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A B757-200 lead technician reports replacing a rudder ratio actuator using the maintenance manual and job card. Both documents had errors and conflicting tests procedures.
| Attributes | |
| ACN | 562820 |
| Time | |
| Date | 200210 |
| Day | Wed |
| Local Time Of Day | 1801 To 2400 |
| Place | |
| Locale Reference | airport : zzz.airport |
| State Reference | US |
| Altitude | agl single value : 0 |
| Environment | |
| Light | Night |
| Aircraft 1 | |
| Operator | common carrier : air carrier |
| Make Model Name | B757-200 |
| Operating Under FAR Part | Part 121 |
| Flight Phase | ground : maintenance |
| Person 1 | |
| Affiliation | company : air carrier |
| Function | maintenance : lead technician |
| Qualification | technician : powerplant technician : airframe |
| Experience | maintenance lead technician : 6 |
| ASRS Report | 562820 |
| Person 2 | |
| Affiliation | company : air carrier |
| Function | maintenance : technician |
| Events | |
| Anomaly | aircraft equipment problem : critical maintenance problem : improper documentation non adherence : far non adherence : published procedure |
| Independent Detector | other other : person 1 |
| Resolutory Action | none taken : detected after the fact |
| Consequence | other other |
| Factors | |
| Maintenance | contributing factor : manuals contributing factor : work cards performance deficiency : inspection performance deficiency : installation |
| Supplementary | |
| Problem Areas | Company Maintenance Human Performance Chart Or Publication Aircraft |
| Primary Problem | Chart Or Publication |
| Situations | |
| Publication | MAINT MANUAL |
Narrative:
Hydraulic leak in tail area, found by crew on walkaround. Maintenance found the rudder ratio changer actuator to be leaking. Printed maintenance manual 27-21-13 for rudder ratio. Talked to maintenance control and they said to use maintenance manual. But I found a job card #27-21-10 to do the job. Found mistakes in the job card on the adjustment and test. Checked maintenance manual and had to go between maintenance manual and job card. Didn't use one solely. It makes the job easier to make mistakes. I was also lead mechanic on the job and had to be the duty quality control for the rii signoff. The paperwork just had too many errors in it. Company's job card not matching up with maintenance manual.
Original NASA ASRS Text
Title: A B757-200 LEAD TECHNICIAN RPTS REPLACING A RUDDER RATIO ACTUATOR USING THE MAINT MANUAL AND JOB CARD. BOTH DOCUMENTS HAD ERRORS AND CONFLICTING TESTS PROCS.
Narrative: HYD LEAK IN TAIL AREA, FOUND BY CREW ON WALKAROUND. MAINT FOUND THE RUDDER RATIO CHANGER ACTUATOR TO BE LEAKING. PRINTED MAINT MANUAL 27-21-13 FOR RUDDER RATIO. TALKED TO MAINT CTL AND THEY SAID TO USE MAINT MANUAL. BUT I FOUND A JOB CARD #27-21-10 TO DO THE JOB. FOUND MISTAKES IN THE JOB CARD ON THE ADJUSTMENT AND TEST. CHKED MAINT MANUAL AND HAD TO GO BTWN MAINT MANUAL AND JOB CARD. DIDN'T USE ONE SOLELY. IT MAKES THE JOB EASIER TO MAKE MISTAKES. I WAS ALSO LEAD MECH ON THE JOB AND HAD TO BE THE DUTY QUALITY CTL FOR THE RII SIGNOFF. THE PAPERWORK JUST HAD TOO MANY ERRORS IN IT. COMPANY'S JOB CARD NOT MATCHING UP WITH MAINT MANUAL.
Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.