View
245
Download
0
Category
Preview:
Citation preview
8/12/2019 Engineer Maint Guide
1/89
maintenance guide for ENGINEERS
CIVIL AVIATION SAFETY AUTHORITY
8/12/2019 Engineer Maint Guide
2/89
For comments and questions
contact: Steve Bell
CASA Aviation Safety Promotion
Telephone: 02 6217 1788
Facsimile: 02 6217 1950
Email: steve.bell@casa.gov.au
Further information can be
downloaded from CASAs
website www.casa.gov.au
To order additional copies, go to
http://casa.jsmcmillan.com.au
2005 Civil Aviation Safety
Authority Australia.
The Civil Aviation SafetyAuthority is responsible for the
safety regulation of Australias
civil aviation operators, and for
the regulations of Australian-
registered aircraft outside
Australian territory.
CASA sets safety standards
and ensures these are met
through effective entry,
compliance and enforcement
strategies. Additionally, CASA
provides regulatory services
to industry, and plays a part
in safety education for the
aviation community. CASA also
administers exams and issues
licences for Australian pilots.
Notice: The information
contained in this document was
correct at the time of publishing
and is subject to change without
notice. This booklet has been
prepared by CASA AviationSafety Promotion Division for
educational purposes only. It
can be changed at any time
without notice and should never
be used for any other purpose.
Reference should be made to
the appropriate legislation at
all times prior to the use of the
information contained herein.
Final Certification 107
The System of Certification -
CAR 42ZE and 42ZN 108
Further Detailed Information 108
ANNEX A 116
Part 1 Interpretation 116
Part 2 Certification of completion
of stages of maintenance
and inspections under
subregulat ion 42G (2) 117
Part 3 Certification of co-ordination
of maintenance 119
Part 4 Final certification 121
ANNEX B Certifying on the
Maintenance Release 124
ANNEX CUseful addresses 126
corrosion and corrosion CONTROLIntroduction 129
The Corrosion Process 129
Oxidisation 130
Galvanic Reactions 130
Corrosion Prevention 133
Metal Coating 133
Corrosion Resistant Substances or
Coatings 133
Painting 134
Preperation 134
Other Coatings 134
Some Simple Rules for Corrosion
Prevention 135
Conclusion 135
fabrication in the course of
MAINTENANCEIntroduction 139
Fabrication 139
Fabrication in the Course of
Maintenance (FitCoM) 140
Required Marking of FitCoM parts 140
Certification Requirements 141
Conclusion 142
quality management SYSTEMSIntroduction 145
CAR 1988 30 and CASR 145(proposed) 146
CAR 1988 30 146
CASR 145 (proposed) 149
Quality Management Principles 149
Quality Management systems approach 153
Differences Between Quality
Standards and Civil Aviation Law 155
Conclusion 156
systems of CERTIFICATIONfor maintenance activitiesReferences 159
Introduction 159
Setting Up a System of Certification 160Aircraft Maintenance and Certification
Systems 160
Using the Manufacturers System of
Certification 161
Using the CASA System of
Maintenance/Schedule 161
What Must Be Included in a
System of Certification 162
Certification For Completion of the
Maintenance 165
Additional Work Sheets 167
Certifying on the Additional Work Sheets 167
Final Certification 169
Co-ordination 170
Conclusion 170
the role of the SUPERVISORSupervision 173
Division 3Who may supervise
maintenance 173
CASA Contacts 175
2 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 3
Contentssystems of MAINTENANCEIntroduction 5
Schedule 5 7
Civil Aviation Regulations 1988 10
Part 1 Daily inspection 10
Part 2 Periodic inspection 12
Part 3 Post inspection check 25
Revised CAAP 41-2(1) 26
Maintenance programs for
class B aircraft 26
CAAP No:39-1 (1) 35
Maintenance requirements for
class A aircraft 35
CAAP No: 42B-1 (0) 40
CAA Maintenance Schedule 40
CAAP 42L-1(0) 58
Inspection of aircraft after abnormal
flight loads, heavy landing or
lightning strike 58
the maintenance RELEASEIntroduction 67
How does the Maintenance Release Work? 67
The Maintenance Release 68
Part 1 69
Part 2 76
Part 3 80
ANNEX AThe new proposed flight
and technical log 82
ANNEX BCertifying on the
maintenance release 85
approved MAINTENANCE DATAIntroduction 89
The Type Certificat ion Process 89
Conclusion 98
certification for MAINTENANCEReferences 103
Certification for Completion of Stages
of Maintenance and CAR 42G
Independent Inspections 103
Co-ordination of Maintenance 105
8/12/2019 Engineer Maint Guide
3/89
systems of MAINTENANCE
5
1. Introduction1 There are two requirements for a system of maintenance;
they are different in the way that they deal with different
operational requirements.
(a) For aircraft operated in RPT or LCRPT (soon to include
Charter), an operators system must be developed and
presented to CASA or an authorised person for approval.
(b) For aircraft operated in Private, Aerial Work and Charter
(Charter is soon to be included in the transport category),
the Registered Operator (Part 47), will need to choose a
maintenance schedule from one of the following:
(i) the manufacturers system of maintenance
(ii) their own approved system of maintenance
(iii) the CASA system of maintenance (schedule 5).
The requirements of (a) are mandatory requirements. For (b)
the choice is up t o the Registered Operator.
What must be included?In every case there are certain requirements that must be met.
These are outlined in CAR 1988 42L and CAR 42M. They are:
A schedule that:
(a) sets out the regular maintenance inspections, tests and
checks to be carried out on the aircraft
(b) sets out when those maintenance inspections, tests and
checks will be carried out e.g. at what intervals
(c) nominates one of the inspections from (a) as the inspection
to be carried out for the purpose of determining whether a
Maintenance Release should be issued for the aircraft.
(d) Sets out details of time-lifed component
This system will continue when the proposed Part 43
regulations are introduced. The difference will be that a
maintenance release, as we currently know it, will not be
issued; instead a certification that the maintenance has been
carried out and that the aircraft is returned to service will be
made in the Flight and Tech Log.
The system must also include the following (CAR1988 42L and CAR 42M):(a) what inspection must be performed when the aircraft suffers a
lightning strike and when it should be carried out
(b) what inspection must be carried out when the aircraft
is subject to abnormal ground or flight loads. This is
determined from the flight manual and type certificate data,
and when this will be done.
c i v i l a v i a t i o n s a f e t y a u t h o r i t y 5
8/12/2019 Engineer Maint Guide
4/89
A list of components, which are time lifed i.e. have specific
overhaul periods listed by the aircraft manufacturer e.g. the
spar. The system must then specify when these components
should be retired, overhauled or removed for test;
(c) The procedures to be followed by the maintenance personnel
when performing the inspections, tests, and checks required by
the system.
The procedures must be in accordance with approved data,
which will normally mean that issued by the manufacturer,
approved by the regulator of the country of manufacture or
by CASA or an authorised person. This will include all of the
methods and limits listed in:
(i) the maintenance manual;
(ii) SBs, SLs etc; and
(iii) any other method approved by CASA i.e. ADs.
(d) If permissible unserviceabilities are approved as a minimum
Equipment List (MEL) then this list is included in the System of
Maintenance (SOM).
(e) Statements identifying the Registered Operator (entitled person
under CAR 1998 Part 45), and the aircraft, (model, type, serial
number and registration mark).
In the case of a transport aircraft the system of maintenance
(SOM) should also contain the maintenance that can be carried
out by a pilot and how each pilot is trained and authorised for this
maintenance.
The new regulations are more specific when it comes to this
aspect; they state what maintenance can be authorised. Any
(outside schedule 8) other maintenance that is required to be
performed by the pilot because of certain types of operation , e.g.
those remote from maintenance sources, can be approved using
a CASA Maintenance Authority (MA) (or its equivalent). To gain
this authority a pilot must have received appropriate training and
experience approved by CASA.
Most, if not all, of the information required above can be taken
from the manufacturers maintenance information. This will include
documents such as:
(a) the Maintenance Manual;
(b) service bulletins, letters, and instructions etc.
In addition to what is supplied by the manufacturer, other
maintenance information can be taken from such information as:
(a) Airworthiness Directives, both Australian and country of
manufacturer or certification;
(b) information material such as
6 7
(i) Airworthiness Advisory Circulars (AACs);
(ii) the Approved Aircraft Flight Manual;
(iii) engine manufacturer s printed material i.e. Operators
Handbooks; and
(iv) other advisory material.
All of this can be used to determine what is included in the system
of maintenance.
For B Class Aircraft Only
Manufacturers Versus CASA System of Maintenance (Schedule 5)
Schedule 5First of all it must be stated that the original purpose behind
the CASA system of Maintenance was for use by owners of
aircraft where the manufacturers system of maintenance
was inadequate for some reason. In some cases the original
manufacturer is no longer willing to support the aircraft
or equipment for whatever reason and in other cases the
manufacturer has not included service information on certain
equipment e.g. the avionics. The reason for this was that the
aircraft that was built to a basic design, which has been modified
over the years to include better, more efficient equipment. For
example no aircraft manufacturer in the 1950s ever dreamed of
the advances in instrumentation, radios or navigation equipment
available today, i.e. GPS. In addition because they produced
a BASIC model they could never be certain what equipment
is or could be fitted. What this means is that the Registered
Operator, to meet the Australian requirements, must include the
maintenance of this equipment in their system.
Schedule 5 is a very comprehensive list of what to do and
when to do inspections. Its limitation is that it does not have
any information on how the inspection is carried out or any
particular requirements or limits. This can only be gained
from approved maintenance data. Approved maintenancedata is defined in CAR 1988 2A. As a guide it is any data from
the aircraft or component manufacturer or any approved by
CASA or the National Airworthiness Authority (NAA) of the
country of manufacturer or certification, check to see that
any data used is approved before use. Approved data must
always be used (CAR 42V makes this a legal requirement). So
approved maintenance data must always be used, even if the
maintenance is performed to Schedule 5, or by a pilot or the
holder of an MA.
s y s t e m s o f m a i n t e n a n c e6 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 7
8/12/2019 Engineer Maint Guide
5/89
Manufacturers System of Maintenance
Several distinct advantages are gained by using the
manufacturers system of maintenance. These are:
1. The manufacturer will generally provide several options,
which will give some alternatives to the strict compliance to
times, i.e. +10% for a periodic inspection.
2. The manufacturer is surely the best person to provide
maintenance information. (They should know how to maintain
the reliability of the aircraft better than anyone).
3. The manufactuturers system will permit use of the various
documents simultaneously, e.g. using the manufacturers
system will give the same details for a daily inspection in
both the maintenance manual and the flight manual.
4. The manufacturers system is the benchmark used when
assessing the applicability of the CASA approved system,
(see CAR 1988 42M).
5. The manufacturers system will reference other approved
data as required. This is usually included in the task cards
for all inspections. This is acceptable and meets part of the
requirements of a system of certification which is required
by CAR 1988 42ZE (1) (a).
Combinations of the Manufacturers System and Schedule 5.
For a non-transport aircraft both schedule 5 and the manufacturers
system of maintenance is automatically approved, which means
that the entitled person need only inform CASA of their use
(usually through the submission of a Log Book Statement (LBS)).
The legislation also permits a combination of both of these
systems without further approval, provided the combination is
clear on the LBS. For example if the manufacturers system is
chosen, Schedule 5 may be included for the avionics. Another
example is when the aircraft manufacturer does not include any
reference to the engine manufacturers system; again these may
be combined (and is in fact recommended). This combination
will not require further approval. In the instance, though, where
additional requirements are to be included at the request of the
entitled person, this system then becomes that persons approved
system and will require CASA approval even if it is based on the
manufacturer s system or even Schedule 5. The same would
apply to compliance with an AD requirement for something to be
included in the SOM.
Note: Mention made to CASA here also includes authorised
persons.
8 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 9
Writing your own System of Maintenance (orMaintenance Schedule)This is not as difficult as it first looks. Writing your own System of
Maintenance can have several advantages. Some of these are:
1. The registered operator can gain some flexibility, whereas
the current schedule 5, for instance, only allows maintenance
to be carried out annually or every 100 hours time in service.
The operator may decide to develop a system where small
amounts of maintenance from the schedule are performed at
regular intervals rather than once a year.
2. The aircrafts general airworthiness would be improved.
3. Certain concessions concerning maintenance intervals can
be granted (for example a small over-run) .
4. The system of maintenance can be tailored to t he operators
specific requirements.
The system must meet the requirements of CAR 42L and
CAR 42M regardless. In addition certain parts of the
manufacturers system can be included along with applicable
parts of the current schedule 5. These two systems are the
basis on which your system would be assessed for approval,
along with the regulations previously mentioned.
It is proposed in the future that the new equivalent to the
current schedule 5 will be limited to aircraft used in private or
aerial work categories and for which there is an inadequate
manufacturers system of maintenance. The manufacturers
system would be the CASA preferred system and will require
no approval. The registered operator will indicate which
system of maintenance is to be used in the same way they do
now (through the LOG BOOK STATEMENT).
An option worth considering, though; is to write your own.
s y s t e m s o f m a i n t e n a n c e8 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 9
8/12/2019 Engineer Maint Guide
6/89
Civil Aviation Regulations 1988Schedule 5 CAA maintenance schedule(subregulation 2 (1))
(definition of CAA maintenance schedule)
Part 1: Daily inspection1.1 An inspection (in this Part called a daily inspection) must be
carried out on the aircraft before the aircrafts first flight on
each day on which the aircraft is flown.
1.2 A A daily inspection must consist of the making of such of
the checks set out in the table at the end of this Part as are
applicable to the aircraft.
Table of checks included in a daily inspection
Section 1: General
1. Check that the ignition switches are off, the mixture control
is lean or cut off, the throttle is closed and the fuel selector
is on.
2. Check that the propeller blades are free from cracks, bends
and detrimental nicks, that the propeller spinner is secure
and free from cracks, that there is no evidence of oil or
grease leakage from the propeller hub or actuating cylinder
and that the propeller hub, where visible, has no evidence
of any defect which would prevent safe operation.
3. Check that the induction system and all cooling air inlets
are free from obstruction.
4. Check that the engine, where visible, has no fuel or oil
leaks and that the exhaust system is secure and free from
cracks.
5. Check that the oil quantity is within the limits specified by
the manufacturer for safe operation and that t he oil filler
cap, dipstick and inspection panels are secure.
6. Check that the engine cowlings and cowl flaps are secure.
7. Check that the landing gear tyres are free from cuts or
other damage, have no plies exposed and, by visual
inspection, are adequately inflated.
8. Check that the landing gear oleo extensions are within
normal static limits and that the landing gear doors are
secure.
9. Check that the wing and fuselage surfaces are free from
damage and that the inspection panels, flight control
surfaces and flight control devices are secure.
10. Check that the interplane and centre section struts are free
from damage and that the bracing wires are of the correct
tension.
11. Check that the pitot heads and static ports are free from
obstruction and that the pitot cover is removed or is free to
operate.
12. Check that the fuel tank filler caps, chains, vents and
associated access panels are secure and free from damage.
13. Check that the empennage surfaces are free from damage
and that the control surfaces control cables and control
rods, where visible, are secure.
14. Check that the canard surfaces are free from damage and
that the control surfaces, control cables and control rods,
where visible, are secure.
15. Check that the flight controls, the trim systems and the
high lift devices operable from the ground have full and
free movement in the correct sense.
16. Check that the radios and antennae are secure and that
where visible, radio units and interwiring are secure.
17. Check that the drain holes are free from obstruction.
18. Check that there is no snow, frost or ice on the wings, tail
surfaces, canards, propeller or windscreen.
19. Check that each tank sump and fuel filter is free from water
and foreign matter by draining a suitable quantity of fuel
into a clean transparent container.
20. Check that the windscreen is clean and free from damage.
21. Check that the instruments are free from damage, legible
and secure.
22. Check that the seat belts, buckles and inertia reels are free
from damage, secure and functioning correctly.
Section 2: Additional items for agriculturalaeroplanes
1. Check that the agricultural equipment is secure.
2. Check that the dump and fan brake mechanisms are free
from obstructions and operate correctly.
s y s t e m s o f m a i n t e n a n c e10 11c i v i l a v i a t i o n s a f e t y a u t h o r i t y
8/12/2019 Engineer Maint Guide
7/89
Section 3: Additional items for seaplanes1. Check that the hull and floats are free from damage,
corrosion and water accumulation.
2. Check that the float attachment struts, bracing wires and
attachment fittings are secure and free from damage and
corrosion.
3. Check that the water rudder and its attachments are secure
and free from damage and corrosion and that the water
rudder has full, free and correct travel.
Part 2: Periodic inspection2.1 Subject to paragraph 2.2, an inspection (in this Part
called a periodic inspection) must consist of the taking of
the actions set out in the table at the end of this Part as
applicable to the aircraft.
2.2 The holder of a certificate of registration for a class B
aircraft may elect to have a section or sections of the
periodic inspection carried out on the aircraft at a different
time from the other sections.
2.3 A periodic inspection must be carried out on a private
aircraft within the period of 1 year from:
(a) the day on which the aircrafts current certificate of
airworthiness was issued; or
(b) the day on which the most recent general maintenance
inspection on the aircraft was completed; whichever is
the later.
2.4 Subject to paragraph 2.5, a periodic inspection must be
carried out on a class B aircraft that is not a private aircraft
within whichever of the following periods expires first:
(a) one year from:
(i) the day on which the aircrafts current certificate of
airworthiness was issued; or
(ii) the day on which the most recent general
maintenance inspection on the aircraft was
completed; whichever is the later;
(b) the aircraft has been in service for 100 hours since:
(i) the aircrafts current certificate of airworthiness was
issued; or
(ii) the most recent general maintenance inspection
on the aircraft was completed; whichever occurred
later.
s y s t e m s o f m a i n t e n a n c e12 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 13
2.5 In spite of paragraph 2.4, if the holder of the certificate of
registration for a class B aircraft that is not a private aircraft
has elected under paragraph 2.2 to have the sections of the
periodic inspection carried out on the aircraft at different
times, the following provisions have effect:
(a) the first carrying out of each section of the periodic
inspection on the aircraft after the election is made must
be carried out within whichever of the following periods
expires first:
(i) 18 months from:
(a) the day on which the aircrafts current certificate
of airworthiness was issued; or
(b) the day on which the most recent general
maintenance inspection on the aircraft was
completed; whichever is the later;
(ii) the aircraft has been in service for 150 hours since:
(a) the aircrafts current certificate of airworthiness
was issued; or
(b) the most recent general maintenance inspection
on the aircraft was completed; whichever
occurred later;
(b) each subsequent carrying out of each section of
the periodic inspection must be carried out within
whichever of the following periods expires first:
(i) the aircraft has been in service for 100 hours since
the section concerned was most recently carried out
on the aircraft;
(ii) 1 year from the day on which the section concerned
was most recently carried out on the aircraft.
2.6 In this Part: general maintenance inspection means a
regular inspection and check of a class B aircraft, its
systems and components that:
(a) is required by the aircrafts maintenance schedule to be
carried out at regular intervals; and
(b) is not required to be carried out before the aircrafts
first flight on each day on which the aircraft is flown.
Private aircraft means an aircraft:
(a) that is a class B aircraft; and
(b) that has a maximum take off weight of 5700 kg or less;
and
(c) that is only used in private operations by:
(i) the owner of the aircraft; or
12 13
8/12/2019 Engineer Maint Guide
8/89
(ii) a person to whom the owner has provided the aircraft
without receiving any remuneration from the person.
2.7 Unless otherwise indicated in the table, where the table
requires a thing to be inspected, the inspection is to be a
thorough check made to determine whether the thing will
continue to be airworthy until the next periodic inspection.
Table of actions included in a periodic inspection
Section 1: The airframe(1) Check the external and internal required placards.
Note Reference should be made to the aircraft flight manual
and airworthiness directives for the required placards.
(2) Take the following action in relation to the mainplane and
empennage (including canards) of the aircraft:
(a) inspect the skins for evidence of wrinkles, buckles,
sheared or loose rivets, corrosion, disbonds and
general damage;
(b) if the skin is fabric, check the strength of the fabric;
(c) inspect the internal structures and spars;
(d) inspect the lift struts, interplane struts, jury struts,
spreaders, chafing discs and bracing wires;
(e) inspect the flight control surfaces, slats, spoilers, tabs,
flaps, mass balance weight attachments, hinge brackets,
tracks and rollers;
(f) inspect the flight control system bellcranks, push pull rods,
torque tubes, cables, fairleads, turnbarrells and pulleys;
(g) inspect the wing and empennage to fuselage
attachments and surrounding structure;
(h) lubricate as necessary.
(3) Take the following action in relation to the fuselage:
(a) inspect the fuselage skin for evidence of wrinkles,
buckles, sheared or loose ri vets, corrosion, disbonds
and general damage;(b) inspect the areas around cut-outs (such as windows
and inspection apertures) for cracks and inspect the
sealing and fit of all doors and emergency exits;
(c) inspect the interior;
(d) inspect the strength of the fabric covering on surfaces;
(e) inspect the internal structure;
(f) inspect the locks, latches and hinges of doors, canopy,
windows which may be opened and direct v ision
windows;
s y s t e m s o f m a i n t e n a n c e14 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 15
(g) check that the windshields and windows are clean and
free from crazing, cracking, discoloration, delamination
and scratches;
(h) inspect the seats, seat attachments, seat adjustment
mechanisms, seat stops, seat belts, safety harnesses
and inertia reels;
(j) inspect the control wheels, control columns, rudder
pedals, control levers, control system bellcranks, push
pull rods, torque tubes and cables;
(k) operate all trim controls through the complete range
of travel and check them for correct trim position
indication;
(l) inspect the brake master cylinders, brake lines,
reservoirs, parking brake linkage and mechanical brake
system operating mechanisms;
(m) check the cabin fire extinguisher for correct charge,legibility of operating instructions and condition of
locking pin or seal and ensure that the extinguisher has
not reached its expiry date;
(n) inspect the heating and fresh air system ducting and
outlets and the airflow control valves;
(p) inspect the emergency and flotation equipment and ensure
that the equipment has not reached its expiry date;
(q) lubricate as necessary.
(4) Jack the aircraft so that the landing gear is clear of the
ground and take the following action:
(a) inspect the undercarriage attachment to the airframe;
(b) inspect the structural members, drag and side braces,
compression members, oleo struts, bracing struts and
torque links;
(c) inspect the leaf or tube spring shock absorbing units
and bungee rubber;
(d) inspect the flexible hoses;
(e) inspect the main wheels and tyres and the nose or tail
wheels and tyres;
(f) clean the wheel bearings, check that they are free from
scoring and brinelling, re-lubricate them, re-install them
and adjust the bearing pre-load;
(g) inspect the brake linings or pads and the brake drums
or discs;
(h) inspect the brake lines and flexible hoses;
(j) inspect the nosewheel or tailwheel steering mechanism
and the shimmy dampener;
14 15
8/12/2019 Engineer Maint Guide
9/89
(k) inspect the landing gear retraction mechanism, the door
and the door operating linkage;
(l) carry out an operational check of the landing gear and
doors and ensure that the adjustment of downlocks,
overcentre links, uplocks and spring tensions are within
the manufacturers specified limits;
(m) lubricate as necessary.
(5) Take the following action in relation to the fuel system:
(a) inspect the fuel tanks (where visible), lines, drains,
vents, signs, filler caps, filler cap securing chains or
cables, filler cap seals and scupper drains;
(b) inspect the fuel selector valves;
(c) inspect the fuel selector valve operating linkage.
(6) Take the following action in relation to the hydraulic system:
(a) remove, clean, and refit the hydraulic system filter element,or if it is unserviceable, install a new filter element;
(b) inspect the hydraulic system reservoirs, powerpack,
accumulators, selector valves, hand pump, pipelines
and flexible hoses.
(7) Inspect the anti-icing and de-icing systems.
(8) Inspect the air-conditioning evaporator, condenser and
compressor and the air-conditioning ducting, pipelines and
units.
(9) Inspect the pressurisation control system and indication
system.
(10) Take the following additional action if the aircraft is used in
agricultural operations:
(a) inspect the hopper, hopper lid and fasteners, baffles
and internal braces;
(b) inspect the spreader, spreader gate and controls;
(c) inspect the spray pump fan, fan mount, fan brake,
spray pump lines, booms and boom supports;(d) inspect the emergency dump doors and dump controls.
(11) Take the following additional action if t he aircraft is a
seaplane:
(a) inspect the external covering and internal structure of
the floats or hull;
(b) drain the bilge compartments, refit and re-lock the drain
plugs;
(c) inspect the float attachment struts, bracing wires and
attachment fittings;
s y s t e m s o f m a i n t e n a n c e16 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 17
(d) inspect the water rudders, water rudder attachments
and water rudder controls, operate and check them for
full and free movement in t he correct sense and for
correct locking;
(e) inspect the protective treatment and finish.
Section 2: The engine(1) Check the external and internal required placards.
Note Reference should be made to the aircraft flight manual
and airworthiness directives for the required placards.
(2) Take the following action in relation to the cowls:
(a) remove, clean and inspect the cowls, cowl flaps and
fastenings.
(3) Inspect, and record the compression of, each cylinder.
(4) Take the following action in relation to the engine oil system:(a) drain the sump or tank and refit the plug and lockwire;
(b) drain the oil cooler and refit and secure the hose;
(c) either:
(i) remove, inspect, clean and refit the pressure filter
and lockwire; or
(ii) remove, open and inspect the cartridge full flow
filter and fit a new cartridge and lockwire;
(d) inspect the oil cooler, oil temperature control valves, oil
tank and attachment fittings;
(e) inspect all oil lines, fittings, breather pipe and the oil
cooler shutter;
(f) refill the sump or tank with the recommended grade
and quantity of oil.
(5) Take the following action in relation to the ignition system:
(a) remove the spark plugs, clean and inspect them, check
the spark plug electrode gap, test the spark plugs and
renew them if required;
(b) inspect the spark plug high tension leads and ceramics;
(c) inspect the magneto housing;
(d) inspect the breaker compartment and cam follower;
(e) inspect the breaker points for serviceability and check
the breaker points gap, magneto engine timing and
synchronisation;
(f) inspect the switch and earth leads;
(g) refit and torque the spark plugs;
(h) refit the spark plug high tension leads.
16 17
8/12/2019 Engineer Maint Guide
10/89
(6) Take the following action in relation to the fuel system:
(a) place the fuel selector in the off position;
(b) remove, inspect, clean and refit the fuel strainers and
screens and lockwire;
(c) drain and flush the carburettor fuel bowl and refit the
plug and lockwire;
(d) inspect the carburettor or fuel injection components;
(e) inspect the throttle and mixture shafts;
(f) inspect all fuel lines and fittings;
(g) move the fuel selector from the off position;
(h) inspect the auxiliary fuel pump for operation;
(i) pressurise and purge the fuel system and inspect it for
leaks.
(7) Take the following action in relation to the induction
system:
(a) remove the air filters, clean them, inspect them and
refit or renew them;
(b) inspect the hot and alternate air systems for the
integrity of seals and for serviceability of valves, shafts,
bearings, magnets and hinges;
(c) inspect the induction manifold and hoses.
(8) Take the following action in relation to the exhaust system:
(a) inspect the exhaust system;
(b) remove the muffler shroud, inspect the muffler and refit
the shroud;
(c) inspect the muffler internally for security of baffle
cones;
(d) inspect the cabin heat flexible hoses.
(9) Take the following action in relation to the engine cylinders
and baffles:
(a) inspect the cylinder assemblies;
(b) inspect the cylinder base to the crankcase area;(c) inspect the rocker covers;
(d) inspect the push rod housing seals.
(10) Take the following action in relation to the crankcase,
accessory housing and firewall:
(a) inspect the engine for evidence of oil leakage;
(b) inspect the accessories and drive belts;
(c) inspect the engine mounts and engine mountbolts;
(d) inspect the engine mount frame;
(e) inspect the firewall, including seals and sealant.
s y s t e m s o f m a i n t e n a n c e18 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 19
(11) Inspect the following controls for full and free movement in
the correct sense:
(a) throttle, mixture and propeller;
(b) alternate air and carburettor heat;
(c) engine bay fuel strainer controls;
(d) oil cooler shutter and cowl flap;
(e) turbocharger.
(12) Take the following action in relation to the propeller:
(a) inspect the propeller for static track;
(b) inspect the propeller hub, spinner and backplate;
(c) inspect the wooden propeller attachment bolts;
(d) inspect the blades;
(e) inspect the counterweights;
(f) lubricate the propeller hub;
(g) service the propeller hub with air.
(13) Take the following action in relation to the turbocharger:
(a) remove the heat shield and inspect the turbocharger
housing for cracks and oil leaks from the inlet and
outlet ports;
(b) inspect the compressor and turbine wheel;
(c) inspect the rotating assembly bearing for end float;
(d) inspect the turbocharger mount;
(e) inspect the transition assembly, the induction and
exhaust components and the clamps;
(f) inspect the upper deck pressure manifold and hoses;
(g) lubricate the waste gate linkages and the butterfly
valve;
(h) inspect the flexible oil lines;
(j) inspect the controllers and actuators;
(k) inspect the compressor by-pass door;
(m) refit the heat shield.
(14) Take the following action in relation to the refitting of the
cowls:
(a) check that no tooling, rags or other foreign objects
remain in the compartment;
(b) inspect the latches and fasteners for correct tension;
(c) inspect the inlet and cooling air ducting;
(d) inspect the landing and taxi light wiring;
(e) inspect the cowl flap linkage and engine drain lines.
18 19
8/12/2019 Engineer Maint Guide
11/89
(15) Chock the wheels and check the brake operation, then set
the park brake, start the engine and take the following
action to determine satisfactory performance in accordance
with the manuracturers recommendations:
(a) stabilise the engine temperatures and pressures;
(b) check the idle speed, mixture and the magneto switch
operation at low engine revolutions per minute;
(c) check the carburettor heat or alternate air operation;
(d) check the gyro or vacuum pressure indication;
(e) inspect the generator or alternator;
(f) check any unusual engine vibration or noises;
(g) check the engine response to throttle application;
(h) check each magneto and propeller governor for operation;
(j) check the static engine revolutions per minute, manifold
pressure and fuel flow;(k) check the idle cut-off operation.
(16) After taking the action described above, remove the cowls,
inspect the engine for oil, fuel or other fluid leaks, then replace
the cowls.
Section 3: The electrical system(1) Check the external and internal required placards.
Note: Reference should be made to the aircraft flight manual
and airworthiness directives for the required placards.
(2) Take the following action in relation t o the air-conditioning
system:
(a) inspect the distribution system electrical components
and interwiring;
(b) inspect the heating and temperature control system;
(c) inspect the reon system electrical components and
interwiring;
(d) inspect the air cycle system electrical components and
interwiring.
(3) Take the following action in relation to the electrical power:
(a) inspect the AC generation system (including the
generator, invertor, regulator, interwiring, control relays
and switching);
(b) inspect the AC distribution system;
(c) inspect the DC generation system (including the
generator, regulator, transformer or rectifier units,
interwiring, control relays and switches);
(d) inspect the DC distribution system (including the busses,
circuit breakers or fuses, relays, switches and interwiring);
s y s t e m s o f m a i n t e n a n c e20 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 21
(e) inspect the starter generator;
(f) inspect the indication systems;
(g) inspect the batteries;
(h) inspect the external power system.
(4) Take the following action in relation to electrical equipment
and furnishing:
(a) inspect the flight compartment (including any spare
bulbs and fuses);
(b) inspect the passenger compartment (including any
spare bulbs and fuses);
(c) inspect the buffet or galley electrical systems, the
lavatory compartment electrical systems and the cargo
compartment electrical systems.
(5) Take the following action in relation to the following fire
protection systems:
(a) inspect the engine fire detection system;
(b) inspect any other fire and smoke detection systems;
(c) inspect the engine fire extinguishing system;
(d) inspect any other fire extinguishing systems.
(6) Inspect the electrical components and interwiring of the
following flight control systems:
(a) the trim and flap system;
(b) the lift dump and spoiler system;
(c) the lift augmenting system.
(7) Inspect the electrical components and interwiring of the
fuel distribution and dump system.
(8) Inspect the electrical components and interwiring of the
main and auxiliary hydraulic systems.
(9) Inspect the electrical components and interwiring of the
following ice and rain protection systems:
(a) the anti/de-ice systems;
(b) the ice detection and indication systems.
(10) Inspect the systems and components that give audible or
visual warnings.
(11) Inspect the electrical components and interwiring of the
following landing gear systems:
(a) the extension and retraction systems;
(b) the wheels, brakes and anti-skid system;
(c) the nose wheel steering system;
(d) the position and warning system;
(e) the anti-retract system.
20 21
8/12/2019 Engineer Maint Guide
12/89
(12) Inspect lights in or on the following areas:
(a) the flight compartment, the passenger compartment
and the cargo and service compartment;
(b) the exterior and emergency systems.
(13) Inspect the electrical components and interwiring of
pneumatic systems.
(14) Inspect the electrical or electronic control panels,
equipment racks and junction boxes.
(15) Inspect the electrical components and interwiring of
passenger, crew and cargo doors.
(16) Inspect the electrical components and interwiring of the
propeller control and anti/de-ice systems.
(17) Inspect the electrical harnesses, excluding the ignition
harness.
(18) Inspect the electrical components and interwiring of the
engine fuel and engine control systems.
(19) Take the following action in relation to the ignition:
(a) inspect the electrical power supplies;
(b) inspect the booster coils, vibrator systems and high
energy ignition systems;
(c) inspect the switching, including by performing an
insulation check of the magneto switch leads.
(20) Inspect the engine starting system.
Section 4: The instruments(1) Check the external and internal required placards.
Note: Reference should be made to the aircraft flight manual
and airworthiness directives for the required placards.
(2) Take the following action in relation to the auto-flight
system:
(a) inspect the autopilot or the automatic flight control
system, including the flight director and stability control
augmentation;
(b) inspect the yaw damper system;
(c) inspect the speed-attitude correction system, including
the auto-trim and mach-trim.
(3) Inspect the flight control surface indication systems.
(4) Inspect the fuel pressure and quantity indication systems.
(5) Inspect the hydraulic power indication system.
(6) Inspect the ice protection indication system.
(7) Take the following action in relation to indicating and
recording systems:
(a) inspect the instrument and control panels;
s y s t e m s o f m a i n t e n a n c e22 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 23
(b) inspect the independent instrument systems, including
the inclinometers, indicators and clocks;
(c) inspect the recorders, including the flight data
recorders, performance or maintenance recorders.
(8) Take the following action in relation to navigation systems:
(a) inspect the flight environment data system, including:
(i) the central air data system; and
(ii) the pitot/static system, including instruments; and
(iii) the stall warning system;
(b) inspect the attitude and direction systems, including:
(i) the magnetic compass; and
(ii) the vertical attitude gyro system; and
(iii) the directional gyro system, including the magnetic
referenced systems; and
(iv) the electronic flight instrument system and multi-function displays;
(c) inspect the independent position determining systems,
including:
(i) the inertial navigation and reference systems; and
(ii) the ground proximity warning systems;
(d) inspect the flight management system, including the
flight management and performance management
systems.
(9) Take the following action in relation to oxygen systems:
(a) inspect the crew, passenger and portable systems;
(b) inspect the indicating systems.
(10) Inspect the pneumatic indicating systems, including the
pressure gauge and warning indicators.
(11) Take the following action in relation to the instrument
pressure or vacuum system:
(a) inspect the distribution system, including the filters,
manifolds, regulating valves, check valves and
plumbing;
(b) inspect the indicating system, including the pressure
gauge and warning system.
(12) Inspect the engine indicat ing systems, including fuel flow,
temperature and pressure.
(13) Take the following action in relation to the engine
indicating systems:
(a) inspect the power indicating system;
(b) inspect the temperature indication system;
(c) inspect the integrated engine instrument system.
22 23
8/12/2019 Engineer Maint Guide
13/89
(14) Inspect the oil indicating systems, including quantity,
pressure and temperature.
(15) Inspect the water injection indicating system.
Section 5: The radio system(1) Check the interior and exterior required placards including
frequency charts.
Note: Reference should be made to the aircraft flight manual
and airworthiness directives for the required placards.
(2) Take the following action in relation to communication and
navigation systems:
(a) inspect the accessible interwiring, plugs and sockets;
(b) inspect the microphones, headsets and cords;
(c) inspect the fuses for adequacy of spares;
(d) inspect the antennae and antenna insulators;
(e) inspect the Emergency Location Transmitter/CrashLocation Beacon batteries for electrolyte leakage and
check that the battery lif e has not expired;
(f) inspect the removable units, mounting racks, vibration
isolators and bonding straps;
(g) inspect the switches and controllers;
(h) inspect the radio panel lamps for adequate illumination;
(j) inspect the radio indicators for legibility.
(3) Take the following additional action in relation to
communicat ion systems in aircraft equipped for I.F.R. flight:
(a) inspect the HF communication system, including for
correct performance by communication with ground
stations or by other means;
(b) inspect the VHF communication system, including for
correct performance by communication with ground
stations or by other means;
(c) inspect the audio system, including for correct
operation of all distribution and amplifying systems in
all modes of operation.(4) Take the following action in relation to navigation systems
in aircraft equipped for I.F.R. flight:
(a) check the ADF system for accuracy and correct
performance in all modes of operation within the limits
specified in section 108.34 of the Civil Aviation Orders;
(b) check the VOR system for correct performance within
the limits specified in section 108.34 of the Civil
Aviation Orders;
s y s t e m s o f m a i n t e n a n c e24
Civil AviationAdvisoryPublicationAugust 1996
This publication is
only advisory but
it gives the CASA
preferred method
for complying with
the Civil Aviation
Regulations.
It is not the only
method, butexperience has
shown that if
you follow this
method you will
comply with the
Civil Aviation
Regulations.
Always read
this advice in
conjunction with
the appropriate
regulations
Contents...
Systems of
maintenance
Independentinspections
Log book
requirements
c i v i l a v i a t i o n s a f e t y a u t h o r i t y 25
(c) check the localiser system for correct performance
within the limits specified in section 108.34 of t he Civil
Aviation Orders;
(d) check the glideslope system for correct performance
within the limits specified in section 108.34 of t he Civil
Aviation Orders;
(e) check the marker system for correct performance in all
modes: an approved simulator may be used for these
tests;
(f) inspect the DME system;
(g) inspect the Omega/VLF system;
(h) inspect the Doppler navigation system;
(j) inspect the weather radar system;
(k) check the ATC transponder system for correct
performance in all modes using the self test facility:
select code 0101 for this test;
(l) inspect the radio altimeter system;
(m) inspect the ground proximity warning system; and
(n) inspect the electronic flight instrument system.
Part 3: Post inspection check3.1 On completion of each section of the inspection, check to
ensure that all tools, maintenance equipment or rags have
been removed from the aircraft and all panel, access doors,
detachable fairings and fillets have been correctly secured.
24 25
8/12/2019 Engineer Maint Guide
14/89
Revised CAAP 41-2(1)
Maintenance programsfor class B aircraftThe relevant regulations and other references
Part IVA of Civil Aviation Regulations (CARs), particularly
Subdivision B, CARs 41, 42, 42A, 42B and 42C dealing with
maintenance programs for class B aircraft
CARs 2A, 42V, 42ZC, 42ZE and 42ZP
The CASA Maintenance Schedule as set out in Schedule 5
of the CARs
Civil Aviation Order (CAO) 100.5, General Requirements in
respect of Maintenance of all Australian Aircraft
CAAP No. 42-1, Inappropriate maintenance programs for
class B aircraft.
Who this CAAP applies to Certificate of Registration holders for class B aircraft
Certificate of Approval holders for class B aircraft
maintenance
Licensed Aircraft Maintenance Engineers
Holders of an Airworthiness Authority
Why this publication was writtenRegulation 41 of the CARs requires that a maintenance program
must be in force for the maintenance of a class B aircraft.
This publication gives guidance on maintenance programs,
identifies the maintenance schedules acceptable to CASA as
defined by regulation 42, 42A, 42B and 42C and the appropriate
certification requirements under regulation 42ZE for the
certification for the completion of maintenance for this class of
aircraft.
Status of this CAAPThe format and layout of t his CAAP has been completelyrevised and replaces CAAP 41-2(0) dated 1 March 1992.
For further informationContact the CASA Airworthiness District Office closest to you.
Civil Aviation Advisory Publication
April 1996
s y s t e m s o f m a i n t e n a n c e26 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 27
The Certificate of Registration holder for a class B aircraft must
not fly the aircraft and must ensure that the aircraft does not start
a flight unless there is a maintenance program for the aircraft and
the program includes provision for the maintenance of all aircraft
components fitted to or provided in the aircraft.
The Regulations provide for one of three maintenance program
options which may be based on either:
the manufacturer s maintenance schedule, under CAR 42A; or
the CASA Maintenance Schedule 5, under CAR 42B; or
a maintenance program developed by the Certificate of
Registration holder and approved by CASA or an authorised
person under CAR 42M.
In providing these options, CASA expected that industry would
recognise the manufacturers maintenance schedule as the most
appropriate for aircraft maintenance.
Many Certificate of Registration holders, however, have elected to
use the CASA Maintenance Schedule 5 believing that compliance
with the CASA Schedule 5, the applicable Airworthiness Directives
(ADs) and the Airworthiness Limitations would satisfy all the
necessary maintenance required for continued airworthiness.
While election of the CASA Maintenance Schedule 5 meets
the minimum requirements set by CASA, the schedule does
not address supporting material contained in the instructions
issued by manufacturers for continued airworthiness, such as
special inspections, structural integrity inspections, corrosion
control programs and continuing airworthiness inspection
programs provided by the manufacturer. Nor does it address the
requirements for those persons carrying out maintenance to do so
in accordance with approved maintenance data (CAR 2A) which is
a consideration of how maintenance tasks shall be performed, e.g.
an inspection.
In the absence of a requirement for a major inspection, the
importance of the instructions issued by manufacturers for
continued airworthiness are not only relevant but essential when
considering that many class B aircraft in Australia are over twenty
(20) years old.
The Certificate of Registration holder for a class B aircraft must
ensure that any maintenance required to be carried out on the
aircraft (including aircraft components fitted to or provided in the
aircraft) by the aircrafts maintenance program is carried out at
intervals determined in accordance with schedules which form part
of that program.
26 27
8/12/2019 Engineer Maint Guide
15/89
The Certificate of Registration holder for a class B aircraft is
responsible for establishing a maintenance program for the
aircraft, which is to be specified in the aircrafts Log Book
Statement, and which may consist of one of t he following
programs applicable to the aircraft:
A program which includes the manufacturers maintenance
schedule, and:
as necessary, CASA Maintenance Schedule 5 instruments
and radio (avionics) inspections;
the manufacturers Airworthiness Limitations;
Australian Airworthiness Directives;
Consideration should, for the purposes of continuing
airworthiness, also include:
special inspections - (manufacturers/modifications/
repairs,etc.);
the manufacturers continuing airworthiness inspection
program;
the manufacturers supplementary and corrosion
inspection programs;
A program which includes the CASA Maintenance Schedule
5, and:
the manufacturers Airworthiness Limitations;
Australian Airworthiness Directives;
Consideration should, for the purposes of continuing
airworthiness, also include:
special inspections - (manufacturers/modifications/
repairs,etc.);
the manufacturers continuing airworthiness inspection
program;
the manufacturers supplementary and corrosion
inspection programs;
A program which consists of an approved maintenance
program under CAR 42M.
MORE THAN ONE MANUFACTURERSMAINTENANCE SCHEDULEIf more than one manufacturers maintenance schedule is available
for the aircraft, e.g., periodic or progressive care, you should take
care to nominate, and remain with one schedule only. There
should be no mix and matching. Also in selecting your schedule,
make sure that the schedule addresses the fit-out of your aircraft
and that it relates to the latest revision of the instructions of the
manufacturer for continued airworthiness.
s y s t e m s o f m a i n t e n a n c e28 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 29
DEFICIENT INSTRUCTIONS/INFORMATIONDeficiencies in instructions issued by manufacturers, or in
manufacturers schedules, generally relate to lack of information
concerning optional instrument and radio systems and roll
equipment. The periodic maintenance of such systems and
associated equipment is best undertaken by reference to the CASA
Maintenance Schedule 5 for when to do it and in accordance
with the approved maintenance data (CAR 2A) for how to do it.
MAINTENANCE RELEASE PERIODAll maintenance required at the nominated inspection for
maintenance release issue must be certified prior to the
maintenance release issue. The periodic maintenance release
inspection must not exceed 100 hours time-in-service or a calendar
period of twelve months, whichever occurs first. To ensure that
no maintenance will be overlooked between periodic inspections,
all maintenance required to be carried out between periodic
inspections are to be endorsed on the Maintenance Required
section of the maintenance release.
CASA MAY GIVE DIRECTIONS FOR INADEQUATEMANUFACTURERS MAINTENANCE SCHEDULESIf CASA thinks t he elected manufacturers maintenance
schedule does not adequately provide for the continued
airworthiness of the aircraft, CASA may, to remedy the
inadequacy, give directions requiring the Certificate of
Registration holder to do either or both of the following, in
addition to comply with the schedule:
take the action described in the directions; and/or
prepare documents containing requirements specified in
the directions that are to be complied with.
Once the direction has been given to take particular action, the
direction then forms part of the aircrafts maintenance program.
CASA MAY DECLARE MANUFACTURERS
MAINTENANCE SCHEDULE INADEQUATECASA may direct under Regulation 42A (6), in the interests of
the safety of air navigation, that the manufacturers maintenance
schedule for a type or model of aircraft must not be used as the
maintenance schedule [see also CAO 100.5]. In this case the
Certificate of Registration holder cannot elect the schedule, but
must either adopt the CASA Maintenance Schedule 5 or develop
and seek approval of a maintenance program.
28 29
8/12/2019 Engineer Maint Guide
16/89
Certificate of Registration holders should be aware that
selection of the CASA Maintenance Schedule 5 is limited in its
application in that t he schedule:
may not be used for helicopters;
in many cases, may not address all relevant periodic
maintenance requirements (schedules, etc.) for a particular
aircraft; and
will not cover the requirements for continuing
airworthiness (eg, service bulletins, service letters, etc.).
For this reason, notwithstanding legislative requirements, CASA
recommends Certificate of Registration holders and/or Certificate
of Approval holders (approved organisations) will need to carefully
evaluate the aircraft manufacturers manuals, in particular the
associated maintenance schedule, and in the absence of any
justifiable reason why the maintenance program cannot be used,
elect and maintain the aircraft to that maintenance program.
ADDITIONAL INSTRUCTIONS TURBINE ENGINESFITTEDIf an aircrafts maintenance schedule is the CASA Maintenance
Schedule 5 and the aircraft has a turbine engine, then all
instructions issued by the engine manufacturer for the continued
airworthiness of the engine must be included and form part of the
aircrafts maintenance program.
Once an election has been made and the Certificate of Registration
holder becomes aware that the maintenance schedule contained
in the aircrafts maintenance program becomes inadequate or
defective and does not adequately provide for the continuing
airworthiness of the aircraft the holder must report the matter
to CASA as required by CAR 42. The Certificate of Registration
holder must then either choose to replace the aircraft maintenance
schedule with another schedule or request CASA or an authorised
person to approve a maintenance program for the aircraft. Such an
election must be made in writing to your local CASA Airworthiness
District Office.
Where the Certificate of Registration holder desires under CAR
42J, or is directed by CASA under CAR 42K/CAR 38, to develop
a maintenance program for the aircraft, that program must
be approved by CASA or an authorised person and should
contain, as a minimum, the following:
s y s t e m s o f m a i n t e n a n c e30 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 31
the name of the Certificate of Registration holder;
the type, model and registration mark of the aircraft to
which the maintenance program applies;
schedules which set out:
- the maintenance to be carried out at specified intervals
and the intervals between maintenance;
- the identity of the inspection to be complied with for the
issue of a maintenance release;
- structural integrity inspections;
- special inspections, including corrosion control,
independent, and weight and balance inspections;
- components subject to overhaul and the intervals
between overhauls;
- components subject to retirement and their retirement
life;
- continuing Airworthiness Inspection Programs;
the maintenance required following lightning strikes, or
when abnormal flight or ground loads have been imposed
on the aircraft;
MEL control procedures (if MEL is approved for the
aircraft); and
amendment procedures for the maintenance program.
Those parts of the maintenance program required by the schedules
and the maintenance required following a lightning strike, etc.,
are to comply with the requirements specified in the approved
airworthiness/maintenance data for the aircraft, unless otherwise
approved or directed by CASA.
Where the details in items above are identical to the
recommendations contained in the approved airworthiness/
maintenance data for the aircraft, the maintenance program need
only contain a reference to the documents in Logbook Statement
Part 1, containing those details.
REQUESTING APPROVAL OF ALTERATIONS TO ANAPPROVED MAINTENANCE PROGRAMThe Certificate of Approval holder may request CASA or an
authorised person to approve proposed alterations to the
maintenance program.
CASA or the authorised person will take into account the aircrafts
relevant manufacturers maintenance schedule (if any) when
considering the approval of the alterations.
30 31
8/12/2019 Engineer Maint Guide
17/89
CASA MAY DIRECT CHANGES TO AN APPROVEDMAINTENANCE PROGRAMCASA may give directions requiring the Certificate of Registration
holder to alter the approved maintenance program or correct any
inadequacies in the program.
All instructions issued by manufacturers, including service bulletins
(refer CAR 2A) that deal with how to carry out maintenance must
be complied with, unless CASA or an appropriately authorised
delegate has explicitly approved an alternative procedure. This
applies regardless of the maintenance program that has been
chosen for the aircraft. Please also see CAR 42V regarding use of
approved maintenance data and CAR 42ZP regarding certification
only to be made where maintenance has been carried out in
accordance with approved data.
ASSESSING MANUFACTURERS DATAThe Certificate of Registration holder needs to confirm thatwhen assessing the instructions issued by manufacturers and
the associated schedules, the data addresses the continuing
airworthiness of the aircraft. The Certificate of Registration holder is
responsible for considering the data to confirm whether an elected
manufacturers maintenance schedule is deficient or otherwise.
If the assessment indicates that the elected schedule is deficient,
then the Certificate of Registration holder is responsible for the
reporting and rectification action as required by CAR 42 - Defective
or inappropriate maintenance program.
As part of the maintenance control function, Certificate of
Registration holders are required to compile a Log Book Statement
Part 1 identifying the aircrafts maintenance program and other
inspections to be complied with. [refer CAR 50A and CAO 100.5]
As previously discussed, there are three maintenance program
options available to the Certificate of Registration holder. The
following typically represent log book statements for each of the
three options that should be considered when compiling the log
book statement:
TYPICAL LOG BOOK STATEMENT CONSIDERATIONSWHEN USING THE CASA MAINTENANCE SCHEDULE 5This aircraft is to be maintained in accordance with the following:
the CASA Maintenance Schedule 5.
the schedule of Airworthiness Limitations contained in the
latest revision of the manufacturers maintenance manual
applicable to this aircraft for all time-lifed components.
all Airworthiness Directives (ADs) applicable to this aircraft.
s y s t e m s o f m a i n t e n a n c e32 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 33
ADs indicating compliance at major inspection are to be
complied with at intervals not greater than three years, or one-year
intervals for aircraft used in agricultural operations.
all inspections which are listed in the:
- approved maintenance/airworthiness data relating to
modifications/repairs incorporated in this aircraft; and
- approved maintenance/airworthiness data relating to
modifications/repairs incorporated in components installed in
this aircraft.
any other requirements recommended by the aircraft or
component manufacturer for the continuing airworthiness of
the aircraft or component. e.g. Corrosion Prevention Control
Programs (CPCPs), or Continuing Airworthiness Inspection
Programs (CAIPs).
TYPICAL LOG BOOK STATEMENT CONSIDERATIONSWHEN USING THE MANUFACTURERSMAINTENANCE SCHEDULEThis aircraft is to be maintained in accordance with the following:
the instructions issued by the manufacturer and the associated
maintenance schedule contained in the latest revision of the
manufacturers maintenance manual.
any instructions for the continued airworthiness of the aircraft
specified by the aircraft or component manufacturer from time
to time;
the CASA Maintenance Schedule 5 for instrument and radio
components and systems not adequately covered by the
manufacturers schedule, as appropriate;
the schedule of Airworthiness Limitations contained in the
latest revision of the manufacturers maintenance manual
applicable to the aircraft for all time-lifed components.
ADs indicating compliance at major inspection, are to be
complied with at intervals not exceeding three years, or one
year intervals for aircraft used in agricultural operations.
all inspections which are listed in the:
approved airworthiness/maintenance data relating to
modifications/repairs incorporated in this aircraft; and
approved airworthiness/maintenance data relating to
modifications/repairs incorporated in components installed
in this aircraft.
any other requirement recommended by the aircraft or
component manufacturer for the continuing airworthiness of
the aircraft or component. e.g. Corrosion Prevention Control
Programs (CPCPs), or Continuing Airworthiness Inspection
Programs (CAIPs).
Civil AviationAdvisoryPublicationAugust 1997
This publication is
only advisory but
it gives the CASA
preferred method
for complying with
the Civil Aviation
Regulations.
It is not the only
method, but
experience has
shown that if
you follow this
method you will
comply with the
Civil Aviation
Regulations.
Always read
this advice in
conjunction with
the appropriate
regulations.
Contents...
Systems of
maintenance
Independentinspections
Log book
requirements
32 33
8/12/2019 Engineer Maint Guide
18/89
TYPICAL LOG BOOK STATEMENT CONSIDERATIONSFOR AN APPROVED MAINTENANCE PROGRAMThis aircraft is to be maintained in accordance with the following:
the current approved maintenance program.
state where located
Note: The approved maintenance program may be attached to the
log book attachment, Log Book Statement Part 1 or alternatively
may be held as an independent document by the Certificate of
Approval holder (maintenance organisation) normally responsible
for the carrying out and certifying for completion of maintenance
on the aircraft.
CertificationRegulation 42ZE requires that a person who carries out
maintenance on an aircraft must ensure that completion of
the maintenance is certified in accordance with an approvedsystem of certification or the CASA system of certification
(Schedule 6 of the CARs) as applicable.
Separate certifications relating to each inspection shall be
made in the appropriate sections of the aircraft log books
pursuant to the pertinent CARs.
s y s t e m s o f m a i n t e n a n c e34 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 35
CAAP No: 39-1 (1)
Maintenance requirementsfor class A aircraft
The relevant regulations and other referencesThis publication should be read in conjunction with Civil
Aviation Regulations 39 (1), 42ZE and Schedule 6 of the CARs.
Who this CAAP applies to Certificate of Registration Registered Operators for class A
aircraft
Holders of a Certificate of Approval for maintenance
of class A aircraft
LAMEs and Maintenance Authority holders
Pilots and flight engineers engaged in RPT operations or
who operate transport category aircraft
Why this CAAP was writtenRegulation 39 of the CARs requires that class A aircraft must
have in force a system of maintenance approved by CASA. This
publication describes the preferred procedures to be followed for
the development and approval of that system of maintenance and
the certification requirements of regulation 42ZE.
Status of this CAAPThis is the second issue of CAAP 39-1. It has been amended
to clarify the maintenance requirements for class A aircraft
by deletion of one sentence. The sentence referred to
maintenance options available to class B aircraft and could
have caused confusion.
This is an interim amendment to rectify this aspect of the CAAP
only. CASAs extensive regulatory review process may result in
further changes to this and other CAAPs.
Systems of maintenanceThe Certificate of Registration holder of a class A aircraft is
required, by regulation 39 of the CARs, to submit for approval,
to CASA or an authorised person, a system of maintenance.
The system of maintenance is to be referred to in the aircrafts
Log Book Statement Part 1 or an approved alternative and
should include, as applicable:
the name of the Certificate of Registration holder;
the type, model and registration mark of the aircraft to
34 35
8/12/2019 Engineer Maint Guide
19/89
which the system applies;
maintenance schedules which include:
- maintenance tasks to be performed at specified intervals
and the intervals between the maintenance;
- the identity of the inspection to be completed for the issue
of a maintenance release;
- structural inspections;
- a list of components subject to an overhaul life
and the intervals between the overhauls, based
upon the manufacturers recommendations and the
recommendations contained in the Maintenance Review
Board (MRB) document for the aircraft;
- a list of components subject to retirement and the
retirement life.
the maintenance required following a lightning strike or
abnormal flight or ground loads;
amendment procedures for the system of maintenance;
servicing procedures including specification and grade of
fluids;
maintenance practices and procedures; and
if not covered by a Maintenance Control Manual:
- MEL control procedures;
- maintenance control procedures, including the planning
system to ensure that all maintenance is completed and
certified for on or before the due time-in-service or date.
If the Certificate of Registration holder is using approved
maintenance data as the system of maintenance, the system
need only contain a reference to that data.
Maintenance schedules are, unless otherwise approved or
directed by CASA or an authorised person, to comply with the
requirements specified in the approved maintenance data or, if
applicable, the current Australian Maintenance Requirements
Documents (AMRD) for the aircraft.
Where a class A aircraft is used in extended range operations
approved under CAO 20.7.1B, the system of maintenance
must also include provision for t he practices and procedures
required to comply with the additional airworthiness
requirements, including those specified in the latest issue of
airworthiness directives and other approved maintenance data.
s y s t e m s o f m a i n t e n a n c e36 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 37
Independent inspectionsAs the system of maintenance will be assessed against the
requirements of the current edition of the manufacturers
instructions, CARs and CAOs, it is advisable to use these
documents as guidance when developing the system.
The definition for Approved Maintenance Data, in CAR 2A,
specifies data that is in force from time to time. This means
that the data used when performing maintenance must be the
current edition in force at the t ime the maintenance was being
performed.
Regulation 42G of the CARs requires an independent
inspection, to ensure correct assembly and f unction of
the flight control systems of an aircraft, t o be carried out
and certified prior to the certification being made for the
completion of maintenance of any part of an aircraft control
system involving:
assembly;
adjustment;
repair;
modification; or
replacement.
Correct assembly and function means:
that the control system and its components have been
correctly assembled and adjusted;
locking devices have been made safe; and
the controls have full and free movement, in the correct
sense, throughout their operating range.
For the purposes of independent inspections, the flight control
system of an aircraft includes:
the main control surfaces;
lift and drag devices;
trim and feel systems;
flight control lock systems;
collective pitch system;
cyclic pitch system;
yaw system;
associated operating mechanisms and/or control systems,
including servo systems; and
ballonet systems in airships.
36 37
8/12/2019 Engineer Maint Guide
20/89
Log book requirements
The first inspection will be performed and certified by the
holder of a:
valid appropriate AME licence; or
valid appropriate maintenance authority.
The second inspection will be performed and certified by
a person, other than the person who performed the first
inspection, who is the holder of :
a valid appropriate AME licence;
a valid appropriate maintenance authority; or
a current pilot licence, other than a student pilot licence, or
a current flight engineer licence, rated for the aircraft t ype
concerned.
Where adjustments of a control system are required
following either the first or second inspection, the appropriate
inspections should be repeated and certified.
The independent inspection and certification requirements
are not required for the connection and disconnection of
optional dual controls which are normally converted from one
configuration to another without the use of tools.
Unless using an approved alternative recording system
under regulation 50B, the instructions issued by CASA for the
compilation of the aircrafts log book are to be complied with.
Regulation 50A requires the Certificate of Registration holder
to keep a log book for the aircraft. Reference to the aircrafts
maintenance schedule will be specified in t he aircrafts Log
Book Statement Part 1. Approved variations to this schedule
will be in the aircrafts Log Book Statement Part 2, and any
exemptions granted will be contained in the aircrafts Log Book
Statement Part 3. If using an approved alternative to the log
book, the alternative records must contain reference to t he
aircrafts system of maintenance.
The Certificate of Registration holder will complete 2 copies of
a Log Book Statement Part 1 (available from any CASA District
Office) nominating the maintenance schedules, inspection
schedules, maintenance release period, maintenance release
inspection and ownership details. When completed, the
Certificate of Registration holder will attach one copy of the
Log Book Statement Part 1 to the front of the aircrafts log book
and submit the second copy to the airworthiness office having
administrative control of the aircrafts records within 7 days of
commencing operations. These schedules must be updated to
38
Civil AviationAdvisoryPublication
March 1992
Contents...
1 Daily Inspection
Schedule
2 Periodic Inspection
Schedule
Systems of
maintenance
c i v i l a v i a t i o n s a f e t y a u t h o r i t y 39
reflect the latest information available from t he manufacturer
and CASA.
Serial numbered items contained, or referred to, in the
schedule for time-lifed components may also have a Lifed
Component Control Record card contained in the body of
the aircrafts log book. This record card is t o be used as a
maintenance planning document and does not replace the
Component History Card also contained in the aircrafts log
book.
The Recurring Airworthiness Directive Control Record and
the Recurring Maintenance Control Record are maintenance
planning documents and do not replace the requirement for
compliance and certification to be made in the Aircraft or
Engine Maintenance Certification Log sections of the log book.
s y s t e m s o f m a i n t e n a n c e38 39
8/12/2019 Engineer Maint Guide
21/89
CAAP No: 42B-1 (0)
CAA Maintenance Schedule
IMPORTANTWhen the Certificate of Registration holder elects to use the
CAA Maintenance Schedule the election includes both the Daily
and the Periodic Inspection Schedules.
The time-in-service between Periodic Inspections is to be 100
hours aeroplane time-in-service or 12 months, whichever
is the earlier, and for aeroplanes below 5700 kg engaged in
private operations this inspection may be performed annually
irrespective of hours flown. The completion of this inspection,
along with any defect rectifications performed as a result of
this inspection, is to be certified for in the aeroplanes log book.
PURPOSERegulation 42B of the CARs provides that the Certificate of
Registration holder of class B aeroplanes may use the CAA
Maintenance Schedule. This publication contains that schedule
as a reprint of the original schedule contained in the CARs,
modified to include provision for the certification of each task
and a final category and co-ordination certification. This will
allow this schedule to be copied and utilised as work sheets.
These schedules have been designed as an option to the
manufacturers maintenance schedules. Before the Certificate
of Registration holder elects t o use this schedule, however, it
is recommended that a study be made of the manufacturers
schedules as it is considered that these are generally more
appropriate for the maintenance of the aeroplane.
STATUSThis is the first issue of CAAP 42B-1, and will remain current
until withdrawn or superseded.
REFERENCESThis publication should be read in conjunction with Civil
Aviation Regulation 42B, and CAAP 41-2.
c i v i l a v i a t i o n s a f e t y a u t h o r i t y
HOW TO OBTAIN COPIES OF THIS PUBLICATIONCopies of this publication may be obtained from:
Civil Aviation Authority Publication Centre
P.O. Box 1986
Carlton South
Victoria 3053
1: DAILY INSPECTION SCHEDULE1.1 The daily inspection is to be carried out, and certified,
before the first flight on each day the aircraft is operated.
1.2 The Daily Inspection Schedule has been prepared tocover various types of aeroplanes and refers to a number
of different design features and types of construction.
Only those items applicable to the aeroplane type being
inspected are to be observed. It is not necessary to open
inspection panels, other than those associated wit h engine
oil or dipsticks for this inspection, but where the powerplant
has quick access cowlings, it is recommended that use
should be made of the increased accessibility to the engine
in completing this inspection.
1.3 The person performing the daily inspection must be an
appropriate person authorised to do so and must certify, in
accordance with the approved system of certification, on
the aircrafts maintenance release for the completion of this
inspection. Appropriate persons for daily inspections are:
(a) the pilot-in-command;
(b) a person holding a valid pilot licence endorsed for the
aircraft type;
(c) the holder of a valid appropriate aircraft maintenanceengineer licence;
(d) the holder of a valid appropriate maintenance authority
covering the aircraft being inspected; or
(e) provided that person has sufficient knowledge and
experience to carry out the inspection, the holder of an
AME licence in either the airframe or engine category but
not necessarily rated for the aircraft or engine type or
group, in respect to all AME licence categories.
s y s t e m s o f m a i n t e n a n c e40 41
Telephone (008) 331676
(008) 334191
(03) 342 2000
Fax (03) 347 4407
8/12/2019 Engineer Maint Guide
22/89
ITEM SCHEDULE1. Check that ignition switches are OFF.
2. Check propeller blades are free from cracks, bends and
detrimental nicks, that the propeller spinner is secure and
free from cracks, there is no evidence of oil or grease
leakage from the propeller hub or actuating cylinder and
that the propeller hub, where visible, has no evidence of any
defect which would prevent safe operation.
3. Check that induction system and all cooling air inlets are free
from obstruction.
4. Check the engine, where visible, for fuel and oil leaks and
that the exhaust system is secure and free from cracks.
5. Check that oil quantity is within the limits specified by
the manufacturer for safe operation and that oil filler cap,
dipstick and inspection panels are secure.
6. Check that engine cowlings and cowl flaps are secure.
7. Check that landing gear tyres are free from cuts or other
damage, have no plies exposed and by visual inspection are
adequately inflated.
8. Check that landing gear oleo extensions are within normal
static limits and that landing gear doors are secure.
9. Check wing, fuselage, empennage and, if applicable, canard
surfaces are free from damage, ensure inspection panels,
flight control surfaces and devices are secure.
10. Check interplane and centre section struts are free from
damage and that bracing wires are of correct tension.
11. Check pitot heads and static ports are free from obstruction
and that pitot cover is removed or is free to operate.
12. Check fuel tank filler caps, chains, vents and associated
access panels for security and condition.
13. Check that all flight controls, trim systems and high lift
devices have full and free movement in the correct sense.
14. Check that all radios and antennae are secure and that wherevisible, radio units and interwiring are secure.
15. Check that all drain holes are free from obstruction.
16. Remove any deposits of frost, snow or ice from wings, tail
surfaces, canards, propeller and windscreen.
17. Check that each tank sump and fuel filter is free from water
or foreign matter by draining a suitable quantity of fuel into
a clean transparent container.
18. Check windscreen for cleanliness and condition.
19. Check instruments are free from damage, for legibility and
security.
c i v i l a v i a t i o n s a f e t y a u t h o r i t y
20. Check that seat belts, buckles and inertia reels are free from
damage, secure and function correctly.
ADDITIONAL ITEMS FOR AGRICULTURALAEROPLANES21. Check that agricultural equipment (e.g. hopper, hopper lid
and fasteners, spray tanks, spray pump and lines, booms
and boom supports, dump doors, fan and fan brake) are
secure.
22. Check that dump and f an brake mechanisms are free from
obstructions and operate correctly.
ADDITIONAL ITEMS FOR SEAPLANES23. Check hull and floats are free from damage, corrosion and
water accumulation.
24. Check float attachment struts, bracing wires and
Recommended