Modifying aircraft avionics systems
Overview
This standard identifies the competences you need to modify aircraft avionics systems, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft. You will be required to change, modify and update aircraft avionics systems in accordance with modification leaflets, latest issue drawings and standards. You will be expected to remove and replace cables, add new cables, change breakout points and change the routeing of cables. You will also be expected to change components, units and trays. You will need to show proficiency in using various tools for cutting, stripping, crimping and soldering, and in the installation of the avionics systems.
Your responsibilities will require you to comply with organisational policy and procedures for the modifications undertaken and to report any problems with the modification activities, components or equipment that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking full responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying modification procedures. You will understand the modification, and its application, and will know about the modification requirements and methods, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the completed modification is to the required specification.
You will understand the safety precautions required when carrying out the modifications. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- obtain and follow the relevant modification specifications and job instructions
- confirm and agree what modifications are to be carried out to meet the specification
- prepare the avionics system for the required modification
- carry out the system modification using approved materials, methods and procedures
- complete the modification within the agreed timescale
- ensure that the modified avionics system meets the specified operating conditions
- produce accurate and complete records of all modification work carried out
- deal promptly and effectively with problems within your control and report those that cannot be solved
- complete the relevant documentation, in accordance with organisational requirements
- leave the aircraft and the work area in a safe and appropriate condition, free from foreign object debris on completion of the activities
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions and procedures to be observed whilst carrying out the modifications to avionics systems (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area in which you are carrying out the modification activities and the responsibility these requirements place on you
- the hazards associated with modifying aircraft avionic systems and with the tools and equipment used and how to minimise them and reduce any risks
the personal protective equipment and clothing (PPE) to be worn during the modification activities
the precautions to be taken to prevent electrostatic discharge (ESD) damage to circuits and sensitive components (such as use of earthed wrist straps)
what constitutes a hazardous voltage and how to recognise victims of electric shock
how to reduce the risks of a phase to earth shock (such as insulated tools, rubber matting and isolating transformers)
the various types of drawing and specifications that are used during the modification
- how to identify the components to be used; component identification systems (such as codes and component orientation indicators)
- preparations to be undertaken on the system, prior to modification
- the methods and techniques to be used for soldering and de-soldering, and the importance of adhering to the procedures
- the methods and techniques to be used for crimping and heat shrinking and the importance of adhering to them
- the methods and techniques to be used for the assembly of screened and unscreened plugs and sockets
- how to identify the difference between composite and metal plugs and sockets
- the different types of cable protection, and reasons for each type
- the various mechanical fasteners that will be used and their method of installation
- the importance of using the specified fasteners for the modification and why you must not use substitutes
- the quality control procedures to be followed during the modification operations
how to conduct any necessary checks to ensure the accuracy and quality of the modification
how to recognise defects (such as misalignment, ineffective fasteners, foreign object damage or contamination)
- the importance of ensuring that the completed modification is free from dirt, swarf and foreign object damage
- why electrical bonding is critical and why it must be both mechanically and electrically secure
- the methods and equipment used to transport, handle and lift components/looms into position and how to check that the equipment is within its current certification dates
- why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- the problems that can occur with the modification operations and how these can be overcome
- the recording documentation to be completed for the activities undertaken and where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the modification activities:
- obtain and use the appropriate documentation (such as job instructions, modification drawings, planning and quality control documentation, aircraft standards and specifications)
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain a safe working environment for the installation activities
- obtain the correct tools and equipment for the activity and check that they are in a safe, tested and usable condition and within current calibration date
- obtain clearance to work on the aircraft and observe all relevant isolation and safety procedures
- follow safe practice/approved installation techniques and procedures at all times
- return all tools and equipment to the correct location on completion of the installation activities
- dispose of waste materials in accordance with approved procedures
Carry out modifications to two different types of avionics system from the following:
- visual display units
- radar systems
- communications systems
- countermeasure systems
- flight guidance and control systems
- electro-optical/infrared
- navigational systems
- instrumentation systems
Carry out six of the following types of modification:
- removing cables
- making changes to panels or sub-assemblies
- adding cables
- changing position or angle of breakout points
- changing routes of cables
- making changes to component on end of cable
- making changes to looms
- changing or adding avionics units/systems
- adding looms to cableform
- changing position of avionics units
- replacing cables of different size or length
Carry out at six of the following processes during the modifications
- soldering and de-soldering
- stripping
- changing electrical trays
- heat shrinking (devices and boots)
- removing cable end fittings
- repositioning units
- crimping (tags and pins)
- changing components
Carry out modifications in compliance with one of the following standards
- Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
- Ministry of Defence (MoD)
- Military Aviation Authority (MAA)
- Aerospace Quality Management Standards (AS)
- customer standards and requirements
- Federal Aviation Authority (FAA)
- company standards and procedures
- BS, ISO or BSEN standards and procedures
- manufacturers standards and procedures
Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:
- build records
- log cards
- job cards
- aircraft flight log
- other specific recording method
Scope Knowledge
Values
Behaviours
You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:
- strong work ethic
- positive attitude
- team player
- dependability
- responsibility
- honesty
- integrity
- motivation
- commitment