License Friendly Work

While working on airplanes we often have the opportunity (and the privilege) to work on complex machines using our trouble shooting smarts. This is very satisfying and all us A&P mechanics should take pride in having this ability.

There are also times when we do what we at SWA call "license friendly work". Examples of this could be:

Window wash

Demo mask
Seat belt extensions, etc.

Lots of guys get sent to a window wash call and they start huffing and puffing about "why can't the flight crew do it" and things like that. Back in the day the flight crews at SWA used to take pride in the fact that they would often wash their own windows. Sounds crazy but it's true! -BUT-that was back in the day.

Now a days with the FAA being the way they are none of the flight crews are willing to wash their own windows (can't blame them). So what option does the crew have but to call us to do it.

Back to some of my fellow mechanics. A few guys hate to wash windows but to me, it's license friendly work. Let's just say it's very hard to get into trouble while washing windows.

I look forward to wiring issues and hydraulic leaks and troubleshooting but towards the end of the week I love me some window washes!

While washing the windshields the flight crews will often open the slider and apologize for calling me out to wash the windows. I always ask them "Do you know how much money they pay me to wash these windows?"
Some weeks all I feel like doing is washing windows!
Hard to get in trouble.

Aircraft Maintenance and Old Age

I know it's been a long time since I've posted (almost a  year!) but I had to get over this whole "Corporate Security" thing. Those of you who are or who know aircraft mechanics know that we can hold a grudge for quite a while! I'm going to continue on every now and then, more stories, more cool tools, etc.

This post is about getting old. It's something that we all have to face and for a lot of us it hits pretty hard and pretty quick. In the early days of my career I did Airline Overhaul. I was crawling around structures, getting into tight corners, lifting heavy-odd shaped things like aircraft lavs, climbing into fuel tanks, laying on aircraft ribs and stringers, grinding all matter of metals and corrosion, you get the picture. Back in the day I was able to do those things and hop right up, walk away, no pain, no aches.

The thought of having to go to work now in my mid 40s and possible climb into a fuel tank is frightening! The little  things are hard these days! Kneeling down to get the bolts off the main tire so we can change it kills my knees. My back puts up a fit when I have to change a flight deck seat. My shoulders scream while I'm changing a position light.

These aches and pains are something all you new up and coming mechs are going to have to look forward to.

The most startling change is the eyes. Back in the day I could read all those tiny tiny tiny wire numbers which are printed on those tiny tiny tiny aircraft wires. I could use a mirror and read those numbers along with those annoying parts data tags on various valves and actuators with no trouble at all. Now part of my Line MX Tool Kit are my reading glasses. Without the help of those suckers I would be in trouble.

I worked with a guy I'll call MDro. MDro was a good mechanic and he was a good supervisor after that. I remember when we would be reading wiring diagrams MDro would wear TWO pairs of reading glasses!

My intent is not to complain about aging but to let you guys know that it gets harder to do this job as you get older. A good friend of mine always say that "it takes a lot of work to make this job look easy". Just know that the work part may not increase but the aches and pain part will.

Scared of the Flight Crews

I work with a great group of mechanics. These guys have done and fixed planes in all kind of conditions, weather, anytime of day or night. I have seen them improvise and use all manner of tooling and improvised tooling for that matter to fix our fleet. All this makes me wonder why it is that a good number of them are scared of the flight crews.

When I say "scared of the flight crews" I'm not talking about being afraid of them physically. What I am saying is more and more of them refuse to terminate their planes and actually talk to the crews. When our planes land for the night we usually go and "terminate" them. As it was explained to me when I first got hired: you do a quick walk around, check the tires and brakes, then go upstairs to talk to the flight crews and see if they have any sqwacks about the aircraft. This always made sense to me, for one, these pilots are stationed in OAK and you can begin to get to know them and build a relationship with them. I have seen a lot of these guys come home from their very first day at SWA and now they are Captains whom I respect and who hopefully respect me as well. I like to think that when they tell me about something they trust me to fix it. Another thing is that when a crew actually tells you about an issue they go into further detail than you could ever get from the logbook write up. These guys fly these planes everyday and even get to know certain planes so when they say something is off they mean it.

There are a good number of the mechanics who refuse to talk to the flight crews. They will do a very detailed walk around, I'm talking like 20 to 30 mins until the crews are long gone and then go up to the flight deck. They will wait until Operations calls to let them know the plane is ready to be moved, again the crew is long gone. Some won't even go to the planes until they are ready by which time-once again-the crews are gone.

One of the remarkable things about SWA that I noticed when I was hired all those years ago is that all the work groups get along. The pilots and the mechanics get along and that was something new for me, having come from Delta where that was not the case. Perhaps these guys have come from a similar circumstance, who knows?

The thing is the simple act of meeting the crews and talking to them even when they have no problems is an essential part of the job in my opinion. Last month I saw a captain who I had not seen in some time when I went up to terminate his plane. He says "Goat!! I haven't seen you in awhile. Not since I transferred to (another base). Man I miss you OAK MX guys. The MX at (another base) never come out to the terminators anymore."

I let him know that it was becoming rare here in OAK as well and I had no idea why. We both came to the decision that they must be scared of the flight crews........who knows why?

Lightning Strike on antenna

And In The End....

The very last day of my work week and I was looking forward to winding down the week on a nice easy note. When we came in on days they told us that a slat was damaged the night before and a new one was on the way. I have to admit I was not looking forward to working it and I decided not to volunteer my services when it came in. We did our normal thing that day and the new slat came in around 11am. The Lead Mechanic, I'll call him 20 Year Grudge, came in and asked who wanted to volunteer. No body moved or said a thing. He left and came back shortly and told one of the guys (lets call him F1) that he was going to help another guy, Banyan, on the slat.

I breathed a sigh of relief! I sat there for about 10 minutes then decided to go and help also. Crazy but true.

Banyan, F1 and 20 Year Grudge were just getting started and I jumped in where I could. Panels had to come off, the actuator had to be disconnected, the anti-ice duct also. Wires checked and moved and the puzzle of what the best way to remove the thing was slowly worked out. The Foreman (lets call him Surf) delivered our new slat and it was prepped.

As I was not assigned the job, when a gate call came over the radio I went to work it along with another guy so that these fellas could keep going. Around shift change 2:30pm the next player arrived-Tuna. Tuna was to be our inspector for the job. When we have large jobs or any time we mess with the flight controls we assign an inspector to look over the work and keep us all honest. Surf came over the radio "Banyan, you wanna stay for swing shift to finish the job?" Banyan was tired, he told me he could not wait to be done today so he could go home. I could tell he did not like the idea of staying but I knew that, like a lot of us, the idea of leaving a job half done was worse to him. He told the swing shift Lead (let's call him SkiBoat) that he would stay if they let Goat stay. he also said that if we stayed we could get the thing done in four hours. SkiBoat got on the radio and said "Hey Surf, Banyan will stay if we let Goat stay, he, Goat and F1 think they can finish in four hours." To my surprise Surf came back and said it was OK!

We got that old slat off and put the new one on. We actually put the new one on three times because we kept forgetting to hook up a wire or bracket or something. We finally got it up and Tuna inspected everything before we did our ops check. Tuna gave the OK to close the panels and we grabbed our screw guns and went to town.

We finished around 4:15 so all in all we spent about 5 hours on the thing. It felt good to work with guys that knew how to get a job done. No whining, no complaints just honest work. These guys don't stop for food or stupid things like that. They work hard and they work hard until the job is done. I am glad and proud to be in this group of workers and I hope that they feel they can rely on me the way I know I can rely on them.

One strange thing that happened: Once we were done and cleaned up F1 comes in and tells us that the plane we were working on is due to be retired in a month and a half! All that work and the plane is most likely going to the desert to be chopped up! We had shed sweat and even some blood to keep this thing flying and in the end...she was an old tired lady.

I have said it before and I will say it again, it's a strange feeling to know the plane you work so hard on is going to be leaving soon. All of us, for years worked hard to keep that plane going, "just get her over the fence" as we say. She no longer makes economical sense to keep around. Most likely she is timed out, too many cycles, not worth keeping with all the new more economical planes coming out. Like the 737-200s that this 737-300 replaced they will slowly fade away until they are stuff of legend, just a story to tell a probbie: "We used to change those heavy slats out here in the sun and rain and in the end...she was parked in the desert and dismantled."

Photo:Bobby Allison via airliners.net

Troubleshooting Be Damned!!

I was working recently when a call came in from MX Control. There was a plane in Portland that they needed two guys to fly up to look at. This was one of our -300s and the "ANTI-SKID INOP" light would illuminate when the crew set the parking brake. Once we figured out who was going on the road trip, me and a guy I'll call "Tactical",  we started our normal pre-road trip routine:

Get your tools ready. I know guys who only bring the tools they think they will need for the specific job they are going to do but I tend to over pack. The problem with just packing what you think you will need is that we often get there and another issue pops up. Also check your flashlights and bring extra batteries.

Check the history. I wish I could tattoo this one some of the guys foreheads. Before you work any problem, if you have the time, you should always check the discrepancy history. If you go and change a part and then look in the history only to find out that someone changed that same part, for the same problem, just yesterday than you just wasted time and a lot of money. In the case of our Anti skid issue we had time so we checked the history. I found history back to over 120 days for this airplane having Anti skid lights coming on. They had changed about everything in the system so we had some troubleshooting ahead of us.

Check the weather! If it's raining where you are going than you better bring some rain gear.

Luckily we have a great stores department but it was not always that way. Once upon a time we had to pack our own parts which means you have to check the effectivity and make sure it will work for the airplane you are going to fix.

Get on your plane and go.

In our case stores packed a control panel, an Anti-skid valve, and a  parking brake valve. We of course had our multi meters and I brought my kit I made for when I have to shoot wires. You will hear the term "shooting wires" or "ringing out" wires. All this means is to check for continuity and power of certain wire runs. We also  printed out and brought with us the wiring diagram for the anti-skid system.

I grabbed my road trip bag, extra set  of clothes, tooth paste and tooth brush, deodorant, etc.

Luckily we got some seats on the plane (did not have to sit on the jumpseats in the flightdeck) and away we went.

Once we landed and made sure our tools were ok we went up to the plane which was parked and turned off. As we opened the jetway door I kiddingly said to Tactical "Watch the thing work now-since they turned the plane off". As sure as a bear s!%&$ in the woods when we turned her on the light was off! "Kick the brakes off and set them again" said Tactical. I did and it all worked according to design.

Now you might think "that's great! let's pack it up and go home", but it's not that easy. We knew that the plane had a long history of this stupid  light coming on so we have a responsibility to try and see what is going on. In some ways this is the hardest type of write up you can get as an aircraft mechanic. The problem comes up and by the time you get there the damn thing works great. As a true mechanic you still have to troubleshoot and try to find out what is going on. As I say we have to try to break it to figure out what's wrong.

As it turned out for Tactical and I we could not get the thing to break again. A few hours into it and we had to contact MX Control to let them know what was going on. We spent about 3-4 hours trying to figure out what the problem was and could not get the stupid anti-skid light to come on when we set the parking brake. After talking to the MX Controller we decided to change the parking brake valve as a precaution and let her ride. Another hour and a half later we were crossing our fingers as we tested the system after changing the parking brake valve and it all still worked. Believe me when I tell you there are times when you change the part and the damn thing is still broke or another thing is busted!

The point of the story is that there are times when you can not get the plane to act in the way that the flight crew did and therefore can not duplicate the problem. That does not mean that you can stop and sign it off. You are still a mechanic and you still should try and get the thing to fault. I'm not saying that there won't be times when you use the old "could not duplicate" for your sign off. The title "mechanic" comes with certain responsibilities and the one I'm talking about now is the responsibility to you. Take your job seriously and use every chance to learn and expand your art.

You Want It When???

While I was at work the other day a call came from Maintenance Control. There was a plane headed our way with a #1 engine bleed air issue. We get calls like this all the time and so it was not all that uncommon to have them request that we check it out. The problem came about when they said we HAD to have it fixed in two hours to make a flight to Midway.

A quick check of the history on the #1 engine bleed air system revealed that it had a 45 day history of problems! In other words this bleed air system has been acting up for over a month now and they wanted it fixed in two hours. I thought it was pretty ballsy of them to say we had to get it done, and I let the lead know how I felt about it. Luckily that day we had a guy on shift who is really good with engines and engine systems. He was able to figure out what was wrong and kick the plane out in about an hour and a half. Anyone who has worked on engine bleed air faults knows that often times multiple high power runs are required to narrow down and fix a problem.

Part of the issue is that the 737-700 is using the same bleed air valves and regulators as the 737-300 series. These valves seem to work well on the -300 engines (CFM-56-3) and are pretty reliable. These same components are not very reliable on the -700 engines (CFM-56-7). Boeing has not figured out why this is so, or at least they are not saying publicly why this is so. Through the grapevine we have heard that the -700 engines put out a different harmonic vibration than the older engines and this small vib is playing havoc with the components. Whatever it is they are still working on a fix!

More troubling is the "you have to get it fixed" statement. There is no way that I have to fix anything in an allotted time period. Make sure that you as a mechanic do not fall into this trap. Pressure is part of the job as I have mentioned before, however, when a component has a bunch of history, going back a lot of days, with a lot of different mechanics and parts thrown at it, proceed with caution. Do not let Maint. Ctrl or any one tell you how quickly you should work. In my example it all worked out fine but it could have easily gone the other way with the plane grounded and not leaving until the next morning. Thank God we had Dark Cloud there to work it (yes that is what we call him).