................ Section 4-10,2
WIRE MARKING ............................................................................................................... SECTION 4-2
Wire Stripping .................................................................................................................... Section 4-3,2
WIRING HARNESS .......................................................................................................... SECTION 4-3
Wiring Inspections ........................................................................................................... Section 4-10,4
WIRING MAINTENANCE PRACTICES ...........................................................................SECTION 4-10
Page: xiii
INDEX Revision: 3 Re-issue
Date: 2018 Feb 09
SECTION 1-0 - AVIONICS PERSONNEL

1. Titles and Responsibilities
A. Description
1) The following paragraphs, headed by the various job titles of the Avionics personnel
at Kelowna Flightcraft Ltd., provide information to whom the position reports to, the
qualifications required to carry out the job, the job requirements as to whom appoints
the individual for the position, their responsibilities, and their duties.
B. Avionics Shop Supervisor
1) Reports To: YLW Maintenance Manager.
2) Immediate Subordinates: Avionics Shop Leads.
3) Qualifications: In possession of a valid AME Type E Category Licence with Aircraft
Certification Authority Issued by KFL.
4) Job Requirements: Must be nominated by the YLW Maintenance Manager.
5) Responsibilities: To ensure the efficient and timely completion of those tasks
assigned by the Planning Group, MOC and YLW Maintenance Manager. To ensure
the YLW Maintenance Manager is kept aware of any technical delays and
administrative problems.
6) Duties:
Duties include, but are not limited to:
a) Tasking and scheduling of Avionics Shop Leads.
b) General administration of Leads, work cards and inter-departmental requests.
c) Supply technical advice to line base personnel.
d) Provide technical assistance for customers as required.
e) Assist in the ongoing training requirements and ensure that on-the-job training
is supplied by qualified AME’s to the unlicensed personnel.
f) Liaise with Engineering and Convair Division to resolve problems outside of the
scope of the crew chiefs.
g) Initiate, recommend or provide solutions through designated channels.
h) Ensure that correct procedures are followed by all maintenance personnel for
the control of all drawings used.
i) Ensure that during any absence, Leads or the senior personnel on each shift is
aware of outstanding tasking requirements.
Page: 1
1-0 Revision: 3 Re-issue
Date: 2018 Feb 09
C. Avionics Assembly and Radio Shop Lead

1) Reports To: Avionics Shop Supervisor.
2) Immediate Subordinates: Avionics Assembly Shop Lead Hand and Avionics Radio
Shop Lead Hand
3) Qualifications: In possession of a valid AME Type E Category license with aircraft
certification authority issued by KFL. A clear and in-depth understanding of
installation practices and procedures. Knowledge of the applicable regulations
pertaining to wiring installation and aerospace vehicles.
4) Job Requirements: Must be nominated by the Avionics Shop Supervisor.
5) Responsibilities: To ensure the efficient and timely completion of those projects/tasks
assigned by the Avionics Shop Supervisor.
6) Duties:
a) To inspect Avionics/Electrical products manufactured by KFL.
b) Tasking and scheduling of all assemblers.
c) On-the-job training for wire harness assemblers and unlicensed avionics
technicians.
d) Preparation of quotes for wire printing, wire table production and harness
builds.
e) General administration of assemblers, and technicians ie. annual reviews,
probationary reviews, time sheets, production cards and work cards.
f) Assist in the process to ensure “on time” delivery of parts for each project.
g) Initiate, recommend or provide solutions through designated channels.
h) Carry out performance checks to ensure conformity and correct technical
content on each project.
i) Ensure that during any absence the Lead Hand is made aware of all
outstanding requirements.
j) Provide technical assistance for customers as required.
Page: 2
Date: 2018 Feb 09
D. Avionics Assembly Shop Lead Hand

1) Reports To: Avionics Assembly and Radio Shop Crew Chief (Also Known as Shop
Crew Chief)
2) Immediate Subordinates: All wire harness assemblers and any other personnel
assigned to harness production.
3) Qualifications: A clear and in depth understanding of harness assembly production
practices and procedures. Must hold a Company SCA.
4) Job Requirements: Must be nominated by Avionics Shop Supervisor.
5) Responsibilities: Responsible to shop crew chief for the timely accomplishment and
quality of produced items.
6) Duties:
Duties include but are not limited to
a) In conjunction with the crew chief the tasking and scheduling of assemblers.
b) Timely delivery of parts to work areas.
c) Wire inventory for upcoming and in work projects.
d) Servicing and repair of used wire harness.
e) Initiate, recommend or provide solutions through designated channels.
E. Wire Harness Assemblers
1) Reports To: Assembly Shop Lead Hand.
2) Immediate Subordinates: N/A.
3) Qualifications: Computer literate, plus On-The-Job training to acceptable standards.
5) Responsibilities: Responsible to the Assembly Shop Lead Hand for the timely
accomplishment and quality of the tasks assigned to them.
6) Duties:
a) Mark and cut lead/harness assemblies in accordance with the Avionics Manual,
relevant manuals and/or guidelines, using wire tables or lead assembly
drawings. All work to be carried out on either production workcards or work
orders.
b) Sort and form lead/harness assemblies to lead assembly drawings or wire
tables.
Page: 3
Date: 2018 Feb 09
c) Terminate wiring at connectors as designated by lead assembly drawings or

installation instructions in accordance with manufacturers specifications
(crimping equipment) AC43/C-17/CAR’s.
d) Wrap and /or tie completed lead/harness assemblies in accordance with
AC43/C-17. Assist in ring-out of designated assemblies.
F. Avionics Radio Shop Lead Hand
1) Reports To: Avionics Shop Crew Chief.
2) Immediate Subordinates: Lab Technicians.
3) Qualifications: Successful graduate from a TCA approved Avionics training course.
a) In possession of a valid A.M.E. Type E license. Must hold a Company ACA.
b) Must have extensive applicable OEM Equipment/System Training.
5) Responsibilities: Responsible to the Avionics Department Supervisor for the timely
accomplishment and quality of the servicing, repair and overhaul of avionics
components.
6) Duties:
a) Responsible for the servicing and repair of all equipment the Avionics
Department is authorised to carry out, in accordance with manufacturers
specifications, laid out in the relevant publications and the completion of work
orders.
b) Provide estimates to stores/outside sales for customer equipment.
c) Carry out all calibrations which do not require the equipment to be returned to a
calibration laboratory.
d) Provide OJT for Lab Techs.
f) Provide technical support to Avionics maintenance technicians in/out shop
environment and bases.
g) Assist customers in purchasing Avionics Equipment.
G. Lab Technician
1) Reports To: Avionics Radio Shop Lead Hand.
2) Immediate Subordinates: N/A.
Page: 4
Date: 2018 Feb 09
3) Qualifications: Successful graduate from a TCA approved Avionics training course.

5) Responsibilities: Responsible to the Avionics Lab Supervisor for the timely
accomplishment and quality of the servicing, repair and overhaul of avionics
components.
6) Duties:
a) Responsible for the servicing and repair of all equipment the Avionics
Department is authorized to carry out, in accordance with manufacturers
specifications, laid out in the relevant publications and the completion of work
orders.
b) Provide lab supervisor with quotes on customer equipment.
c) Initiate, recommend or provide solutions through designated channels.
Page: 5
Date: 2018 Feb 09
SECTION 2-0 - AVIONICS ORGANIZATIONAL CHART

1. Organization Chart
A. Distribution of Responsibilities
1) The following organization chart depicts the distribution of responsibilities of the
Avionics Department at Kelowna Flightcraft Ltd.
Director of Maintenance
YLW Maintenance Manager
Avionics Shop Supervisor
Avionics
Assembly Shop and
Radio Shop Crew Chief
Assembly Shop Radio Shop

Lead Hand Lead Hand
Wire
Lab Technician
Assemblers
Figure 1 - Avionics Organization Chart
Page: 1
Date: 2018 Feb 09
.
SECTION 3-0 - MANUAL REVISION

1. Procedures
A. General
1) The Avionics Shop Supervisor is responsible for the periodic review and revision of
this manual and shall ensure that it accurately describes the Quality Procedures
currently in use within the Avionics Department.
2) Changes shall be accomplished by replacement of the complete page(s) affected by
the change.
3) Each revision shall be numbered consecutively beginning at number one for the first
revision of each issue.
4) Revision numbers will revert to 1 following a re-issue.
5) The revision number and date shall appear on each affected page. A marginal
indication shall be placed on the inside margin to indicate where changes, additions
or deletions have taken place since the last revision.
6) Avionics Manual change request are processed using the Document Change History
(Form QA-700) and can be raised by any employee. Once raised it will be reviewed
and approved/rejected by the Avionics Shop Supervisor, then moved on to QA for
approval.
Page: 1
Date: 2018 Feb 09
SECTION 4-0 - PROCESS CONTROL

1. General
This section describes the various process used in the Avionics Department only. On-Aircraft
Avionics and Electrical procedures are detailed in Chapter 20 – Standard Practices of each
aircraft type Maintenance Manual and/or aircraft type Wiring Diagram Manual.
Page: 1
Date: 2018 Feb 09
SECTION 4-1 - USE OF IRIDITE 14-2 AND ISOPREP 188

1. Process
A. General
1) This work instruction is to define the process for use of Iridite 14-2.
a) Iridite 14-2 is a chemical process that produces a protective chromate
conversion film on aluminum and aluminum alloys.
2) Application is by brush or swab, producing coatings ranging from clear to dark yellow,
the darker coatings provide the greatest corrosion protection.
2. Safety & Handling
A. General
1) Iridite 14-2 is a highly acidic material that contains chromium compounds.
2) Store in tightly closed container away from direct heat and sunlight.
3) Do not store near combustibles and reducing materials.
4) Do not swallow.
5) Contact with other materials may cause fires.
6) Avoid breathing powder dust during mixing operations.
7) Avoid breathing solution vapor or mist.
8) Wear an approved respirator, in accordance with CSA Z94.4, 1982 or most recent
edition.
9) Use with adequate ventilation.
10) Iridite 14-2 can cause severe burns on contact with eyes and skin and may be
harmful if swallowed.
11) When handling, wear rubber gloves, rubber apron, rubber boots, safety goggles and
face shield.
12) Wash thoroughly after handling.
NOTE 1: Iridite 14-2 solutions at concentrations substantially in excess of 4oz/gal
(30g/L) will slowly decompose and release toxic concentrations of
cyanide gas. Read Material Safety Data Sheet carefully before use.
NOTE 2: When mixing Iridite 14-2 or Isoprep 188 ALWAYS add the crystals to the
water.
Page: 1
Date: 2018 Feb 09
3. Typical Process Cycle

A. Clean (as recommended)
1) Degreasing: Degrease heavily soiled work with a solvent wash, then acid clean. For
lightly soiled or fingerprinted work, acid clean alone should be sufficient.
2) Mechanical Cleaning: Sanded, ground, wire brushed, or freshly cut surfaces may be
treated with Iridite 14-2 without cleaning provided the treatment is accomplished
immediately.
3) Acid Cleaning: Apply the solution (Isoprep188) with brush or swab until water breaks
disappear and surface is completely wet. Let stand for 3 to 5 minutes, rinse
thoroughly before applying Iridite 14-2.
NOTE 1: Isoprep 188 solution – 6 to 8 oz/gal (45 to 60 g/L)
4) Rinse
B. Iridite
1) Iridite 14-2: Apply the solution with brush or swab. Let stand for 1 to 3 minutes, rinse
thoroughly and dry. Usually the film produced by a single application is light in color.
a) Repeat applications of fresh solution increases film thickness to where a golden
yellow or brown color appears.
NOTE 1: Iridite 14-2 solution – 1 ¼ oz/gal (9.4 g/L)
2) Rinse
3) Dry
a) Drying: May be accomplished by warm air application, the temperature of which
is not to exceed 160°F (71°C). Or dry cloth wipe, providing the cloth is free of all
contamination, chemical or otherwise.
Page: 2
Date: 2018 Feb 09
SECTION 4-2 - WIRE MARKING

1. Process
A. Industry Standards
1) The following assures that wiring conforms to Engineering and authorized industry
standards, when using cold laser method of wire marking.
2. Procedure
A. Wiring Inspection Procedure
1) General
a) Ensure that up-to-date approved drawings, applicable Production work cards or
work orders are available and used, also that a wire table has been produced
and loaded into the wire marker PC.
b) Unless otherwise specified all new wiring being used shall conform to SAE-
AS50881, MIL-W-22759D, Supp. 1B, or the customers engineering drawings
KAPTON OR PVC insulated wire shall not be used.
c) Examine wire lettering on selective basis for legibility shade and positioning,
also inspect insulation for nicks and abrasions.
d) Ensure wire marking conforms to engineering drawings with respect to wire
codification.
e) Unless otherwise specified ensure that wire marking conforms to SAE-
AS50881, identification shall be at intervals of not more than three inches along
their entire length and within three inches of each junction or termination point
or both.
f) Marked sleeves will be used where the cable itself cannot be marked. The
sleeves will be secured at 3-foot intervals and within three inches of each
junction and/or termination point, unless otherwise specified.
g) Wire identification at terminal boards shall be between termination point and
where wire joins bundle.
h) At completion of process product will be inspected and approved and where
applicable a Form One or C of C will be raised.
Page: 1
Date: 2018 Feb 09
SECTION 4-3 - WIRING HARNESS

1. Preparation
A. Standards
1) The following assures that wiring harness preparations conforms to authorized
standards.
2) Always use drawings at latest revision, work cards or work orders.
2. Wire Stripping
A. General
Ensure that:
1) There are no nicks or broken strands;
2) All insulation is removed from the stripped area and,
3) The wire should be stripped to a length suitable to the connection being made:
a) Crimp pins and sockets without an integral cup, and splices that do not crimp
down on to insulation (ie: Raychem) – the wire should be visible in the contact
inspection hole and insulation must be within 0.016 and 0.031 inches from the
end of the contact.
b) Crimp pins and sockets with an integral cup, the wire should be visible in the
contact inspection hole and insulation must be inside the cup, but so the ending
of the insulation is still visible upon inspection.
c) Crimps that include a two part crimp, conductor as well as an insulation
retaining crimp (ie: AMP) the wire should be stripped to the length that
accommodates both crimps with no overlap of insulation into the conductor
crimp and such that the conductor is visible at the inspection hole, or end.
4) Perform an inspection IAW approved design data, or in the case where design data
does not detail inspection criteria, perform the inspection IAW the applicable section
of IPC-A-620.
a) In the case of a conflict between the Engineering data and IPC-A-620,the
Engineering data shall take precedence.
3. Crimping
A. Verification
1) Verify that the following is satisfied:
a) Standard crimping Mil Spec crimping tools MIL-C-22520/1 , MIL-C-22520/2,
MS3191-1 and MS3191-2 are used along with OEM Recommended tooling to
perform this procedure.
Page: 1
Date: 2018 Feb 09
b) All crimping tools are checked for proper calibration with GO/NO-GO gauge
before each series of operations.
c) After crimping, ensure the wire is visible in inspection hole and insulation is
within specifications.
d) Ensure that the correct insertion tool is used for crimp type contacts during
installation.
B. Completed unmated connectors
Completed unmated connectors following assembly operations shall be protected with
suitable dust cap.
1) Perform an inspection IAW approved design data, or in the case where design data
does not detail inspection criteria, perform the inspection IAW the applicable section
of IPC-A-620.
a) In the case of a conflict between the Engineering data and IPC-A-620,the
Engineering data shall take precedence.
Page: 2
Date: 2018 Feb 09
SECTION 4-4 - ELECTRICAL HARDWARE, TRAYS, ETC. RADIO RACK SHELVES OFF
AIRCRAFT
1. Preparation and Assembly
A. Standards
1) The following assures that assembly of electrical hardware, trays, etc. conforms to
authorized standards.
2) Always use up-to-date drawings, work cards or work orders.
B. Verification
1) Verify that the following are satisfied:
a) All drilled/manufactured holes are to drawing requirements (size, location,
deburring, and/or counter-sink).
b) All fasteners and hardware conform to drawing specification as to type,
location, and installation.
c) Bonding and grounding surfaces shall be free of all oil, grease, paint, anodic
film, and other non-conducting material with particular attention to preparation
of bare metal contact areas, and that the bare metal contact area has been
etched and treated with chemical conversion coating per Mil-DTL-5541 Class 3
(latest revision) or as specified by approved work instructions.
d) Installation of components/assemblies as to correct part, location, orientation
and method of installation conform to drawings,
e) Where accessibility permits bolts and screws shall be installed with head
uppermost. The exception may be ground studs and cable clamp assemblies;
f) No more than four ground wires shall be terminated on one ground lug, and no
more than four ground lugs to one stud,
g) Wiring/harness installation conforms to drawings and specification requirements
as to wiring type, length, routing, method of termination, and mounting.
C. Testing
1) All connectors shall be tested for continuity between termination points.
NOTE 1: In most cases harness trays and shelves will only be terminated at one
end at this point prior to aircraft installation.
NOTE 2: Point to point harnesses not routed through radio rack will be installed
and inspected in aircraft prior to termination.
Page: 1
Date: 2018 Feb 09
2. Work Cards or Work Orders

A. Completion of Work
1) Work cards or work orders to be reviewed as work proceeds, and signed (stamped)
on satisfactory completion of work.
Page: 2
Date: 2018 Feb 09
SECTION 4-5 – AVIONICS TOOLING REFERENCE

1. Procedure
A. Proper Use guidelines
1) For use and operational guidelines on the following avionics tooling and equipment
refer to the manufacturers manuals:
a) Crimping Tools
b) Insertion / Extraction Tools
c) Electric Heat Guns
d) Pneumatic Heat Gun
e) Pitot / Static Test Adapter
f) Tensile Tester
g) CAPRIS 50-300
h) Wire Strippers.
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Date: 2018 Feb 09
SECTION 4-6 - CONTROL OF INSPECTION MEASURING AND TEST EQUIPMENT

1. General
Calibration, inspection, and verification of the following avionics equipment shall be performed by
appropriately trained and authorized personnel as determined by the Quality Assurance Manager
or delegate with reference to the Production Manual, Section 4-0.
A. Calibration of Crimping Equipment Go/No-Go Gauges (24 months)
1) Inspection Procedure
a) Inspect gauge for physical defects, replace as required.
2) Calibration
a) Carry out a dimentional check of the Go and No/Go portions of the gauge in
accordance with the Manufacturer’s requirements utilizing standards and
measuring equipment calibrated traceable to National or International
standards.
b) Use Form No. AV-004, Calibration of Crimping Equipment Go/No-Go Gauges
to record inspection results.
B. Crimping Tool Calibration
1) Calibration
a) Perform a general visual inspection of the equipment for any worn, damaged,
bent or broken pieces.
• Visually inspect mating surfaces, tips and jaws.
• Verify smooth and consistent operation of equipment.
b) Carry out a calibration check of the tool utilizing the specified Go and No/Go
gauge and/or a calibrated crimp-height comparator in accordance with the
latest revision of the Manufactures Instructions / Data Sheet.
c) Use Form No. AV-005, Periodic Inspection & Testing of Crimping tools – to
record inspection results.
C. Calibration of Linaire Panels
1) Inspection Procedure
a) Inspect panel for physical defects, replace/repair as required.
b) Referring to the applicable Linaire Manual, check the function of all switches for
correct mechanical and electrical operation.
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Date: 2018 Feb 09
2) Calibration
a) Carry out a calibration check of each meter movement (in each range as
required) in accordance with the appropriate calibration tables.
b) Record all pertinent data on Form No. AV-002, Calibration of Linaire Panels, on
completion.
Page: 2
Date: 2018 Feb 09
SECTION 4-7 - SOLDERING OF ELECTRICAL CONNECTIONS

1. Procedures
A. General
1) The following gives the procedures of terminating wiring using the soldering process.
B. Solder Practices
1) Use solder practices as defined in the manufacturers Aircraft Maintenance Manual
(AMM), Component Maintenance Manual (CMM) or Standard Wiring Practices
Manual (SWPM).
2) If none of the above apply, use IPC-A-610
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Date: 2018 Feb 09
SECTION 4-8 – INTENTIONALLY LEFT BLANK
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Date: 2018 Feb 09
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Date: 2018 Feb 09
SECTION 4-10 - WIRING MAINTENANCE PRACTICES

1. Process Control
A. General
1) The following section describes the minimum wire maintenance practices to be
carried out at Kelowna Flightcraft Ltd. for its fleet of aircraft and on customer aircraft
accordingly.
2) Wiring specification can be found in associated aircraft manufacturers AMM Chapter
20, WDM Chapter 20 or Standard Wiring Practices Manual.
a) In the absence of aircraft manufactures data please refer to AC43.13, IPC-A-
620, SAE-SA50881 or any approved Engineering documents.
B. Particular Points of Installation
1) Approved devices shall support wires, cables and harnesses, at intervals of not more
than 24 inches.
2) Continuous lacing shall not be used.
3) Cable supports do not restrict movement of equipment shock mounts.
4) Tape or cord not used for primary support.
5) Whenever possible wires shall be marked in terminals and junction boxes between
termination point and entry of wire into bundle.
6) The use of plastic tie wraps should be limited to pressurized areas. Lacing cord is the
preferred means of securing wiring bundles.
C. Lug Termination
1) Slack length shall be a minimum of two times lug barrel length in vicinity of lug and
available for lug replacement. On connectors a minimum of one inch slack between
second clamp and termination. Drip loop requirement for downward dressed wiring to
connectors, terminal blocks, panels, or junction boxes.
D. Bonding
1) Bonding and grounding surfaces shall be free of all oil, grease, paint, anodic film, and
other non-conducting material. Hardware shall be of appropriate size for the lugs
being used.
E. Power Checks, Ground Checks and Continuity Checks
1) General Precautions
2) Do not use oversize probes in connector sockets, this may result in splayed or
damaged sockets. Use the proper mating pins only.
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Date: 2018 Feb 09
3) Do not puncture wire insulation with a probe or attach clamps to wire insulation while
testing.
4) Do not use lead pencils to count pins in connectors, points can break off and lodge in
connectors.
F. Power Checks and Ground Checks
1) On all new and modified systems, presence of AC and DC power at the correct
termination point will be verified prior to Line Replaceable Unit installation.
2) On all new and modified systems, all grounds will be verified for correct resistance
and termination point prior to LRU installation.
G. Continuity Checks
1) Use an ohm meter or multimeter set to the OHMS range Rx1 currently in cal. zero
meter by shorting leads note meter resistance. (This is resistance of test leads and
any extensions being used)
2) Whenever possible system ring-out will be carried out using the following guidelines:
3) Check each wire for continuity between each termination point on wire to end point as
specified on the applicable wiring diagram. Check for shorts to ground.
4) All switches in each system are to be tested for correct sense and operation.
5) All shielded cables are to be checked for short circuits between each of the inner
wires and the shield and wire-to-wire within the shield, as well as continuity.
6) Zero plus the measurement in (1) above is the acceptable nominal meter reading for
continuity checks.
2. Wire Inspection
A. General
1) As a general rule, wiring that is undisturbed will have less degradation than wiring
that is reworked. As wiring and components become more brittle with age this effect
becomes more pronounced.
3. Possible Wire Degradations
A. Causes
1) Vibration: Tend to accelerate degradation over time, resulting in intermittent contacts
and symptoms. Look under clamps.
2) Maintenance: Improper rework can contribute to long term problems and wiring
degradation. Repairs made by line maintenance can have limited durability and
should be redone at convenient maintenance opportunities.
3) Indirect Cause: Events, such as pneumatic duct ruptures, can cause damage that,
while not initially evident, can later cause wiring problems.
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Date: 2018 Feb 09
4) Contamination: Hydraulic fluid is a common cause of wiring component degradation.

It is very damaging to connector grommets and wire bundle clamps, this can lead to
indirect damage such as arcing and chafing. Other common chemicals can potentially
cause degradation of electrical components, i.e., fuel, corrosion inhibiting
compounds, waste system chemicals, cleaning agents, and de-icing fluids.
5) Heat: Wiring that is not designed for high temperatures and is exposed to heat can
accelerate degradation. This type of degradation is sometimes seen in galleys and
behind lights.
4. Wiring Inspections
A. Special Attention Installations
1) Types of Installations that Merit Special Attention during Wiring Inspections.
a) Clamping points: Wire chafing is aggravated by damaged clamps, clamp
cushion migration or improper clamp installation.
b) Connectors: Worn environmental seals, missing seal plugs, missing dummy
contacts, or lateral pressure on connector grommets can compromise
connector integrity and allow contamination to enter the connector, leading to
corrosion or grommet degradation.
c) Terminations: Terminal lugs and splices are susceptible to mechanical damage,
corrosion, heat damage, and chemical contamination. Also the build up and nut
torque on large gauge wire studs is critical to their performance.
d) Backshells: Wires may break at backshells due to excessive flexing, static
pressure, or missing build-up.
e) Sleeving: Damage to sleeving and conduits, if not corrected, will often lead to
wire damage.
f) Grounding: Grounding points must be checked for condition and security,
cleanliness and corrosion. Any grounding points that are corroded or have lost
their protective coating should be repaired.
2) Aircraft Locations that Merit Special Attention during Wiring Inspections.
a) Wings: Wing trailing or leading edges often expose wiring to difficult
environmental conditions on landing and/or take-off.
b) Engines: Engine, pylons, nacelle and APU area experience high vibration, heat,
frequent maintenance, and is susceptible to chemical contamination.
c) Wheel Wells: This area is exposed to severe external environmental conditions
in addition to vibration and chemical contamination.
d) Panels: Electrical panels wiring is particularly prone to broken wires and
damaged insulation when these high density areas are disturbed during
modifications and refurbishment.
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Date: 2018 Feb 09
e) Feeders: Power feeders should be checked for signs of overheating and

security. This applies to galley power feeders, main and APU generator power
feeders.
f) Doors: Doors, stairs, have moving or bending harnesses that should be
inspected.
g) Battery: Wires in the vicinity of aircraft batteries are susceptible to corrosion and
discoloration.
Page: 4
Date: 2018 Feb 09
SECTION 5-0 - CONTROL OF WORK ORDER (FORM NO. M3MTC-M255)

1. Control Process of the Work Order (M3)
A. Initiating Work Order
1) Request for services generally made by email or parts requisition.
B. Controlling Work Order
1) If the service request is for a pre-determined part, the part must exist in the M3
system. If part does not exist, it needs to be created by use of the M3 interface
program.
2) If part is not pre-determined (ie: wire kits), a part number will be assigned based on
work order that generated the demand or drawing/document number. Once assigned,
part number again needs to be created in the M3 system.
3) A work order is then created for the service using M3 program MOS170. Details on
the work order must include work to be performed, part numbers, serial numbers,
references to drawings and/or datasheets to complete the service.
a) There is a minimum of two operations listed on a work order, one of which is for
the service to be completed and the second for the inspection of the work that
was done. Once this information has been entered into MOS170, the request is
then ‘released’, and creates the actual work order MOS100.
4) Prior to release to production all Work Orders shall be reviewed and approved by an
independent ACA or SCA to ensure that all of the requirements have been identified.
a) The review and release to production shall be recorded on the Work Order.
5) It is the responsibility of the technician, installer or assembler to ensure each
operation worked on is completed and correct by signing and dating the appropriate
operation.
6) Once all MOS100 operations have been completed, the work order is reviewed by the
ACA/SCA to ensure each operation is satisfactorily done, that all materials used have
been recorded and picked on the work order, that the technician has signed and
dated the operations they completed and that the ACA/SCA has signed, dated and
stamped the final operation, verifying that all work is complete.
a) The work order is then closed and the product placed in a holding location to
wait distribution to its required destination.
C. Moving the final product
1) A distribution order is then created using M3 program MMS100. The distribution order
maintains a virtual path to track the products progress through the system.
a) Once the distribution order has been created, the part and any pertinent
documentation are transferred from the Avionics holding location to the parts
destination.
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Date: 2018 Feb 09
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Date: 2018 Feb 09
SECTION 5-2 - WARRANTY WORK

1. Production Control
A. Process
1) This section describes the production control process in the event that an Avionics
repaired or manufactured product is returned under warranty by a customer (inside or
outside).
B. Procedure
1) Initiating Work
a) Repair warranty – The Avionics Shop Lead and/or supervising technician will
initiate the internal process once the rejected product has been identified in the
Avionics Department – Form M3MTC-M255 will be used for tracking purposes.
C. Original Equipment Manufacture (OEM) Warranty
1) Initiating Work
a) The OEM places the warranty request using their own paperwork. The Avionics
Shop Lead and/or supervising technician will initiate the internal process. Form
M3MTC-M255 will be used for tracking purposes.
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5-2 Revision: 3 Reissue
Date: 2018 Feb 09
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Date: 2018 Feb 09
SECTION 7-0 - TRAINING

1. Training
A. General
1) This section identifies the training requirements for the Avionics Department in
accordance with the Maintenance Policy Manual Section 13.
2) Training will be recorded on form TRA-901 and forwarded to the Training Department.
B. Avionics Department Supervisor
1) Quality Manual update (KFL MPM, MCM, H&S, RMS, Avionics)
2) Human Factors
3) MEL – 3 hrs
4) Controlled Goods
5) WHMIS
6) Type Training as required
7) ESD Training to be determined based on previous experience as required.
C. Avionics Crew Chief
2) Human Factors
3) MEL – 3 hrs
4) Controlled Goods
5) WHMIS
D. Avionics AME
2) Human Factors
3) MEL – 3 hrs
4) Controlled Goods
5) WHMIS
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Date: 2018 Feb 09
E. Avionics Apprentice/Technician
2) Human Factors
3) Controlled Goods
4) WHMIS
F. Wire Harness Assembler
2) Human Factors
3) Controlled Goods
4) WHMIS
G. Lab Lead/Technician
2) Human Factors
3) WHMIS
5) Applicable Equipment Courses as required by Dealership Approval
7) Controlled Goods
H. Avionics Assembly Shop Lead Hand
2) Human Factors
3) Controlled Goods
4) WHMIS
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Date: 2018 Feb 09
SECTION 8-0 - AVIONICS LABORATORY OPERATIONS

1. General
It provides avionics bench services for Kelowna Flightcraft’s fleet of aircraft (Inside Customer).
The laboratory also provides avionics bench services and warranty to outside customers in line
with the lab’s various dealership agreements.
A. Approved dealerships
Kelowna Flightcraft Ltd., Avionics laboratory is an approved dealership of:
1) Honeywell/Allied Signal/Bendix King
2) N.A.T. (Now Chelton Avionics)
3) Universal Avionics Systems
4) Rockwell Collins
5) BF Goodrich (Now L3 Communications)
6) CAL Corporation
7) ICOM Canada
8) Sandel Avionics
9) L3 Communications
10) EMS Technologies
11) Free Flight Systems
12) Gables
13) Shadin Company Inc.
14) Cobham
15) Mid Continent
16) Technicsonic
17) Aspen Avionics
18) AEM – Anodyne Electronics Manufacturing
2. Laboratory Technicians
A. Responsibilities
1) Lab technicians provide the laboratory technical expertise. Refer to section 1-0 (I) of
this manual for a description of responsibilities.
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Date: 2018 Feb 09
SECTION 8-1 - LABORATORY PRODUCTION

1. Process
A. General
1) Parts and Line Replaceable Units (LRU) are routed to Stores from the line
maintenance stations and from external customers.
2) This section provides the production process of equipment for both these types of
customers.
2. Line Maintenance Stations
A. Parts & LRUs
1) Stores personnel deliver LRUs to the lab.
2) A list of the delivered LRUs accompanied by MOS170 for each item is submitted to
the Assembly Shop Lead Hand.
3) The Assembly Shop Lead Hand prepares a Work Order form (M3MTC-M255).
4) Once a Work Order has been issued, the lab technician will assess the work to be
carried out and the parts to be ordered.
5) If the cost of the repair, alignment or overhaul is economically justified, the technician
will carry out the work required to make the LRU serviceable again.
6) If the cost is Beyond Economical Repair (BER), the technician will advise the Stores
Rotable Department of the unit condition and route the unit to Warehouse.
3. External Customers
A. Parts & LRUs
1) External customers report to outside sales with the part or LRU requiring check,
repair or overhaul.
2) The Assembly Shop Lead Hand fills out a Work Order form (M3MTC-M255) and a
quote (ie: AV-011 or MTC-155), for each customer part or LRU. (Refer to 8-2,
Avionics Laboratory Report.)
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Date: 2018 Feb 09
SECTION 8-2 - LABORATORY REPORT (FORM MTC-155)

1. Avionics Laboratory Report
A. General
1) The Avionics Laboratory Report form provides our customers with a detailed record of
the work carried out on a unit in the avionics laboratory.
B. Use
1) This form can be generated by the Sales & Repairs group or by the Avionics
Department. It will provide the details of a quote for a particular work request and is
the record of quote approval from the customer.
C. Procedure
1) Form MTC-155 is available in electronic format to the Outside Sales group and the
Assembly Shop Lead Hand and Avionics Laboratory technicians.
D. Initiating the form
1) Initiating the form is done whenever a unit comes in from one of two points:
a) Sales & Repairs Group: A customer sends in a unit for repair. The Sales &
Repairs Group generates a MOS170 records it in the top right hand corner of
the form along with the date. Then provides the particular of the customer. The
unit is routed to the Avionics section along with the Avionics Lab Report form
(MTC-155).
2) The mandatory data to be completed on the form is mostly relative to the customer
information (name, contact, unit details, etc., and is contained in the first portion of the
report.
3) The required work description is needed in all cases. Kelowna Flightcraft aircraft: the
aircraft tail number, unit position.
NOTE: an Avionics Work Order must be recorded on the form for work to start.
4) Upon completion of the initial physical inspection of the received unit in the avionics
laboratory, the technician will complete the “Shop Receiving Inspection” section of the
report.
5) When the basic unit test is completed, the technician will complete the ”Initial Bench
Test Findings” section.
6) The “Repair Approval” section of the form will be completed in all cases.
a) For outside sales, the customer MUST approve the quote for any work to
continue on that unit.
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Date: 2018 Feb 09
b) Getting the customer to sign and date at the bottom of the section completes
this requirement.
c) For Kelowna Flightcraft units, this approval is not required. However, repair
justification must still exist and should the repair be extensive, the Avionics
Shop Supervisor or his delegate, will determine if the work should continue or
not.
E. Customer Approves Quote
1) Once the customer has approved the quote, the work can continue on the unit.
a) When the unit is serviceable, the technician will complete the “Shop Action &
Findings” section of the form. This form will be attached to the Maintenance
Release Tag. Copy of the form is kept with the work order on file.
F. Customer Refuses Quote
1) If the customer refuses the quote, the unit will be shipped back to the customer
without any of the repair carried out.
a) The technician will complete the “Shop Action & Findings” section of the form
with a similar type of statement: “Quote refused by customer, unit returned – No
repair carried out”. This form will be attached and kept with the work order on
file.
G. Beyond Economical Repair (BER)
1) If a unit after test is deemed to be Beyond Economical Repair (BER), the Customer
will be advised by use of the “Repair Approval” section of the report. The quote
values will still be compiled along with the Fair Market Price of the unit under test. It is
now the customer’s decision to continue or stop the repair process.
Page: 2
Date: 2018 Feb 09
SECTION 9-0 - NON-CONFORMING PRODUCT

1. Control
A. Procedure
1) The following details the procedure for controlling a product that does not conform to
requirements specified in Aircraft Maintenance Manuals / Manufactures Manuals or
other approved product description documents.
a) Adequate documentation clearly identifying the nature of non-conformance will
be maintained.
B. Non-Conformance and General Action
1) The ACA is responsible to document a non-conforming product during the Inspection
/ Repair / Overhaul or Testing Process.
2) An “Unserviceable” Tag (Form No. STO-805) shall be filled out stating the condition of
the product in the “Details” section and the Tag attached to the product.
3) These products shall be stored in the designated Quarantine Area in the Avionics
Department.
a) If a product is identified as a non-conforming product during a Manufacturing
Process the procedures in the “Aircraft Products Manufacturing Manual Section
5-0” are to be adhered to.
C. Rejected / Beyond Economic Repair or Scrapped Product.
1) The ACA is responsible to document a Rejected / Beyond Economic Repair or
Scrapped Product.
2) An “Unserviceable” Tag (Form No. STO-805) shall be filled out stating the condition of
the product in the “Details” section and the Tag attached to the product.
3) The Product may then be routed through stores for processing together with all its
completed documentation.
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Date: 2018 Feb 09
SECTION 10-0 – ELECTROSTATIC SENSITIVE DEVISE (ESD) - HANDLING

1. Handling
A. Policy / Procedures
1) All electronic rotables and expendables whether identified or not as an Electrostatic
Discharge Sensitive Device (ESD) shall be handled in accordance with the
recommendations in this section and the appropriate Component Maintenance
Manual.
a) Failure to adhere to these recommendations can have an impact on KFL
operations. ESD damage can cause excessive warranty returns and a resulting
shortage in critical spare units. ESD failure of units just installed on the aircraft
after shop repair can cause departure delays. ESD damage to a unit can result
in intermittent operation and may recur many times before the cause is
identified.
b) Training is required for all personnel who handle ESD Equipment.
c) Electrostatic controlled work stations should be equipped with the following
minimum equipment:
• Multi-layer type static-dissipative table mat. (With resistance to
earth/service equipment ground less than 109 ohms)
• Ground wrist straps. (Continuous electrical path to ESD ground)
d) Resistance checks will be made of all ESD safety equipment to ensure it is
functional. All resistance checks will be the responsibility of the Tool Crib and
the operator. Work areas affected by this requirement are shops that
overhaul/repair ESD parts or components and in Stores/Receiving Inspection
area where ESD parts or components are accepted into the system.
• Wrist straps will be checked prior to the first use of the day by the
operator and recorded on the ESD Log sheet. Completed log sheets only
need to be retained showing the previous month.
• Table mats will be checked every 6 months by the Tool Crib and records
maintained.
B. ESD Components
The following must be complied with to protect ESD Components
1) Store and Transport ESD parts, assemblies and circuit boards only in labeled and
sealed conductive static shielding materials. (Anti-static bags, anti-static or conductive
dust caps.)
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Date: 2018 Feb 09
2) Remove, handle and re-package static sensitive parts, assemblies and circuit
cards/boards only at approved static-controlled work stations.
CAUTION: ORDINARY PLASTICS AND SYROFOAM ARE PROHIBITED FROM
BEING IN CONTACT WITH ESD MATERIAL OR INSIDE ESD
PROTECTIVE PACKAGING.
3) All packages containing ESD items must have approved ESD labels affixed.
Whenever the packaging is damaged or cannot be identified as ESD protective, it
should be replaced. (See sample ESD labels, this section.)
C. Line Replaceable Unit (LRU) Handling
1) All ESD sensitive LRU’s will have an ESD label. The label will be affixed to the unit by
the appropriate shop or vendor in accordance with the Component Maintenance
Manuals.
2) ESD identified LRU’s must have anti-static or conductive dust caps installed on
connectors before leaving the shop or vendor. These types of caps must remain on
the unit until it is to be replaced in the aircraft or tested on shop bench.
NOTE 1: Fully assembled LRU’s do not need special anti-static bags or boxes. The
LRU is completely protected from ESD by its metal case and the anti-
static or conductive dust caps.
NOTE 2: The removal/installation of aircraft ESD components (i.e., LRUs – black
boxes) may not require the use of a wrist strap, depending on aircraft type
and systems. However, wrist straps shall be used whenever ESD devices
(i.e., circuit boards, card files, etc.) are removed or installed.
3) When removing an ESD sensitive LRU from the aircraft, ensure all input sources and
power are off. Remove the anti-static or conductive dust caps from the serviceable
LRU and place them on the unserviceable unit.
4) It is the technician’s responsibility to ensure the wrist strap being used for aircraft
maintenance has been tested to verify continuity.
CAUTION: UNSERVICEABLE UNITS ARE SUSCEPTIBLE TO ADDITIONAL
DAMAGE FROM ESD IF NOT HANDLED PROPERLY.
DO NOT TOUCH THE CONTACTS OF THE SERVICEABLE OR

UNSERVICEABLE UNITS, IF CONTACTS NEED TO BE TOUCHED
ONLY CARRY OUT THIS FUNCTION AT A PROPERLY AND
APPROVED STATIC CONTROLLED WORK STATION.
Page: 2
Date: 2018 Feb 09
D. ESD Handling
1) ESD components shall be removed and protected in accordance with the applicable
manufacturer’s maintenance manual.
2) ESD sensitive components shall be adequately protected (approved caps, plugs,
bags, tape, etc.) while removed from the aircraft.
3) It shall be the maintenance technician’s responsibility to properly protect ESD
sensitive components at the time of removal and ensure the ESD components are
stored on a suitable storage rack, or in approved packaging.
Page: 3
Date: 2018 Feb 09
APPENDIX A - FORMS
1. Forms List
A. General
1) AV-001, TD Amp Calibration
2) DND-008, Component Shop Assessment Sheet
3) MTC-113, Work Carried Out
4) M3MTC-M255, Repair Work Order
5) MTC-125A, Additional Work Order Sheet
6) AV-004, Calibration of Crimping Equipment
7) AV-005, Crimping Tool Calibration
8) AV-002, Calibration of Linaire Panels
9) AV-003, Avionics Laboratory Report
10) MTC-260, Calibration Record Chart
11) MTC-261, KF Cal
12) MTC-263, KF Cal (Rectangle)
13) MTC-264, KF Cal (Round)
14) AV-008, KF Avionics Label
15) AV-009, KF Avionics ELT Label
16) QA-766, Library Document Request
17) QA-733a, Form 1 (Maintenance)
18) QA-733b, Form 1 (Manufacturing)
19) AV-011, Avionics Shop Work Request/Quote Form
20) AV-006, Annual Testing of Solder Stations
21) AV-007, Annual Testing of ESD Mats
22) AV-010, AVC Tool Signout
Page: 1
APPENDIX A Revision: 3 Re-issue
Date: 2018 Feb 09

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Avionics Shop Manual

Telephone: (250) 491-5500

Manual Owner: Vinny Sharma

MANUAL NUMBER: __________

REVISION NO. AFFECTED PAGES ISSUE DATE

0 Re-issue All Pages - Reissue 10 Nov 2009

SECTION 1-0 AVIONICS PERSONNEL

SECTION 2-0 AVIONICS ORGANIZATIONAL CHART

SECTION 3-0 MANUAL REVISION

SECTION 4-0 PROCESS CONTROL

SECTION 4-1 USE OF IRIDITE 14-2 AND ISOPREP 188

3. Typical Process Cycle

SECTION 4-2 WIRE MARKING

SECTION 4-3 WIRING HARNESS

SECTION 4-5 AVIONICS TOOLING REFERENCE

SECTION 4-6 CONTROL OF INSPECTION MEASURING AND TEST EQUIPMENT

SECTION 4-7 SOLDERING OF ELECTRICAL CONNECTIONS

SECTION 4-8 INTENTIONALLY LEFT BLANK

SECTION 4-9 INTENTIONALLY LEFT BLANK

SECTION 4-10 WIRING MAINTENANCE PRACTICES

SECTION 5-0 CONTROL OF WORK ORDER (FORM NO. M3MTC-M255)

SECTION 5-1 INTENTIONALLY LEFT BLANK

SECTION 5-2 WARRANTY WORK

SECTION 6-0 INTENTIONALLY LEFT BLANK

SECTION 7-0 TRAINING

SECTION 8-0 AVIONICS LABORATORY OPERATIONS

SECTION 8-1 LABORATORY PRODUCTION

SECTION 8-2 LABORATORY REPORT (FORM MTC-155)

SECTION 9-0 NON-CONFORMING PRODUCT

SECTION 10-0 ELECTROSTATIC SENSITIVE DEVISE (ESD) - HANDLING

LIST OF EFFECTIVE PAGES

Copy No. Holder of Copy

SECTION 1-0 - AVIONICS PERSONNEL

C. Avionics Assembly and Radio Shop Lead

D. Avionics Assembly Shop Lead Hand

c) Terminate wiring at connectors as designated by lead assembly drawings or

3) Qualifications: Successful graduate from a TCA approved Avionics training course.

SECTION 2-0 - AVIONICS ORGANIZATIONAL CHART

YLW Maintenance Manager

Avionics Shop Supervisor

Assembly Shop Radio Shop

Figure 1 - Avionics Organization Chart

SECTION 3-0 - MANUAL REVISION

SECTION 4-0 - PROCESS CONTROL

SECTION 4-1 - USE OF IRIDITE 14-2 AND ISOPREP 188

3. Typical Process Cycle

SECTION 4-2 - WIRE MARKING

SECTION 4-3 - WIRING HARNESS

2. Work Cards or Work Orders

SECTION 4-5 – AVIONICS TOOLING REFERENCE

SECTION 4-6 - CONTROL OF INSPECTION MEASURING AND TEST EQUIPMENT

SECTION 4-7 - SOLDERING OF ELECTRICAL CONNECTIONS

SECTION 4-8 – INTENTIONALLY LEFT BLANK

SECTION 4-9 – INTENTIONALLY LEFT BLANK

SECTION 4-10 - WIRING MAINTENANCE PRACTICES

4) Contamination: Hydraulic fluid is a common cause of wiring component degradation.

e) Feeders: Power feeders should be checked for signs of overheating and

SECTION 5-0 - CONTROL OF WORK ORDER (FORM NO. M3MTC-M255)