Air Legs Book

8/4/2019 Air Legs Book

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ETU - MHS Aviation Bhd 1

CONTENTS

Chapter Subject Pg.

1. The Chicago convention 51.1 Introduction1.2 The Agreement . 6

2. The I.C.A.O.2.1 Introduction 82.1 Implementation of the convention .9

3. The Malaysian Civil Aviation Legislation3.1 The M.C.A.R 113.2 Arrangement of the M.C.A.R. 123.3 Compliance of the M.C.A.R .. 15

4. Department of Civil Aviation Malaysia4.1 Introduction ................................. 184.2 The Airworthiness Division . . 194.3 DCA Publication . 20

5. Other Airworthiness Authoritiesand its Publication5.1 The Air Navigation Order and

the Civil Aviation Authorities 255.2 CAA Publications 26

PART 1 - LEGISLATION AND ADMINISTRATION

Chapter Subject Pg.

6. The Federal Aviation Regulation andthe Federal Aviation Authorities. . 31

7. Aircraft Registration 32

8. Nationality and Registration Mark.. 33

9. Air Operator Certificate 34

10. Approved Organization . 36

11. Airworthiness Legislation

11.1 Essential Features . 38

11.2 General Certification Requirement 39

12. Certification of Aircraft

12.1 Type Certificate.... 4012.2 Certificate of approval of Radio

License 41

12.3 Certificate of Airworthiness 42


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CONTENTS

Chapter Subject Page13. Flight Manual .. 44

14. Categories of Aircraft .. 45

15. Aircraft without a valid C of A

15.1 General . 4815.2ACondition . 4915.3BCondition .. 51

16. Aircraft Constructed outside Malaysia

16.1 Certification and Maintenance.. 52

17. Maintenance Schedule

17.1 General 5317.2 Approval . 54

18. Certificate of Maintenance Review

18.1 General .. 5718.2 Condition of Issue .... 58

19. Inspection, Overhaul, Repair,

Replacement, Modification,

Scheduled Maintenance Inspection .. 62

16.1 Certificate of Release

to Service 6316.2 C.R.S for S.M.I 65

Chapter Subject Page20. Duplicate Inspection

. 20.1 Definition. 68

20.2 Requirements . 6920.3 Certification . 71

21. Modification

21.1 Introduction 7221..2 Minor and Major Modification .. 73

21.3 Fees 7321.4 Approval of Modification .. 74

22. Mandatory Modification and

Inspection

22.1 General 7722.2 Compliance .............. 7823.3 Modification Documents 7924.4 Recording and Certification . 79

PART 2- DOCUMENTS AND RECORDS23. Log Book

23.1 General 8123.2 Log book Entries 82


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Chapter Subject Page

24. Technical Log

24.1 General .. 83

24.2 Technical Log Book Entries 84

25. Operation Manual

25.1 General . 85

26. Master and Minimum Equipment Lists

26.1 General . 86

27. Documents to be Carried on

Aircraft 87

28. Maintenance, Overhaul and

Repair Manuals

28.1 General . 8828.2 Specification .. 9028.3 ATA Specification 9128.4 Layout 93

Chapter Subject PageOTHER AIRWORTHINESS REQUIREMENTS29. Mandatory Reporting

29.1 General 100

30. Weight and Balance

30.1 General. 10230.2 Definition.. 10330.3 Aircraft Weight Schedule 104

31. Approved Release Certificate . 105

32. Approved Store Procedures

32.1 Introduction .. 11432.2 Storage Conditions 116

END


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LEGISLATION AND ADMINISTRATION


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1.1 Introduction

In the early months of 1944 the government of the United States invited 55 Alliedand neutral States to attend a conference in Chicago to review the problems and issuesassociated with future international civil aviation. Fifty two (52) States accepted theinvitation and their delegates held discussions in November 1944.

The outcome was the Convention on International Civil Aviation signed at Chicagoon 7 December 1944 usually known as the CHICAGO CONVENTION 1944.

Those States participating at the convention were identified as Contracting States.Malaysia is a Contracting State.

One of the primary objectives of the Chicago Convention was to promote and develop the

principles and techniques of international air navigation and air transport technical standardsand recommended practices.

1. CHICAGO CONVENTION 1944


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It was not found possible to reach an agreement satisfactory to all, but at theconference two agreements was established and signed as follow:

International Air Service Transit Agreement -made provision for aircraft of any signatory power to fly over or to

land for technical reasons in the territory of any other signatory

and

International Air Transport Agreement -made provision, amongst other thing, for the carriage of traffic between

the State of registration of the aircraft and any other signatory State.

One of the issues to which the conference delegates attached great importance

was the question of the exchange of commercial rights in International aviation.

To administer these agreement a permanent body was established and known as TheInternational Civil Aviation Organization-I.C.A.O

1.2 THE AGREEMENTS


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States participatingat the convention were

identified as ContractingStates

two agreements was

established and signed

Int. Air Transit Agreement&

Int Air Svs Transit Agreement

Fifty two (52)States accepted

the invitation

signed at

Chicagoon 7

December 1944

CHICAGO

CONVENTION


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2.1 Introduction

ICAO was also set up as a means to secure international co-operation on highest possibledegree ofuniformity in regulations and standards, procedures and organization regarding civil aviationmatters. INTERNATIONAL CIVIL AVIATION ORGANIZATION (I.C.A.O) wasestablished on 4 April 1947. At the invitation of the Government of Canada, Montreal waschosen as the Headquarters of the organization.

The text of the Convention is in the English, French, Spanish and Russian languages (In due courseChinese will be added) and are deposited in Washington in the archives of the government of theUnited States and remain open for additional signatories i.e. for countries wishing to becomeContracting States.

Presently there were 190 such States.

2. International Civil Aviation OrganizationI.C.A.O


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Article 37 of the Convention requires contracting states to collaborate in securing thehighest practicable degree of uniformity in Standard, Regulations, ProceduresandOrganizationsto facilitate and improve air navigation. To this end, ICAO is required toadopt international standards and recommended practices and procedures.

In Malaysia, provision for giving effect to the Article 37 of the Chicago Convention andgenerally regulating air navigation was made in the Malaysian Civil Aviation Act 1969which requires contracting states to collaborate in securing the highest practicabledegree of uniformity in regulations, standards and procedures and organizations tofacilitate and improve air navigation.

This is the authority for the Malaysian Civil Aviation Regulation, a statutory instrumentwhich set out in detail the law of the land concerning civil aviation, inconformity with thestandards and recommended practices of the International Civil Aviation Navigation.

2.2 Implementation of the convention


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MALAYSIA and the INTERNATIONAL LEGISLATION

Chicago Convention

1944

International Civil Aviation

Organization 1947

Malaysian Legislation Similar Legislation by other Contracting State

Malaysian Civil Aviation Act (MCAA) 1969

Malaysian Civil Aviation Regulation (MCAR)

1996

Enforcement By Ministry of Transport


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The Malaysian Civil Aviation Regulations (MCAR) details the provisions concerning Civil Aviation.These regulations came into effect on 01 April 1996 and it is applicable to ALL CIVIL

AIRCRAFT REGISTERED IN MALAYSIA. Enforcement of the MCAR is the responsibility of theDepartment of Civil Aviation Malaysia of the Ministry of Transport.

3. THE MALAYSIAN CIVIL AVIATION LEGISLATION

The MCAR 1996* is promulgated under Section 3 of the Malaysian Civil Aviation Act 1969 whichstipulates that the Minister is empowered to give effect to article 37 of the Chicago Convention andregulate civil aviation. The provisions contained in the regulations are in accordance with the Chicago

Convention procedures 1944 and the annexes related to the standard, practices and proceduresadopted or recommended for adoption by the International Civil Aviation Organization.

The MCAR replaces the British Air Navigation Order 1953 which Malaysiahas been complying through the years until the MCAR came into effect.

The MCAR prescribes for : Airworthiness Requirements Personnel Licensing

Regulations Governing Aircraft Operation

3.1 The MCAR

* Latest amendment was incorporated the 20th Sept 2004


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I. Preliminary

II. Registration and marking of Aircraft .

III. Licensing of Air Services

IV. Air Operators Certificate

V. Airworthiness and Equipment of Aircraft

VI. Aircraft Crew Licensing

VII. Operation of Aircraft

VIII. Fatigue of Crew

IX. Documents and Records

X. Control of Air TrafficXI. Aerodromes, Aeronautical Lights and radio

Stations

XII. Investigation of Accidents

XIII. Detention and Sale of Aircraft

XIV. Aircraft Mortgages

XV. Landing, Parking and Housing, Passenger Serviceand Air Navigation Facility charges

XVI. Generals

3.2 Arrangement of the MCAR -

3.2.1 The Regulations

The 204 REGULATIONS of the MCAR are divided into 16 PARTS followed by 16 SCHEDULES.

26. Certificate to be in force

27. Issue and renewal of Certificate of

Airworthiness


29. Technical Log

30. Inspection, Overhaul, Replacement and

Modification

31. Licensing of Maintenance Engineers

32. Aircraft to be equipped33. Radio equipment of aircraft

34. Minimum equipment regulations

35. Aircraft, Engine and Propeller Log Books

36. Aircraft weight schedule

37. Access and Inspection for airworthiness

purpose

Regulations contained in Part V-Airworthiness and Equipment of aircraft covers regulation 26 to 37

which are of particular importance to LAE.

Parts Parts

In these Parts are contained several regulations for example:


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The purpose of the schedule is to give specific information on subject matter contained in the

regulations of the MCAR

3.2.2 The Schedules

26. Certificate to be in force

27. Issue and renewal of Certificate of

Airworthiness


29. Technical Log30. Inspection, Overhaul, Replacement

and Modification

31. Licensing of Maintenance Engineers

32. Aircraft to be equipped

33. Radio equipment of aircraft

34. Minimum equipment

regulations

35. Aircraft, Engine and PropellerLog Books

36. Aircraft weight schedule

37. Access and Inspection for

airworthiness purpose

Example: PART 5 Regulation 33 (2) states, the aircraft shall be equipped with radio and

navigation equipment in accordance with the

Sixth Schedule-

which itemizes the radio navigation equipment to

be carried in aircraft.

Example:Part V-Airworthiness and Equipment of aircraft - regulation 26 to 37 (are of particular importance to LAE)Example:Part V-Airworthiness and Equipment of aircraft - regulation 26 to 37 (are of particular importance to LAE)


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3.2.3 Arrangement of the Schedules

1st Schedule

Part A - Table of General Classification of AircraftPart B - Nationality and Registration Marks of a Malaysian Aircraft

2nd Schedule - A, B and C Conditions

3rd Schedule - Categories of Aircraft and Purpose of Flight

4th Schedule - Maintenance Engineers : Privileges of Licenses

5th Schedule - Aircraft Equipment

6th Schedule - Radio and Radio Navigation Equipment to be Carried in Aircraft7th Schedule - Aircraft, Engine and Propeller Log Books

8th Schedule - Flight Crew of Aircraft : Licenses and Ratings

9th Schedule - Public Transport - Operational Requirements

10th Schedule - Documents to be Carried by Malaysian Aircraft

11th Schedule - Rules of the Air and Air Traffic Control

12th Schedule - Fees and Charges

13th Schedule - Operator's Responsibilities and Aircraft Operating Conditions14th Schedule - Medical Requirements

15th Schedule - Vehicle in Movement Area

16th Schedule - Penalties

Part A- Provisions referred to in sub-regulation 188(6)

Part B- Provisions referred to in sub-regulation 188(7)


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3.3 COMPLIANCE OF THE MCAR

The Department of Civil Aviation ensures that Malaysian operators are complying with the Malaysian CivilAviation Regulations (MCAR).

Then Malaysian Civil Aviation Regulations states, among others, that an aircraft would qualify for aCertificate of Airworthiness if the aircraft is fit to fly having regard to the Airworthiness Notices issued bythe Department of Civil Aviation and also to the code of airworthiness certification and proceduralrequirements from time to time in force under :

a) the Federal Aviation Regulations (FAR) of the United States of America.

b) the British Civil Airworthiness Requirements (BCAR) issued by the CivilAviation Authority of the United Kingdom.

c) the Joint Airworthiness Requirements (JAR) issued by the Joint AviationAuthorities of the European States.

In addition, the Maintenance Schedule Approval Document issued by the Department of Civil

Aviation states that it is the responsibility of the Operator to observe compliance to therecommendations issued by the Aircraft or Equipment manufacturers in Maintenance Manuals,Recommended Maintenance Schedules, Service Bulletins, CAAIPs, Mandatory Aircraft Modificationsand Inspection Summary, Airworthiness Directives, CAA Additional Directives and Instructions issued bythe recognized Airworthiness Authority of the country of origin of the Aircraft.


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DEPARTMENT OF CIVIL AVIATION

AND

PUBLICATIONS


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MINISTRY OF TRANSPORT

DEPARTMENT OF CIVIL AVIATIONMALAYSIA

AIRWORTHINESS DIVISION OTHER DIVISION

AIRWORTHINESS NOTICES

DEPARTMENT OF CIVIL AVIATION MALAYSIA


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4. DEPARTMENT OF CIVIL AVIATION MALAYSIA

4.1 Introduction

Department of Civil Aviation (DCA) Malaysia is established as an organization under the Ministry of Transport

Malaysia. The DCA was formed to provide enforcement service to ensure all aviation activities are regulated

and conducted in accordance to the law of Malaysia. One of its functions is that of certifying the airworthiness of

aircraft and this is performed by the airworthiness division of the DCA in accordance with the provision of Part V

of the MCAR. The administrative procedure and technical requirements for obtaining and maintaining a Certificate

of Airworthiness are prescribed in DCA Airworthiness Notices No.1 and 2.. Technical staff of the airworthiness

division who are responsible for ensuring adherence to DCAs AN are known as surveyors.

Divisions in the DCA:

FLIGHT OPERATIONS

AIRWORTHINESS

AIR TRAFFIC SERVICES (ATS)

AIRPORT STANDARDS

AIR TRANSPORT

MANAGEMENT & FINANCE

AVIATION SECURITY

FLIGHT CALIBRATION

CIVIL AVIATION COLLEGE

ATS INSPECTORATE


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FUNCTION

Registration of all civil aircraft

Certification of aircraft standards

Licensing of aircraft maintenance engineers

Approval of organizations for maintenance aircraft and equipment

Certification of aircraft manufacture

Aircraft accident investigations

4.2 THE AIRWORTHINESS DIVISION


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Airworthiness Notices

To circulate information to all concerned with airworthiness of civil aircraft

Pink Papers

Mandatory Compliance

Requirement

White Papers

General Information

Administrative andTechnical Procedures

Copies for sale

to

Holders of Malaysian

Aircraft Maintenance

Engineers Licenses

Operators/ owners of

Aircraft on Malaysian

Register

Organizations approved

By the DCA under

BCAR section A8

4.3 DCA Publication


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No 3,10, 12 and 51 are significant to all Licensed Aircraft Maintenance Engineers in relation to Regulation 28

and 30 of the MCAR.

AN No 3 Licensed Aircraft Maintenance Engineers- Responsibilities in relation to the issue ofCertificate of Maintenance Review and Certificate of Release to Service.

AN No 10 - Aircraft Maintenance EngineersType Rating

AN No 12 - Requirement for Malaysian registered aircraft in respect of the certification of

Overhaul, replacement, Repair, Modification, Mandatory Inspection and SMI

AN No 51 - Duplicate Inspection of a Control System

Airworthiness Notices significant to Licensed Aircraft Maintenance Engineer


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LATEST ISSUE 9 15 May 2005. Effective Notices..

Forward - Issue 7

05Issue 6 Application for Malaysian AME Licenses.

Issue 1 Appendix 1 45Issue 4 Airworthiness flight tests

76Issue 2 Approval of Equipment

Issue 1 Appendix 1

77Issue 3 Requirement and procedures for grant of airworthiness

approvals for RVSM, RNP and BRNAV.

Issue 1 Appendix 1

78Issue 2 Approval of modificationIssue 1 - Appendix 1 to 7

83Issue 2 Flight RecordersAeroplane

Issue 1 Appendix 1

83AIssue 1 Flight RecordersHelicopters. Appendix 1

85Issue 1 Approval of Training Organization

86Issue 1 Airborne Collision Avoidance System (ACAS II)

87Issue 1 Minimum Equipment Lists (MEL)

88Issue 1 Airplane Flight Manual (AFM) 89Issue 1 Maintenance Schedule/ Program

90Issue 1 dangerous loss of pressurization in Pressurized aeroplane

91Issue 1 Multiple scribe mark scratches

92Issue 1 Aircraft Autoland operations. Appendix 1

93Issue 1 Statement attesting noise certification


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5 OTHER AIRWORTHINESS AUTHORITIES AND

ITS PUBLICATIONS


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The Air Navigation OrderA.N.O (U.K).

.In Britain, the A.N.O is a statutory Instrumentand is the Legislation (law) laid

before parliament and approved by The British Queen, and when promulgated

constitute the law of the land related to civil aircraft, as provided by the Civil

Aviation Act 1949. The CAA meet these responsibilities largely by the preparation

and publishing of British Civil Airworthiness Requirements - BCAR (and other

publications).

5.1 The Air Navigation Order (A.N.O)

and The Civil Aviation Authorities (C.A.A)

The requirement interpret the Legislation in Part III of the ANO but comprise only the minimum requirement.

Civil Aviation AuthoritiesC.A.A (U.K)

The CAA was set up in 1972 to bring together the regulation of civil aviation within one body.

One of the primary responsibility of the CAA is the certification and approval of aircraft andtheir constituent part. This function is carried out by the Safety Regulation group (SRG)

SRG also prescribe airworthiness procedures based on current legislation, carry out approvalof organization, issues licenses to Aircraft Maintenance Engineers and maintenance certificateson specific aircraft types, engines and systems.


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British Civil Airworthiness Requirements ( BCAR)

*Civil Aircraft Airworthiness, Information and Procedures

*Airworthiness Notices

C.A.A Additional Directives

Part I, II and III of Foreign Airworthiness Directives

Mandatory Aircraft Modifications and Inspections Summary

5.2 C.A.A Publications

British Civil Airworthiness Requirement (BCAR)

Published by the CAA of UK. State the minimum technical requirements and

Administrative procedures for the :

a. Issue and renewal of Certificates and Licenses,

b. Maintenance and construction of aircraft .

c. Approvals of Personnel and Equipments,d. Approvals of Design, Manufacturing and Maintenance Organization

e. Certification and continued airworthiness procedures.

It is necessary to distinguish between Legislation and Requirement.


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BCAR - Content

Currently consists of these section:

*SECTION AAIRWORTHINESS PROCEDURES

WHERE THE CAA HAS PRIMARY

RESPONSIBILITY FOR TYPE

APPROVAL OF THE PRODUCT

SECTION BAIRWORTHINESS PROCEDURES

WHERE THE CAA DOES NOT

HAVE PRIMARY RESPONSIBILIY FOR

TYPE APPROVAL OF PRODUCT

*SECTION L

LICENSING

SECTION M

EMISION CERTIFICATION

SECTION N

NOISE

SECTION Q

NON-RIGID AIRSHIP

SECTION S

SMALL LIGHT AEROPLANE

BCAR 23

LIGHT AEROPLANES

BCAR 29

ROTORCRAFT

SECTION R

RADIO

BCAR 31

MANNED FREE BALOON* Most significant to Aircraft

Maintenance Engineer


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JOINT AIRWORTHINESS REQUIREMENTS (JAR)

The Joint Airworthiness Requirements ( JAR) are made under the co-operation of theAirworthiness Authorities of certain European countries to agree on a common comprehensiveairworthiness requirements. The UK C.A.A has adopted requirements for the relevant

product.

JAR -1 - Definitions and Abbreviations

JARAPU - Auxiliary Power Units

JAR22 - Sailplanes and Powered Sailplane

JAR25 - Large Aeroplane

JARAWO - All Weather OperationsJAR66 - Certifying Staff

JAR - 145 - Approved Maintenance Organizations

JAR - 147 - Approved Training Organization


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Civil Aircraft Airworthiness Information and Procedures (CAAIP)

All person concern with the maintenance of civil aircraft and Aircraft equipment should be

aware of CAAIP, a collation of technical leaflets dealing with aircraft engineering practices

and processes and information on variety concerned with the inspection of civil aircraft during

, overhaul, repair and maintenance. The leaflet are written as recommendation and acceptable

practices, the information being essentially of a general nature with to deal with specific types

of aircraft, engine or specific equipment.

The information is essentially of a general nature. Contain information during manufacture,

overhaul, repair, maintenance operation and procedures.


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Airworthiness NoticesU.K

Provides a means of publishing Airworthiness Information at short notices

Technical

(Blue copies)

Mandatory

(Pink copies)

Administrative

(White copies)

Airworthiness Notices No. 6 and No.7 gives general information

publication dates and latest issue number of all CAA publication

Copies are issued to

Each organization

Approved under the ANO

By the British C.A.A

Owners of an aircraft

On the U.K register

All Licensed Aircraft

Maintenance Engineers

Having current British

licenses


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6. FEDERAL AVIATION ADMINISTRATION (U.S.A)-F.A.A

and the FEDERAL AVIATION REGULATIONF.A.R

Introduction

The Federal Aviation Administration

The Federal Aviation Administration ( F.A.A.) was incorporated in 1967 under the Dept of

Transport. Its basic responsibility is to provide safety in flight is maintained and the

promotion and regulation of civil aviation to ensure its safe and orderly growth.

All civil aircraft certified for operation by the F.A.A. must be maintained in accordance to

the Federal Aviation Regulation (F.A.R.) issued by F.A.A.

The Federal Aviation Regulation (F.A.R.)

The Federal Aviation Regulation are published as Chapter 14 of the United States Code of Federal

Regulations. The regulations are the minimum standards which have been set to ensure, as much as

possible, aviation safety. The regulations are divided into parts such as FAR Part 25, AirworthinessStandards: Transport Category Aircraft; or FAR part 147, Aviation Maintenance School


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Introduction.

A civil aircraft must be registered in some country, normally that of the owners country. The

aircraft must comply with the law of the country. Normally an aircraft is registered in the

Owners country and must comply with the law of the country. In Malaysia, a Certificate of

Registration is issued by DCA. It must be carried on the aircraft during any flight outside

Malaysia.

The Certificate of Registration is limited to one issue

NOTE: No aircraft shall fly in or over Malaysia unless it is registered in Malaysiaor a Contracting State, EXCEPT the following aircraft which may fly unregistered

within Malaysian airspace only:

a) A glider flying not for the purpose of public transport or aerial work.b) Any aircraft flying in accordance with the B Conditions set out

in the Second Schedule of MCAR.c) Kites and captive balloons.

7. AIRCRAFT REGISTRATION

(Ref: AN No.66, Regulation 3 of the MCAR)

The certificate will remain valid until:

a) Change of ownership

b) Aircraft Destroyed or permanently withdrawn

from use.


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.

Fig. 1 Certificate of Registration

8 Nationality and Registration Mark(Ref: Regulation 6, MCAR)

Registration Marks.

(1) An aircraft is identified by its nationality

and Registration marks (e.g. 9M-ABC)

which must be displayed.

(2) The marks to be borne by a Malaysian

aircraft shall comply with Part B of the First

Schedule.

(2) The Nationality and Registration marks,

together with the name and address of the

registered owner, must also be inscribed on

a fireproof metal plate fixed near to the

entrance to the aircraft.


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9. AIR OPERATORS CERTIFICATE.

(Ref: AN No.68, Regulation 24, MCAR)

(1) A Malaysian registered aircraft shall not fly on any flight for the purpose of public transport

otherwise than under and in accordance with the terms of an Air Operator's Certificate

granted to the operator of the aircraft under Regulation 24 of the MCAR.

(2) The DCA shall grant an air operator's certificate to any person applying

for it if he is satisfied that that person is competent, having regard in particular to his

previous conduct and experience, his equipment, organization, staffing, maintenance

and other arrangements, to secure the safe operation of an aircraft of the type specified

in the certificate on flights of the description and for the purposes so specified.

(3) It is the operators responsibility to satisfy the DCA that his maintenance support

arrangements are to a satisfactory standard. The operator may have his own maintenance

organization or contract to a DCA approved maintenance organization.


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Fig. 2 Air Operator Certificate


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10. APROVED ORGANIZATIONS. Ref: AN No.70, MCAR Pt 5 Reg. 38

An aircraft is not permitted to fly unless ithas been certified that all work on it hasbeen carried out in accordance with D.C.A.Airworthiness Notices. Work on aircraftand aircraft equipment is done by a largenumber of companies. These companiesmust be approved by DCA. Such company

is known as ApprovedOrganization andis given a Certificate of ApprovalReference Number (e.g. AO/02/88) whichis quoted on certificate issued


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The Malaysian Civil Aviation Regulation through the medium of Airworthiness Noticesmakes provision for the adoption of the code of airworthiness certification and proceduralrequirements published as FARs, JARs and BCARs as standards acceptable to the DCA,

the adoption standard for approval of organization and are as follows:

EASA Part 145 for Organization that carry out of aircraft, its engines and components,auxiliary power units and specialized processes.

BCAR A8-5 for B3 process companies.

BCAR A8-6 for B4 test houses.

BCAR A8-10 for approval of welders.


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11.1 Essential Features

The law contained in Part 5 of the MCAR are intended to set and maintain a high standard of

airworthiness by strict control of the design, construction and maintenance of aircraft. The control isachieved by the issue of certain certificates without which the aircraft is not permitted to fly.

Issue of Certificates strictly limited

to only personnel Qualified, Authorized

or Approved by DCA

REGULATIONS

CONTAINED IN

PART V OF THEM.C.A.R. ENSURES:

The Setting and Maintaining

High Standard of

Airworthiness

Making legal flight possible only

by the issue of the following

certificate

Certificate of Airworthiness

Maintenance Schedule

CRS for SMI

CMR

CRS

Type Certificate

11. AIRWORTHINESS LEGISLATION


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A certificate of airworthiness is issued for the prototype and for every other aircraft built to the same design. Thestandard of airworthiness is maintained by periodic renewal of the C of A. in many cases at the interval of 1 year oras stated in the C of A. subject to the satisfactory inspection of the aircraft and scrutiny of its technical record.

Between the time of issue and renewal of the C of A, an aircraft, like any other vehicle need to be serviced andoverhauled with the object of preventing or anticipating fault and deterioration. Such condition which occurs shouldbe located at an early stage by regular inspection. These condition are the basis for the MAINTENANCESCHEDULE, a document which set out a plan for the regular maintenance and inspection for every part of theaircraft. The work is carried out during a series of maintenance checks. Maintenance in accordance to themaintenance schedule is a requirement for a public transport aircraft and certain other aircraft. At the end of thespecified maintenance checks, a certification is issued (i.e. CRS for SMI) to certify that the maintenance schedule

has in fact been completed.

Whether or not an aircraft receive a scheduled maintenance, there will be an unscheduled repairs, replacements,modifications, overhauls and mandatory inspections. All these work must be carried out accordance tospecifications, drawings and maintenance, overhaul and repair manuals which is the basis on which the certificateof airworthiness is issued. A CERTIFICATE OF RELEASE TO SERVICE must be issued to certify the work hasbeen done and in a manner approved by the DCA. This applies to work carried out on and aircraft and equally toequipment and parts removed from the aircraft to a workshop.

The authority for issuing certificates is strictly limited to persons qualified by experience or examination. In anapproved organization, designated staff may be authorized to sign Certificate of Release to Service in respect ofcertain range of work to be carried out by that organization. For work done outside an approved organization,certificate of release to service must be issued by a licensed aircraft engineers provided that the work is within thelimits set by the endorsement on his license and does not include manufacture of parts.

11.2 GeneralCertification Requirements


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12. CERTIFICATION OF AIRCRAFT. Ref. AN No 1

12.1 Type CertificateGeneral

It is required that before an aircraft can be issued a Malaysian Certificate of Airworthiness in theTransport, Aerial Work or Private Category, that the aircraft for which certification is required, must betype approved by DCA or an internationally recognized airworthiness authority.

A Type Certificate constitutes a statement that the design of the type to which the Certificate refers(and variants) has been approved by the Airworthiness Authority of the Country origin of the aircraft.

Applicant for Malaysian certification should be aware that all aircraft, irrespective of their size, willnormally be subject to investigation by DCA.

When DCA is satisfied, all aircraft of similar type would qualify for C of A.

This requirement applies to all categories with the exception of special Categories.

The application for the issue of a C of A will also serve as an application for a type Certificate.

Malaysia does not issue Type Certificates for imported aircraft. Acceptance is based on process of

validation by granting a Malaysian Certificate of Airworthiness.


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12.2 Certificate of Approval of Aircraft Radio Installation.Ref: An 27

Another condition for issue a Certificate of Airworthiness is a requirement for an aircraft radio installation

An aircraft radio installation must comply with:

a. Malaysian Airworthiness Requirement

b. The Malaysian Radiocommunication Regulation 1957

The aircraft Station License is issued by the Telecommunication Department (Jabatan Telekom) subject

to the approval the by DCA. The approval is by the issue of a Certificate of Approval of Aircraft Radio

Installation, DCA Form Number JPA/ AU/ R2.


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12.3 CERTIFICATE OF AIRWORTHINESS. Ref: AN No.1, 2, 27

Introduction

An aircraft is not normally allowed to fly without a certificate of airworthiness which is valid under the law ofthe country in which the aircraft is registered. If the aircraft is registered in Malaysia, the C of A is issued andrenewed by the DCA, who in the case of an aircraft constructed outside Malaysia, may render valid a C of Agranted under the law of another country.

DCA may validate C of A issued to any aircraft under the law of any other country.

a) PROTOTYPE

b) PROTOTYPE (MODIFIED)

c) SERIES

d) AIRCRAFT CONSTRUCTED OUTSIDE MALAYSIA

Aircraft which does not qualify for the C of A, a Permit to Fly may apply.

Department of Civil Aviation can issue a Certificate of Airworthiness for all these Aircraft:


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C of A FORM JPA 22L-REV-/-(DCA) provide these information:

C of A NUMBER

NATIONALITY AND REGISTRATION MARKS CONSTRUCTORS NAME

CONSTRUCTORS DESIGNATION OF AIRCRAFT

AIRCRAFT SERIAL NUMBER

AIRCRAFT CATEGORY

PERIOD OF VALIDITY

Ref: MCAR Reg. 27, AN No. 1 and 2, BCAR Chap. A3-4

C of A Renewal

The C of A must be renewed periodically at the interval of one, two or three years as specified in the

C of A form JPA 22L. It ceases to be in force if the aircraft or its equipment is maintained,

overhauled, repaired or modified other than in a manner and with the material approved by DCA

In most cases the C of A comprises a FORM JPA -22L and a FLIGHT MANUAL.

TheFORM is a SINGLESHEET which may be conveniently displayed on the aircraft.

13 Fli ht M l


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THE FLIGHT MANUALFORMS PART OF

THE C of A

LIMITATIONSPROCEDURES

OTHER INFORMATIONthe observance of whichis essential for the safeoperation of the aircraft

Mandatory placardsAnd instrumentColor coding and

Limitations sectionIndicated byAsterisk(*)

NOTE:The C of A includingthe flight Manualmust be carried on

Aircraft (public-Transport/AerialWork flight) and

ALLINTERNATIONALFLIGHTS

13. Flight Manual.

THE FLIGHT MANUAL ISACCEPTED AND APPROVEDBT THE D.C.A. FOR USE BY

THE FLIGHT CREW.The Manual contains:

The Flight Manual is issued by the DCA as part of the Certificate of Airworthiness and is intendedprimarily for use by the flight crew. It gives the limitations, procedures and other information theobservance of which is essential for the safe operation of the aircraft.


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14. Categories of Aircraft for the purpose of Certificate ofAirworthiness Certification. (Ref: AN No 81, MCAR Reg.26)

An aircraft may be flown only for the purposes corresponding to the category or categories specifiedon its Certificate of Airworthiness.

The Category and Purpose for which aircraft may fly are as follows :

TRANSPORT CATEGORY ( PASSENGER ) :Any purpose.TRANSPORT CATEGORY (CARGO ) :

Any purpose other than the public transport of passengers.AERIAL WORK CATEGORY :Any purpose other than public transport.PRIVATE CATEGORY :

Any purpose other than public transport or aerial workSPECIAL CATEGORY :

Any purpose, other than public transport specified in the Certificate of Airworthiness but not includingthe carriage of passengers unless expressly permitted.

The C of A, including the flight manual, must be carried on the aircraft for the purpose of publictransport or aerial work and all international flights.


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Fig.8 Certificate of AirworthinessFig.9 Flight Manual Approval


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Fig.7 Form JPA-AP2

15 AIRCRAFT WITHOUT A VALID CERTIFICATE OF AIRWORTHINESS


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15. AIRCRAFT WITHOUT A VALID CERTIFICATE OF AIRWORTHINESS

CONDITIONS UNDER WHICH FLIGHT IS PERMITTED.

A & B CONDITION.(Ref: Sub regulations 3(1), 5(5), 6(3), 26(1) AND 62(7) and 2ndSchedule of MCAR)

15.1 General

There are certain circumstances in which an aircraft is required to fly without there being in

force a valid certificate of airworthiness. The condition under which such flight are permitted

are detailed in the 2nd Schedule of the MCAR.

The A Conditions apply to established type of aircraft, where the B Conditions apply toprototype aircraft, experimental aircraft and flying test-beds (of engine in particular).


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15.2 A Condition.

The principle circumstances I which flight are made under the A Conditions are flight tests associated

with:

The renewal of C of A.

The approval of modification

The issue of a C of A for a series aircraft.

Under the A Conditions, It is also required prior to flight, that the aircraft and its engines be declared fit for flight

either by an appropriately licensed engineer authorized to issue a Certificate of Fitness for Flight(Fig.6) under A

Conditions, or a person approved by DCA to issue such a certificate.

Flight shall take place with minimum flight crew and only carry those persons performing duties relative to thepurpose of the flight and ensure the safety of the aircraft.

The carriage of cargo is not allowed and the aircraft shall not be flown over any congested area of the city except for

that which is necessary for the aircraft to take off from or land in accordance with approved DCA procedures.

Can be used for more than one flight provided the original airworthiness condition is not

affected during the period of Validity.

The certificates shall be issued in DUPLICATE. One copy on aircraft and one copy elsewhere.

The period of validity shall be stated but shall but shall not exceed 7 days


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Fig 6. Certificate of Fitness For Flight


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The ground and airborne facilities required to satisfy the B condition are very comprehensive

and only organizations specifically approved for the purpose are permitted to conduct flight

trials under B conditions.

The flight shall be made under supervision approved by DCA and subject to any additional

conditions which may be specified in such approval.( refer to BCAR Chap. A8-9 ).

All flight Under B shall be covered by a Certificate of Clearance.

Signatories for the C of C is as per BCAR Chap. A8-9.

15.3 B Condition

The principle circumstances I which flight are made under the B Conditions are flight tests

associated with:

Experimenting with, or testing he aircraft. Prototype aircraft qualifying for the issue of the a C of A.

The approval of a modification

Demonstrations for sales purpose


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16. AIRCRAFT CONSTRUCTED OUTSIDE MALAYSIA

An aircraft which has been constructed in a foreign country may be registered in Malaysia, providing its owner is a

Malaysian subject otherwise qualified in accordance with the MCAR. After registration, the owner must apply to the

DCA for a Certificate of Airworthiness, enclosing the Certificate of Airworthiness issued by the authority of the

country of origin. I most cases the aircraft will be a series aircraft of a type with a well documented record.

The DCA investigation will take into account the airworthiness standard of the foreign country and any reciprocal

agreements in force. The DCA will seek to provide a level of safety equivalent to that required as provided for inAirworthiness Notice No.1 and its appendices. And for this purpose may impose special conditions prior to the issue

of the C of A.

On completion of all the requirements, the DCA issue a Malaysian Certificate of Airworthiness, including the

Flight Manual where applicable.

Considering the subsequent maintenance of the aircraft it must comply with the modifications and inspections which

have been classified as mandatory by the airworthiness authority of its country of origin. Details of suchmodifications and inspection are laid down in Airworthiness Notices No.4.

16.1 CERTIFICATION AND MAINTENANCE - General


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17. MAINTENANCE SCHEDULE

(Ref; MCAR Regulation 28, AN No.89)

17.1 General

The continued airworthiness of an aircraft is dependent on its maintenance to a carefully planned

programme of checks repeated at regular intervals. These maintenance check is known as Maintenance Schedule

and includes detail of the extent and frequency of routine inspections and maintenance.

Note the difference between a maintenance schedule and a maintenance manual. The schedule

say what Is to be done while the maintenance manual describe how each operation is to be done.

The MCAR states that an aircraft shall not be issued or renewed with a Cof A unless it is

maintained in accordance to an Approved Maintenance Schedule to which it applies.

An aircraft maintained in accordance with an approved Maintenance Schedule must

have that fact certified by the issue of a Certificate of Release to Service

for Scheduled Maintenance Inspection(Fig.10) and a Certificate of MaintenanceReview must be in force before that aircraft is legally permitted to fly for hire or reward.


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17.2 Approval of Maintenance Schedule

Reference Number, Issue Number & Date.

Registered name and address of owner/operator.

Provision for recording Scheduled Amendments. Type of aircraft Engines and Propeller.

Areas of operations, class of work in relation to work area.

WHEN SUBMITTING FOR APPROVAL, THE MAINTENANCE SCHEDULE

MUST CONTAIN THE FOLLOWING BASIC INFORMATION

Approval of a maintenance Schedule shall be signified by the issue of Maintenance Schedule Approval

Document by the Dept. of Civil Aviation which will be located on the 1st page of the Maintenance

Schedule to which it is related.

An operator, Air Operator Certificate holders, or aircraft owner shall submit

to DCA a maintenance schedule or program, for approval before intending

to operate an aircraft.


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18 CERTIFICATE of MAINTENANCE REVIEW CMR


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18. CERTIFICATE of MAINTENANCE REVIEW -CMR

(requirement by Regulation 30, MCAR 1996. Ref: AN No.12)

18.1 General

An aircraft registered in Malaysia in respect of which a Certificate of Airworthiness in the transport category

(passenger, Cargo) or aerial work category is in force shall be subject to a maintenance review at interval

specified in the Maintenance Schedule Approval document. At the completion of the review a Certificate of

Maintenance review is issued.

The issue of a CMR provides evidence that, at the date of issue, the aircraft was is compliance with the

requirement of the Maintenance Schedule approved by DCA and that all modifications and inspectionsclassified as mandatory has been satisfied. A copy of the current CMR must be carried on board the aircraft it

relates.

For aircraft above 2730 MTWA the CMR is required to be issued for a maximum period of four months.

For aircraft below 2730 MTWA the CMR is required to be issued for a maximum period of one year in case

of aircraft in Private Category unless otherwise agreed or directed by DCA, the CMR must be aligned with

the renewal of the C of A.

Conditions and procedures for the issue of a Certificate of Maintenance Review are set out in the AN No. 12

and Chapter A6-2 of the BCAR

18 2 Condition of Issue


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18.2 Condition of Issue

THE ISSUE OF

CERTIFICATE OF

MAINTENANCE REVIEW

CERTIFIES THAT

(Fig. 10)

ALL MAINTENANCE SPECIFIED IN THE

APPROVED MAINTENANCE SCHEDULE

HAS BEEN CARRIED OUT WITHIN THEPRESCRIBE TIME PERIOD AND ANY

EXTENSION TO LIMITING PERIOD IS IN

ACCORDANCE WITH DCA APPROVED

PROCEDURES.

ALL MODIFICATIONS AND INSPECTIONS

DEEMED MANDATORY BY DCA HAVE BEEN

CARRIED OUT WITHIN THE PRESCRIBE TIMEPERIOD AND ANY EXTENSION TO LIMITING

PERIOD IS IN ACCORDANCE WITH DCA

APPROVED PROCEDURES.

ALL CERTIFICATES OF

RELEASE TO SERVICE

REQUIRED HAVE BEEN

ISSUED

ALL DEFECTS ENTERED

IN THE TECHNICAL LOG

HAVE BEEN RECTIFIED

OR DEFERRED


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THE CMR SHALL BE ISSUED AT TIMES STATED IN RELEVANT APPROVAL DOCUMENT OFTHE MAINTENANCE SCHEDULE. PERIOD OF VALIDITY IS AS ON CERTIFICATE.

CATEGORIES OF SIGNATORIES REQUIRED AFTER EACH CHECKS PERIOD ETC. ARE

SPECIFIED IN THE APPROVAL DOCUMENT

A CMR SHALL BE ISSUED ONLY BY:

1) THE HOLDER OF AN AME LICENSE GRANTED OR RENDERED VALID IN MALAYSIA

OR THE HOLDER OF SUCH LICENSE GRANTED UNDER THE LAW OF ANY COUNTRY

PRESCRIBED IN ACCORDANCE WITH THE PRIVILEDGES ENDORSED ON THE

LICENSE AND SUBJECT TO ANY CONDITION WHICH MAY BE PRESCRIBED.

2) A PERSON AUTHORIZED BY THE D.C.A TO ISSUE A CERTIFICATE FOR MHS

AVIATION. NAME OF SIGNATORIES WILL BE FOUND IN THE M.O.E.

A CMR IS ISSUED IN DUPLICATE. ONE CARRIED ON AIRCRAFT AND ANOTHER

ONE ELSEWHERE (TECHNICAL RECORDS).

IT IS KEPT FOR TWO YEARS FROM DATE OF ISSUE.


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CERTIFICATE OF MAINTENANCE REVIEW

AIRCRAFT TYPE ...........................................NATIONALITY &

REGISTRATION MARK

CERTIFIED THAT A MAINTENANCE REVIEW OF THIS AIRCRAFT

AND SUCH OF ITS EQUIPMENT AS IS NECESSARY FOR ITS

AIRWORTHINESS HAS BEEN CARRIED OUT IN ACCORDANCE

WITH THE REQUIREMENTS OF THE MALAYSIAN CIVIL AVIATION

REGULATIONS FOR THE TIME BEING IN FORCE.

THE NEXT MAINTENANCE REVIEW IS

SIGNED D.C.A. APPROVAL / LICENSE

DATE .

FIRM .

The CMR shall be issued in following format


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Fig. 10 CMR


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Definitions

Overhaul - An overhaul is a major work operation which involves dismantling, bench

testing and renewal of operational life.

Modification - Modification are changes made to a particular aircraft including its

components, engines, propellers, radio station, accessories, instruments,

equipments and their installation.

Replacement - A replacement is a work operation which involves the removal andreplacement of the same part And the substitution of another similar part.

Repair - A repair is any work relating to rectification which does not come under

one of the above heading.

Mandatory

Inspection - Any inspection classified as mandatory by the DCA, where the inspection

I tself is the work.

Scheduled

Maintenance

Inspection - Any inspection including test required by the approved maintenance

schedule.

19. INSPECTION, OVERHAUL, REPAIR REPLACEMENT AND MODIFICATION

19 1 Certificate of Release to Service


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19.1 Certificate of Release to Servicerequirement by Regulation 30, MCAR 1996. Ref: AN No.12)

After the overhaul, repair, replacement, modifications, mandatory inspection or scheduled maintenance inspectionof an aircraft or of such of its equipment as is necessary for the airworthiness of the aircraft the aircraft is not

permitted to fly until all the appropriate certificate to service have been issued relating to the work done. This

applies to all aircraft registered in Malaysia with a M.T.A.W. exceeding 2730 kg and, with the exception to aircraft

below that. A CRS is required in respect of the overhaul, repair or modification of any equipment provided

incompliance with Part 5 of the MCAR and of all radio equipment.

A CRS statement always start with the words The work recorded above.. which means the CRS releases the

aircraft/equipment only in relation to the work recorded and does not mean the complete aircraft is fit for release forservice.

Within an approved organization, a certificate of release to service may be issued by a person for the purpose. This

approval is granted by the official in charge of the quality department and in accordance with the MCAR

Work which is done outside an approved organization may be covered by a certificate of release to service issued

by the holder of an aircraft maintenance engineers license, providing that the work falls within the category andrating of the license.

Certificate of Release to Service must be retained as part of the log book for two years after the aircraft or its

equipment to which it refers has been permanently withdrawn from service.


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Content

The CRS shall contain the particulars of work done or the inspection completed and the

organization and place that the work is carried out. Depending upon the application of

the certificate, details of the aircraft type, registration, component type, part number,

batch number and serial number.

Certification Statement

The certification shall be worded in the following manner:-

The work recorded above has been carried out in accordance withthe requirements of the M.C. A. R. for the time being force and

in that respect the aircraft/equipment is fit for release to service.

The CRS shall be signed and dated by a licensed or approved person holding an appropriate

Type rating. The signatory shall also record his license and approval number, as appropriate.

The signatories for the CRS can is specified in the DCA Approval Document for the

Maintenance Schedule.

19 2 Certification for the completion of Scheduled Maintenance Inspection


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19.2 Certification for the completion of Scheduled Maintenance Inspection

(CRS for SMI) requirement by Regulation 30, MCAR 1996. Ref: AN No.12)

The CRS for SMI is required at the completion of a Scheduled Maintenance Inspections.

Certification is only required in the various licensed categories there is work in that

category during the SMI.

Scheduled Maintenance Inspection (SMI) means any group of inspections and tests called

up by a Maintenance Schedule.(Fig.12) E.g. Check, Inspections, Periodic etc.

CRS will not be required for any SMI scheduled at interval of less than 45 hours or 28 days

These limitation being applied separately.

It is not necessary to raise individual CRS (SMI) certification on each work sheet/card, but

it is mandatory to raise one document at the completion of an SMI containing all the

necessary CRS signatures and making references to the work carried out.

Certification shall only be made when all the works within the group of SMI has beencompleted unless company procedure acceptable to DCA permit.


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Fig.11 Master Signature Schedule Fig.12 Maintenance Schedule


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RETENTION OF DOCUMENTS

CERTIFICATE OF RELEASE TO SERVICE RELATING TO PUBLIC TRANSPORT OR AERIAL

WORK AIRCRAFT, SHALL BE KEPT BY THE OPERATOR IN THE APPROPRIATE LOG BOOK

OR ASSOCIATED DOCUMENT FORTWO YEARS AFTER THE AIRCRAFT, ENGINE, OR

VARIABLE PITCH PROPELLER TO WHICH THE CERTIFICATES RELATES HAS BEEN

DESTROYED OR HAS BEEN PERMANENTLY WITHDRAWN FROM USE.

20. DUPLICATE INSPECTION OF CONTROL SYSTEM.


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20.1 DEFINITION

Control SystemA system by which the flight path, attitude or propulsive force of an aircraft is changed,

Including the flight, engine and propeller controls, the related system controls and

associated operating mechanism.

Duplicate Inspection

An inspection first made and certified by one qualified person and subsequently made and certified by a

second qualified person

Ref: AN No.51

Vital Points

Any point on an aircraft at which a single mal-assembly could lead to a

Catastrophe i.e. loss of aircraft and/or fatalities

For aircraft with a type certificate issued on or after 1st January 1986, the

Vital points shall be identified and listed in the Maintenance documents.

Where such point has been identified, they will be subjected to duplicate

Inspection following initial assembly and subsequent disturbances.

20.2 RequirementsGeneral


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A duplicate inspection of all control systems in an aircraft shall be made after initial assembly

and before a CRS has been issued and in any case before the first flight.

NOTE: Depending on the extent of work it may be possible to limit the duplicate inspectionto that part of the system which has been disturbed. It is desirable that the inspections

of the control system are made as near as is practicable to the time of the intended flight.

If a control system is disturbed after completion of the duplicate inspection, the part that has

been disturbed shall again be inspected in duplicate and a CRS issued before the aircraft flies.

When carrying out a duplicate inspection, the inspectors should look out for thefollowing

1. That all attachments and adjustment points have been correctly and securely assembled

2. The full and free movement, in the correct sense, is obtainable at the termination of the

control run relative to the pilots control movement

3. That all cockpit indicators register the correct indication relative to the control system

position.4. That the full and free movement of the controls is obtained when all panels and fairing

are finally secured.

Person Qualified to make First or/and second part of A Duplicate inspection.


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Should a minor adjustment of a vital point/control control system be necessary when the aircraft is away

from base, the Second Part of the duplicate inspection may be completed by a Pilot or Flight Engineer

licensed for the type

For aircraft below 5700 kg, Duplicate Inspection for minor adjustment to control system can be signed by

holders of a type rated licensed in Cat. A and/or C on other type within the Category.(AN.No.3 Para. 1.7)

a. Appropriately rated Licensed Aircraft Engineers

b. Appropriately authorized persons employed by an approved organization


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20.3 DUPLICATE INSPECTION - Certification

When a Duplicate Inspection has been completed, a Certificate of Release to Service must be

raised which will detail the work carried out on the control system including an entry as detailedbelow:

SIGNATURE LICENSE/APPROVAL NO. DATE

1st Inspection

2nd Inspection

When both parts of the Duplicate Inspection have been certified, the C.R.S. will be closed in the

normal manner. Should subsequent ground or flight test require further adjustments, another

Duplicate Inspection will be required and another C.R.S. issued.

21. MODIFICATION


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Ref: MCAR Reg. 30, AN No. 4, 78

21.1 Introduction

After the initial issue of a certificate of airworthiness, any changes made to the aircraft or its equipmentconstitute a modification. Before a modification which has not been previously approved is carried out,

approval by the DCA or by delegated Authority must be obtained. The procedure for obtaining approval

depends whether or not the modification is designed by an organization approved for that purpose.

The approval of a modifications will be subject to compliance with procedures outlined in Airworthiness

Notice No. 78.

Approved OEM data

Modifications which are classified as OEM( organization that design the product ) requires DCAs installation

approval.

Modifications contained in service bulletins approved by the authority of the state of design which are

classified as OEM does not require DCAs approval.

Approved Non OEM dataThese modification requires DCAs installation approval.

Other than the approved data, the modification package is further classified as either Major or Minor

modification by the relevant airworthiness authorities.

At an early stage in the design of a modifications brief particulars shall be furnished to the D.C.A who will

classify it as Major or Minor Modification.

21.2 MAJOR AND MINOR MODIFICATION


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Major Modifications are changes that:

a. Have appreciable effect on the weight, balance, structural strength,

reliability, operational characteristic, or other characteristic affecting

the airworthiness of the product. or

b. Are not done according to accepted practice or cannot be done by

elementary operation or

c. Require the particulars given in the Certificate of Airworthiness, or

or associated documents, be amended, although no physicalchange of the product is involved.

Minor Modifications are changes other than major modification.

21.3 FEES

Minor - Modification ApprovalFree of Charge

Major Modification ApprovalCharged by the hour by D.C.A


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Fig.15

22. MANDATORY MODIFICATIONS AND INSPECTION


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Mandatory modifications MUST be embodied (if applicable) in all aircraft of the type and a date is

set by which the time the modification must be embodied

Detail of Mandatory Modification are circulated by the Manufacturer to owners and Operatorsby Service Bulletins.

Mandatory Modifications for aircraft or equipment of American manufacture are Published FAAAirworthiness Directives

No DCA approval is required.

( AIRWORTHINESS DIRECTIVES/SERVICE BULLETINS )Ref: AN No. 4

22.1 General

When an aircraft is affected by a mandatory inspection or modification, it is illegal forthe aircraft to be flown( unless permitted by DCA) until the prescribed requirementhas been complied with.

Operators and maintenance organizations are required to obtain from AirworthinessDivision, DCA all relevant mandatory information relating to the relevant type ofaircraft, engines and equipment with which they are involved.

22.2 Compliance to Mandatory Modification and Inspection(Airworthiness Directives)


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(Airworthiness Directives)

For the purpose of compliance, the prescribed requirements for the mandatory modificationsand inspections are in 3 different categories:

1. For aircraft registered in Malaysia, Airworthiness Notice issued by DCA.

2. For aircraft, engines, propellers or installed equipment for which Malaysia isthe State of Design and the Certifying Authority, DCA will issue

Airworthiness Directives (AD) which will be known as CAM AD.

3. For aircraft ,engines, propellers or installed equipment for which Malaysia is ValidatingAuthority and the State of Registry the following will apply :

a) Airworthiness Directives issued by the Certifying Authority or State of Design(formerly known as State of Manufacturer) of the aircraft,engines,propellers or installedequipment.

b) Airworthiness Directives issued by DCA which will be known as VAM AD.

These VAM AD replace the MCAD and LTO.


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22.3 Modification Documents and Identification

Modification documents must bear :

Modification Reference Number Issue Number and Date A Description of the Modification together with a list of parts and Assemblies

affected and where necessary drawing of Parts before and after Modification Where Modification affect unit interchangeability a separate type or Designation

reference must be allocated. Where parts is modified a new part number must be issued

22.4 Modification Recording and Certification

The work detail are entered in the aircraft log book or alternative maintenance record.

The maintenance Approval must be quoted with brief description in log book. All Modification carried out are recorded in the Modification Record Book. At the conclusion of the work a Certificate of Release to Service must be issued


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DOCUMENTS AND RECORDS

23. LOG BOOKS Ref: Regulation 35 of MCAR.


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g

23.1 General

As one of the measure for ensuring the continuing airworthiness of aircraft, the greatest importance is attach

to keeping a complete history of the aircraft. In particular this means a full and accurate record of the

maintenance, inspection, overhaul, repair, replacement and modifications. Since the check schedule to which

an aircraft is maintained is related to the total flying hours and associated factors, it is also necessary to record

the particulars of all flight completed especially the duration of flight.

For that purpose it is a statutory requirement for the operator of every aircraft registered in Malaysia to keep

log book for each:

Aircraft Engine Variable Pitch Propeller

Initially books are raised by aircraft manufacturers. They are responsible for entering essential data in

the introductory pages.

Subsequent information are entered by the operator. Approved log books are available from the CAA

Note:Initiation of a continuation Log Book is the responsibility of the user and he shouldtransfer sufficient data for continuity and should number the Log Book consecutively.

23.2 Log Book Entries


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Log book entries must include

Routine entries includes aircraft registration marks, engine and propeller type and

serial number and position of each engine and propeller.

Particulars of maintenance checks, inspections, overhauls, repairs, replacements andmodifications. Results of fuel flow tests, detail of compass adjustments, rigging checks and flying

control movements. References to related CRS Operating times for aircraft engines and propellers.

Note:

Ensure log books accompanies when receiving returned component.

Filing

Where the particulars of histories are too voluminous to be included in the logbook, the DCA will accept records on separate sheet suitably filed.

Log book are to be kept in Technical Records. All log books and associated records must be kept until a date 2 years after the

aircraft, engine or variable pitch propeller has been destroyed or

permanently withdrawn from service. When engine/s or propellers are sent for overhaul or repair, log book must

accompany

ENTRIES MUST BE MADE NOT MORE THAN SEVEN DAYS AFTER THE EXPIRY OF THE CMR IN FORCE AT

THE TIME OF OCCURANCE

24. TECHNICAL LOG.Ref: regulation 29 of MCAR


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24.1 General

A Technical log must be carried on Malaysian registered aircraft in relation to aircraft with C of A ineither Transport or Aerial work category is in force.

The Technical Log should be compiled by the operator.

At the end of every flight by an aircraft to which this regulation applies, the commander of theaircraft shall enter-(a) the times when the aircraft took off and landed;(b) particulars of any defect which is known to him and which affects the airworthiness

or safe operation of the aircraft, or if no such defect is known to him, an entry tothat effect shall be made; and

(c) such other particulars in respect of the airworthiness or operation of the aircraft asthe DCA may require,

The Commander must also make an appropriate entry if there are no defects. If there are a

number of consecutive flights by the same commander, beginning and ending on the same day, atthe same aerodrome, entries in the Technical Log can be made at the end of the last consecutiveflight except where a defect occurs during an earlier flight.


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24.2 Technical Log Entries

The Technical Log should contain the following:-

(a) A valid Certificate of Maintenance Review

(b) A Maintenance Statement with details of the next Scheduled Maintenance

Inspection due in order to comply with the Maintenance Schedule and any

out of phase inspections schedule before that time.

(c ) Sector Record page section, containing all the information required by BCAR

which includes a Certificate of Release to Service for SMI

(d) A Deferred Defect Record page section, containing the information required byBCAR

All Technical Log entries are required to be in duplicate, one copy of which is to be removed and retained on the

ground prior to the next flight. Where it is not practicable to do so, aero planes or helicopters not exceeding 2730

kg MTWA may carry the copy on any container approved by the CAA for the purpose. It is also the

responsibility of the operator to ensure that the relevant information contained within the Technical Log is

transferred to the organizations responsible for aircraft maintenance or component overhaul.

25. OPERATIONS MANUAL. Ref: Regulation 47 of the MCAR


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25.1 General

Malaysian aircraft which flies for the purpose of public transport except for an aircraft

used for the time being solely for flights not intended to exceed 60 minutes in duration,which are either-

(a) flights solely for training persons to perform duties in an aircraft; or(b) flights intended to begin and end at the same aerodrome.

The operator of every aircraft shall-

(a) make available to each member of his operating staff an operations manual;(b) ensure that each copy of the operations manual is kept up to date; and

(c) ensure that on each flight every member of the crew has access to a copy ofevery part of the operations manual which is relevant to his duties on the flight.

Each operations manual shall contain all such information and instructions as may be

necessary to enable the operating staff to properly perform their respective duties

including, in particular, giving information and instructions relating to public transport

operational requirements.The operator of the aircraft shall, furnish the DCA with a copy of the whole of the

operations manual, the operator shall make such amendments or additions to the

operations manual as the DCA may require for the purpose of ensuring the safety

of the aircraft or of persons or property carried therein or the safety, efficiency or

regularity of air navigation.

25. OPERATIONS MANUAL.Ref: Regulation 47 of the MCAR

26. MASTER AND MINIMUM EQUIPMENT LISTS.

Ref: Reg 34 of MCAR AN No 87


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Ref: Reg.34 of MCAR, AN No.87

MCAR regulation 34 requires that Malaysian registered aircraft to have minimum equipment while still allowing

the safe operation of the affected aircraft.The aircrafts allowable equipment deficiencies shall be documented in the form of a Minimum Equipment List(MEL) approved by DCA.

Master Minimum Equipment List (MMEL)

The MMEL is a permissive list of items, that may temporarily be inoperative on an aircraft although stillmaintaining the desired level of safety at the time of dispatch on revenue operations, whilst, operating within ascheduled maintenance programme

The MMEL is established for a particular aircraft type by the organization responsible for the type design with theapproval of the state of design containing items, one or more of which is permitted to be unserviceable at thecommencement of a flight.

Minimum Equipment Lists

MMEL is used by the operator to develop a Minimum Equipment List (MEL) applicable solely to his ownoperation.

The MEL shall be prepared by the operator and shall be no less restrictive than the approved MMEL for the sameaircraft type.

27. DOCUMENTS TO BE CARRIED ON AN AIRCRAFT

Ref: 10th Schedule MCAR


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Ref: 10th Schedule MCAR

R - Certificate of Registration

A - Certificate of Airworthiness

M - Certificate of Maintenance Review.

R - Radio Licenses

C - Crew Licenses

L - Load Sheet

O - Operation Manual

T - Technical Log

N - Notified Procedures

28. MAINTENANCE, OVERHAUL AND REPAIR MANUAL


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,

28.1 General

Manuals are compiled by all manufacturers of aircraft, engine, propellers, ancillary components and all

other support equipment essential to the relevant in-service maintenance programme.

All information on the aspect of the specific tasks involved is covered in separate manuals. The

manufacturers provides maintenance manual, overhaul manual and repair manual. In addition, a wiring

diagram, an illustrated part catalogue and in some cases a tools and equipment lists and a separate weight

and balance manual is also provided. This separate manual principle applies particularly where

manufacturers adopt the standard format recommended in ATA Spec 100.

As a result of the different work covered by these manuals, there are variations in the breakdown of each,

but basically, the breakdown of information is by systems. This is best illustrated by considering the

breakdown of a Maintenance Manual. The major divisions are termed Groups, each being divided into

chapters and allocated chapter numbers as shown in figure 1. Each chapter is arranged alphabetically in a

group, and is divided into sections and then further subdivided into subjects designated by a dash number, as

shown in the following example:-

Manuals containing information and recommendations necessary for the maintenance


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Manuals containing information and recommendations necessary for the maintenance,

overhaul and repair of aircraft, including engines and auxiliary power units, propellers,

components, accessories, equipment, instruments, electrical and radio apparatus and their

associated systems and radio stations fixed fittings must be provided by the

contractor/manufacturer to comply with the procedures for the grant of C of A. These manualsare approved and certified under the authority of the appropriate approved organization.

Requirement and guidance on the format and context of these manuals is given in BCAR

Chapter A5-3 and its appendix.

The certification must be on the TITLE PAGE of each manual.

A copy of each manual must be lodge with the DCA

If requested by the DCA, the manual must be submitted for approval

Revision of amendments must be certified separately and recorded on a separate record sheet

The Registered of the Manual is responsible for making all arrangement with originator

regarding revisions and amendments etc.

If the Manufacturer subsequently publishes documents which may affect the manual, thedocument must be certified for content and accuracy.

Amendments must be covered by letter of transmittal


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Manuals are produced to conform with any of the following standards are acceptable,

subject to the inclusion of any variations which may be required by the CAA

Specifications for Aircraft Technical Publications issued bythe SOCIETY of BRITISH AEROSPACE COMPANIES.

S.B.A.C.

ATA 100 Specifications for Manufacturers Technical DataAIR TRANSPORT ASSOCIATION of AMERICA

SPECIFICATION NUMBER 100

(A.T.A. 100).

28.2 MANUALSSPECIFICATIONS

28.3 MANUALSA.T.A. SPECIFICATION


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For modern civil aircraft operation the operators emphasis is on doing only the work which is necessary,

in the quickest, most economical and most efficient

manner-thereby contributing to the reduction of operating and maintenance cost.

To enable this objective to be met, a plan for presenting documentations was drafted by the AIR

TRANSPORT ASSOCIATION of AMERICA and adopted by the INTERNATIONAL AIR

TRANSPORT ASSOCIATION (I.A.T.A) as a standard for

use in their member airlines as a basis for INTERNATIONAL STANDARDIZATION:

This plan is designated A.T.A. Specification No. 100

The manuals defined and described by ATA Specification 100

are as follows:

Maintenance manual

Overhaul Manual

Illustrated Part Catalogue

Tools and Equipment Lists

Wiring Diagram Manual

Service Bulletins

Structural Repair Manual

Weight and Balance Manual.

TYPICAL CONTENTSMaintenance Manual


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TYPICAL CONTENTS

MAINTENANCE

MANUAL

INTRODUCTION DESCRIPTION OPERATING

CONTROLSERVICINGMAINTENANCEPRACTICE

28.4 MAINTENANCE MANUAL LAYOUT - CHAPTER IDENTIFICATION


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(A.T.A.100)

All chapters are identified by a number within its group e.g.

Group

AIRCRAFT GENERAL

TIME LIMITS/

MAINTENANCE CHECKS 5

DIMENSION & AREAS 6

Group

STRUCTURE

STRUCTURES 51

DOORS 52

FUSELAGE 53

Group

AIRCRAFT SYSTEM

STANDARD PRACTICE 20

AIRFRAME

COMMUNICATION 23ELECTRICAL POWER 24

HYDRAULIC POWER

29

Group

POWERPLANT

POWERPLANT 71

ENGINE 72

IGNITION 74


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GROUP CHAPTER NUMBERS

AIRCRAFT GENERAL 1 - 19

AIRCRAFT SYSTEM 20 - 49

STRUCTURES 50 - 59

PROPELLERS/ROTOR 60 - 69POWERPLANT 70 - 89

CHAPTERSECTION -SUBJECT


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A THREE PART numbering system is used to identify CHAPTER-SECTION-SUBJECT.

27 - 31 - 0

The first number is

the CHAPTER number.

Identifies the MAJOR

functional system.

CHAPTER 27

Flight Controls

The middle number is the section

number and identifies a specific

system, sub-system, or group of

Related assemblies

The last number

is the subjectnumber. Identifies

all information

relative to specific

Unit, Minor assy. or

Simple system.

SECTION 31

Elevator and tab

Control System.

SUBJECT- 0

0 for complete

System information.

11 or higher number

For individual component.

SUBJECT PAGE IDENTIFICATION


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Each subject is a page numbered with itself and the identification of each page is by both the subject number and

the topic or subtopic page number. These identification numbers appear in the lower outside corner of each page.

The subject are divided into reasonably topics and subtopics IN BLOCKS OF 100 to enable the locate the

desired information more readily.

The topics as defined by A.T.A. Specification 100 are:

DESCRIPTION AND OPERATION, TROUBLE SHOOTING and

MAINTENANCE PRACTICES.

THE SUBTOPIC

SERVICING,

REMOVAL/INSTALLATION,

ADJUSTMENT/TEST,

INSPECTION/CHECK,

CLEANING/PAINTING and

APPROVED REPAIRS.

Topics and Subtopics that are divided into page groups in blocks of 100 assigned as follows


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1. - 100 Description and Operation. The purpose of this block is to explain the location,

configuration, function, operation and control of a complete system. The specification

requires that the text and illustrations be presented in a form which is also suitable for

training of maintenance personnel.

101200 Trouble Shooting. In the maintenance of any type of aircraft, good trouble shooting

is done by a rationalized process of elimination and not by guesswork. To make this

effective, this block of page group is set out in a form of charts having three basic

headings: 1. Possible Cause, 2. Isolation Procedure, 3. Correction.

201300 Maintenance Practices. The purpose of this block is to explain describe: Servicing,Removal/Installation, Adjustment/test, Inspection Checks, Cleaning/Painting and

Approved Repairs. Depending on the extent of the work to be carried out in each case

the procedure may be treated individually in additional page block of 100 from 301 to

900.

28.5 Standard Practices


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Standard industrial practices such as Magnaflux testing, dye penetrant testing, riveting, plating etc. are not

normally included in the manuals unless the practice is new or unique. If the manufacturers policy requires

their inclusion in the manuals, they are covered within a chapter group entitled StandardPractices.

Basically, the foregoing principles of breaking down information are applicable to all other manuals but

variations arise, due to the different work requirements - e.g.. The work detailed in a maintenance

manual compared with that detailed in an overhaul manual.


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OTHER AIRWORTHINESS REQUIREMENT

29. Mandatory Reporting Ref :MCAR Regulation 195.


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29.1 General

Regulation 195 of the MCAR requires reports to be rendered to the DCA of any incident, defect or

malfunctioning of the aircraft, or any of its equipment, where such or malfunctioning, if not corrected,

would endanger the aircraft, its occupants, or any other person. It also applies to any ground equipment

used for the purpose of or in connection with the operation of the aircraft.

Every person who -

(a) is the operator or the commander of a Malaysian registered aircraft;(b) carries on the business of manufacturing, repairing or overhauling any aircraft, or any equipment or part

thereof;

(c) signs a CMR or CRS in respect of any aircraft, its equipment.

(d) is the licensee of a licensed aerodrome,

shall

(i) make a report to the DCA of any reportable occurrence of which he knows

(ii) make a report to the DCA, information which is in his possession or control

and which relates to a reportable occurrence which has been reported by

him or by another person


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30. WEIGHT AND BALANCE OF AIRCRAFT


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Aircraft exceeding 5700 Kg (12,500lbs) MTWA must be re-weighed within 2 years after the date of

manufacture and, after this, a check weighing must be carried out at intervals not exceeding 5 years andat such times as the D.C.A. may require.

Aircraft must be weighed to determine the Basic Weight and the corresponding Centre-of-Gravity

position when all the manufacturing have been completed.

The need for accuracy when weighing aircraft is extremely important. Incorrect data could cause subsequent

overloading of the aircraft resulting in an increase of structural loads and reduction in performance

30.1 General


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30.2 DEFINITIONS

BASIC EQUIPMENT is the inconsumable fluids (e.g. coolant and hydraulic fluid)

and equipment which is common to all roles for which the operator intend to use the aircraft.

BASIC WEIGHT is the weight of the aircraft and al of its basic equipment, plus that of the

declared quantity of unusable fuel and unusable oil. In case of turbine engine aircraft, the

MTAW of which does not exceed 5700kg (12,500ib), it may also include the weight

Of usable oil

VARIABLE LOAD is the weight of the crew and of items such as crew baggage, removable

Units and other equipment the carriage of which depends upon the role for which the operator

Intends to use the aircraft for a particular flight.

DISPOSABLE LOAD is the weight of all persons (e.g. passengers) and items of load

Including fuel and other consumable fluids carried in the aircraft other than the basic

Equipment and variable load.

M.T.A.W is the Maximum Total Weight Authorized for the aircraft and its contents, at which the aircraft maytake off anywhere in the world, in the most favorable circumstances in accordance with the Certificate of

Airworthiness or Flight Manual.

30.3 Aircraft Weight Schedule.Ref: MCAR Reg. 36


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(1) Every flying machine and glider in respect of which a certificate of airworthiness issued

or rendered valid under these Regulations is in force shall be weighed, and the positionof its centre of gravity shall be determined, at such time and in such manner as the DCA

may require.

(2) Upon the aircraft being weighed the operator of the aircraft shall prepare a weight

schedule showing-

(a) either the basic weight of the aircraft, that is to say, the weight of the aircraft whenempty together with the weight of unusable of fuel and unusable oil in the aircraft

and of such items of equipment as are indicated in the weight schedule, or such

other weight as may be approved by the DCA