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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
28. Certificate of Maintenance Review
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
28. Certificate of Maintenance Review
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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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