engineer maint guide

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maintenance guide for ENGINEERS

CIVIL AVIATION SAFETY AUTHORITY


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For comments and questions

contact: Steve Bell

CASA Aviation Safety Promotion

Telephone: 02 6217 1788

Facsimile: 02 6217 1950

Email: [email protected]

Further information can be

downloaded from CASAs

website www.casa.gov.au

To order additional copies, go to

http://casa.jsmcmillan.com.au

2005 Civil Aviation Safety

Authority Australia.

The Civil Aviation SafetyAuthority is responsible for the

safety regulation of Australias

civil aviation operators, and for

the regulations of Australian-

registered aircraft outside

Australian territory.

CASA sets safety standards

and ensures these are met

through effective entry,

compliance and enforcement

strategies. Additionally, CASA

provides regulatory services

to industry, and plays a part

in safety education for the

aviation community. CASA also

administers exams and issues

licences for Australian pilots.

Notice: The information

contained in this document was

correct at the time of publishing

and is subject to change without

notice. This booklet has been

prepared by CASA AviationSafety Promotion Division for

educational purposes only. It

can be changed at any time

without notice and should never

be used for any other purpose.

Reference should be made to

the appropriate legislation at

all times prior to the use of the

information contained herein.

Final Certification 107

The System of Certification -

CAR 42ZE and 42ZN 108

Further Detailed Information 108

ANNEX A 116

Part 1 Interpretation 116

Part 2 Certification of completion

of stages of maintenance

and inspections under

subregulat ion 42G (2) 117

Part 3 Certification of co-ordination

of maintenance 119

Part 4 Final certification 121

ANNEX B Certifying on the

Maintenance Release 124

ANNEX CUseful addresses 126

corrosion and corrosion CONTROLIntroduction 129

The Corrosion Process 129

Oxidisation 130

Galvanic Reactions 130

Corrosion Prevention 133

Metal Coating 133

Corrosion Resistant Substances or

Coatings 133

Painting 134

Preperation 134

Other Coatings 134

Some Simple Rules for Corrosion

Prevention 135

Conclusion 135

fabrication in the course of

MAINTENANCEIntroduction 139

Fabrication 139

Fabrication in the Course of

Maintenance (FitCoM) 140

Required Marking of FitCoM parts 140

Certification Requirements 141

Conclusion 142

quality management SYSTEMSIntroduction 145

CAR 1988 30 and CASR 145(proposed) 146

CAR 1988 30 146

CASR 145 (proposed) 149

Quality Management Principles 149

Quality Management systems approach 153

Differences Between Quality

Standards and Civil Aviation Law 155

Conclusion 156

systems of CERTIFICATIONfor maintenance activitiesReferences 159

Introduction 159

Setting Up a System of Certification 160Aircraft Maintenance and Certification

Systems 160

Using the Manufacturers System of

Certification 161

Using the CASA System of

Maintenance/Schedule 161

What Must Be Included in a

System of Certification 162

Certification For Completion of the

Maintenance 165

Additional Work Sheets 167

Certifying on the Additional Work Sheets 167

Final Certification 169

Co-ordination 170

Conclusion 170

the role of the SUPERVISORSupervision 173

Division 3Who may supervise

maintenance 173

CASA Contacts 175

2 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 3

Contentssystems of MAINTENANCEIntroduction 5

Schedule 5 7

Civil Aviation Regulations 1988 10

Part 1 Daily inspection 10

Part 2 Periodic inspection 12

Part 3 Post inspection check 25

Revised CAAP 41-2(1) 26

Maintenance programs for

class B aircraft 26

CAAP No:39-1 (1) 35

Maintenance requirements for

class A aircraft 35

CAAP No: 42B-1 (0) 40

CAA Maintenance Schedule 40

CAAP 42L-1(0) 58

Inspection of aircraft after abnormal

flight loads, heavy landing or

lightning strike 58

the maintenance RELEASEIntroduction 67

How does the Maintenance Release Work? 67

The Maintenance Release 68

Part 1 69

Part 2 76

Part 3 80

ANNEX AThe new proposed flight

and technical log 82

ANNEX BCertifying on the

maintenance release 85

approved MAINTENANCE DATAIntroduction 89

The Type Certificat ion Process 89

Conclusion 98

certification for MAINTENANCEReferences 103

Certification for Completion of Stages

of Maintenance and CAR 42G

Independent Inspections 103

Co-ordination of Maintenance 105


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systems of MAINTENANCE

5

1. Introduction1 There are two requirements for a system of maintenance;

they are different in the way that they deal with different

operational requirements.

(a) For aircraft operated in RPT or LCRPT (soon to include

Charter), an operators system must be developed and

presented to CASA or an authorised person for approval.

(b) For aircraft operated in Private, Aerial Work and Charter

(Charter is soon to be included in the transport category),

the Registered Operator (Part 47), will need to choose a

maintenance schedule from one of the following:

(i) the manufacturers system of maintenance

(ii) their own approved system of maintenance

(iii) the CASA system of maintenance (schedule 5).

The requirements of (a) are mandatory requirements. For (b)

the choice is up t o the Registered Operator.

What must be included?In every case there are certain requirements that must be met.

These are outlined in CAR 1988 42L and CAR 42M. They are:

A schedule that:

(a) sets out the regular maintenance inspections, tests and

checks to be carried out on the aircraft

(b) sets out when those maintenance inspections, tests and

checks will be carried out e.g. at what intervals

(c) nominates one of the inspections from (a) as the inspection

to be carried out for the purpose of determining whether a

Maintenance Release should be issued for the aircraft.

(d) Sets out details of time-lifed component

This system will continue when the proposed Part 43

regulations are introduced. The difference will be that a

maintenance release, as we currently know it, will not be

issued; instead a certification that the maintenance has been

carried out and that the aircraft is returned to service will be

made in the Flight and Tech Log.

The system must also include the following (CAR1988 42L and CAR 42M):(a) what inspection must be performed when the aircraft suffers a

lightning strike and when it should be carried out

(b) what inspection must be carried out when the aircraft

is subject to abnormal ground or flight loads. This is

determined from the flight manual and type certificate data,

and when this will be done.

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A list of components, which are time lifed i.e. have specific

overhaul periods listed by the aircraft manufacturer e.g. the

spar. The system must then specify when these components

should be retired, overhauled or removed for test;

(c) The procedures to be followed by the maintenance personnel

when performing the inspections, tests, and checks required by

the system.

The procedures must be in accordance with approved data,

which will normally mean that issued by the manufacturer,

approved by the regulator of the country of manufacture or

by CASA or an authorised person. This will include all of the

methods and limits listed in:

(i) the maintenance manual;

(ii) SBs, SLs etc; and

(iii) any other method approved by CASA i.e. ADs.

(d) If permissible unserviceabilities are approved as a minimum

Equipment List (MEL) then this list is included in the System of

Maintenance (SOM).

(e) Statements identifying the Registered Operator (entitled person

under CAR 1998 Part 45), and the aircraft, (model, type, serial

number and registration mark).

In the case of a transport aircraft the system of maintenance

(SOM) should also contain the maintenance that can be carried

out by a pilot and how each pilot is trained and authorised for this

maintenance.

The new regulations are more specific when it comes to this

aspect; they state what maintenance can be authorised. Any

(outside schedule 8) other maintenance that is required to be

performed by the pilot because of certain types of operation , e.g.

those remote from maintenance sources, can be approved using

a CASA Maintenance Authority (MA) (or its equivalent). To gain

this authority a pilot must have received appropriate training and

experience approved by CASA.

Most, if not all, of the information required above can be taken

from the manufacturers maintenance information. This will include

documents such as:

(a) the Maintenance Manual;

(b) service bulletins, letters, and instructions etc.

In addition to what is supplied by the manufacturer, other

maintenance information can be taken from such information as:

(a) Airworthiness Directives, both Australian and country of

manufacturer or certification;

(b) information material such as

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(i) Airworthiness Advisory Circulars (AACs);

(ii) the Approved Aircraft Flight Manual;

(iii) engine manufacturer s printed material i.e. Operators

Handbooks; and

(iv) other advisory material.

All of this can be used to determine what is included in the system

of maintenance.

For B Class Aircraft Only

Manufacturers Versus CASA System of Maintenance (Schedule 5)

Schedule 5First of all it must be stated that the original purpose behind

the CASA system of Maintenance was for use by owners of

aircraft where the manufacturers system of maintenance

was inadequate for some reason. In some cases the original

manufacturer is no longer willing to support the aircraft

or equipment for whatever reason and in other cases the

manufacturer has not included service information on certain

equipment e.g. the avionics. The reason for this was that the

aircraft that was built to a basic design, which has been modified

over the years to include better, more efficient equipment. For

example no aircraft manufacturer in the 1950s ever dreamed of

the advances in instrumentation, radios or navigation equipment

available today, i.e. GPS. In addition because they produced

a BASIC model they could never be certain what equipment

is or could be fitted. What this means is that the Registered

Operator, to meet the Australian requirements, must include the

maintenance of this equipment in their system.

Schedule 5 is a very comprehensive list of what to do and

when to do inspections. Its limitation is that it does not have

any information on how the inspection is carried out or any

particular requirements or limits. This can only be gained

from approved maintenance data. Approved maintenancedata is defined in CAR 1988 2A. As a guide it is any data from

the aircraft or component manufacturer or any approved by

CASA or the National Airworthiness Authority (NAA) of the

country of manufacturer or certification, check to see that

any data used is approved before use. Approved data must

always be used (CAR 42V makes this a legal requirement). So

approved maintenance data must always be used, even if the

maintenance is performed to Schedule 5, or by a pilot or the

holder of an MA.

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Manufacturers System of Maintenance

Several distinct advantages are gained by using the

manufacturers system of maintenance. These are:

1. The manufacturer will generally provide several options,

which will give some alternatives to the strict compliance to

times, i.e. +10% for a periodic inspection.

2. The manufacturer is surely the best person to provide

maintenance information. (They should know how to maintain

the reliability of the aircraft better than anyone).

3. The manufactuturers system will permit use of the various

documents simultaneously, e.g. using the manufacturers

system will give the same details for a daily inspection in

both the maintenance manual and the flight manual.

4. The manufacturers system is the benchmark used when

assessing the applicability of the CASA approved system,

(see CAR 1988 42M).

5. The manufacturers system will reference other approved

data as required. This is usually included in the task cards

for all inspections. This is acceptable and meets part of the

requirements of a system of certification which is required

by CAR 1988 42ZE (1) (a).

Combinations of the Manufacturers System and Schedule 5.

For a non-transport aircraft both schedule 5 and the manufacturers

system of maintenance is automatically approved, which means

that the entitled person need only inform CASA of their use

(usually through the submission of a Log Book Statement (LBS)).

The legislation also permits a combination of both of these

systems without further approval, provided the combination is

clear on the LBS. For example if the manufacturers system is

chosen, Schedule 5 may be included for the avionics. Another

example is when the aircraft manufacturer does not include any

reference to the engine manufacturers system; again these may

be combined (and is in fact recommended). This combination

will not require further approval. In the instance, though, where

additional requirements are to be included at the request of the

entitled person, this system then becomes that persons approved

system and will require CASA approval even if it is based on the

manufacturer s system or even Schedule 5. The same would

apply to compliance with an AD requirement for something to be

included in the SOM.

Note: Mention made to CASA here also includes authorised

persons.

8 c i v i l a v i a t i o n s a f e t y a u t h o r i t y 9

Writing your own System of Maintenance (orMaintenance Schedule)This is not as difficult as it first looks. Writing your own System of

Maintenance can have several advantages. Some of these are:

1. The registered operator can gain some flexibility, whereas

the current schedule 5, for instance, only allows maintenance

to be carried out annually or every 100 hours time in service.

The operator may decide to develop a system where small

amounts of maintenance from the schedule are performed at

regular intervals rather than once a year.

2. The aircrafts general airworthiness would be improved.

3. Certain concessions concerning maintenance intervals can

be granted (for example a small over-run) .

4. The system of maintenance can be tailored to t he operators

specific requirements.

The system must meet the requirements of CAR 42L and

CAR 42M regardless. In addition certain parts of the

manufacturers system can be included along with applicable

parts of the current schedule 5. These two systems are the

basis on which your system would be assessed for approval,

along with the regulations previously mentioned.

It is proposed in the future that the new equivalent to the

current schedule 5 will be limited to aircraft used in private or

aerial work categories and for which there is an inadequate

manufacturers system of maintenance. The manufacturers

system would be the CASA preferred system and will require

no approval. The registered operator will indicate which

system of maintenance is to be used in the same way they do

now (through the LOG BOOK STATEMENT).

An option worth considering, though; is to write your own.



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Civil Aviation Regulations 1988Schedule 5 CAA maintenance schedule(subregulation 2 (1))

(definition of CAA maintenance schedule)

Part 1: Daily inspection1.1 An inspection (in this Part called a daily inspection) must be

carried out on the aircraft before the aircrafts first flight on

each day on which the aircraft is flown.

1.2 A A daily inspection must consist of the making of such of

the checks set out in the table at the end of this Part as are

applicable to the aircraft.

Table of checks included in a daily inspection

Section 1: General

1. Check that the ignition switches are off, the mixture control

is lean or cut off, the throttle is closed and the fuel selector

is on.

2. Check that the propeller blades are free from cracks, bends

and detrimental nicks, that the propeller spinner is secure

and free from cracks, that there is no evidence of oil or

grease leakage from the propeller hub or actuating cylinder

and that the propeller hub, where visible, has no evidence

of any defect which would prevent safe operation.

3. Check that the induction system and all cooling air inlets

are free from obstruction.

4. Check that the engine, where visible, has no fuel or oil

leaks and that the exhaust system is secure and free from

cracks.

5. Check that the oil quantity is within the limits specified by

the manufacturer for safe operation and that t he oil filler

cap, dipstick and inspection panels are secure.

6. Check that the engine cowlings and cowl flaps are secure.

7. Check that the landing gear tyres are free from cuts or

other damage, have no plies exposed and, by visual

inspection, are adequately inflated.

8. Check that the landing gear oleo extensions are within

normal static limits and that the landing gear doors are

secure.

9. Check that the wing and fuselage surfaces are free from

damage and that the inspection panels, flight control

surfaces and flight control devices are secure.

10. Check that the interplane and centre section struts are free

from damage and that the bracing wires are of the correct

tension.

11. Check that the pitot heads and static ports are free from

obstruction and that the pitot cover is removed or is free to

operate.

12. Check that the fuel tank filler caps, chains, vents and

associated access panels are secure and free from damage.

13. Check that the empennage surfaces are free from damage

and that the control surfaces control cables and control

rods, where visible, are secure.

14. Check that the canard surfaces are free from damage and

that the control surfaces, control cables and control rods,

where visible, are secure.

15. Check that the flight controls, the trim systems and the

high lift devices operable from the ground have full and

free movement in the correct sense.

16. Check that the radios and antennae are secure and that

where visible, radio units and interwiring are secure.

17. Check that the drain holes are free from obstruction.

18. Check that there is no snow, frost or ice on the wings, tail

surfaces, canards, propeller or windscreen.

19. Check that each tank sump and fuel filter is free from water

and foreign matter by draining a suitable quantity of fuel

into a clean transparent container.

20. Check that the windscreen is clean and free from damage.

21. Check that the instruments are free from damage, legible

and secure.

22. Check that the seat belts, buckles and inertia reels are free

from damage, secure and functioning correctly.

Section 2: Additional items for agriculturalaeroplanes

1. Check that the agricultural equipment is secure.

2. Check that the dump and fan brake mechanisms are free

from obstructions and operate correctly.

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Section 3: Additional items for seaplanes1. Check that the hull and floats are free from damage,

corrosion and water accumulation.

2. Check that the float attachment struts, bracing wires and

attachment fittings are secure and free from damage and

corrosion.

3. Check that the water rudder and its attachments are secure

and free from damage and corrosion and that the water

rudder has full, free and correct travel.

Part 2: Periodic inspection2.1 Subject to paragraph 2.2, an inspection (in this Part

called a periodic inspection) must consist of the taking of

the actions set out in the table at the end of this Part as

applicable to the aircraft.

2.2 The holder of a certificate of registration for a class B

aircraft may elect to have a section or sections of the

periodic inspection carried out on the aircraft at a different

time from the other sections.

2.3 A periodic inspection must be carried out on a private

aircraft within the period of 1 year from:

(a) the day on which the aircrafts current certificate of

airworthiness was issued; or

(b) the day on which the most recent general maintenance

inspection on the aircraft was completed; whichever is

the later.

2.4 Subject to paragraph 2.5, a periodic inspection must be

carried out on a class B aircraft that is not a private aircraft

within whichever of the following periods expires first:

(a) one year from:

(i) the day on which the aircrafts current certificate of

airworthiness was issued; or

(ii) the day on which the most recent general

maintenance inspection on the aircraft was

completed; whichever is the later;

(b) the aircraft has been in service for 100 hours since:

(i) the aircrafts current certificate of airworthiness was

issued; or

(ii) the most recent general maintenance inspection

on the aircraft was completed; whichever occurred

later.


2.5 In spite of paragraph 2.4, if the holder of the certificate of

registration for a class B aircraft that is not a private aircraft

has elected under paragraph 2.2 to have the sections of the

periodic inspection carried out on the aircraft at different

times, the following provisions have effect:

(a) the first carrying out of each section of the periodic

inspection on the aircraft after the election is made must

be carried out within whichever of the following periods

expires first:

(i) 18 months from:

(a) the day on which the aircrafts current certificate

of airworthiness was issued; or

(b) the day on which the most recent general

maintenance inspection on the aircraft was

completed; whichever is the later;

(ii) the aircraft has been in service for 150 hours since:

(a) the aircrafts current certificate of airworthiness

was issued; or

(b) the most recent general maintenance inspection

on the aircraft was completed; whichever

occurred later;

(b) each subsequent carrying out of each section of

the periodic inspection must be carried out within

whichever of the following periods expires first:

(i) the aircraft has been in service for 100 hours since

the section concerned was most recently carried out

on the aircraft;

(ii) 1 year from the day on which the section concerned

was most recently carried out on the aircraft.

2.6 In this Part: general maintenance inspection means a

regular inspection and check of a class B aircraft, its

systems and components that:

(a) is required by the aircrafts maintenance schedule to be

carried out at regular intervals; and

(b) is not required to be carried out before the aircrafts

first flight on each day on which the aircraft is flown.

Private aircraft means an aircraft:

(a) that is a class B aircraft; and

(b) that has a maximum take off weight of 5700 kg or less;

and

(c) that is only used in private operations by:

(i) the owner of the aircraft; or

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(ii) a person to whom the owner has provided the aircraft

without receiving any remuneration from the person.

2.7 Unless otherwise indicated in the table, where the table

requires a thing to be inspected, the inspection is to be a

thorough check made to determine whether the thing will

continue to be airworthy until the next periodic inspection.

Table of actions included in a periodic inspection

Section 1: The airframe(1) Check the external and internal required placards.

Note Reference should be made to the aircraft flight manual

and airworthiness directives for the required placards.

(2) Take the following action in relation to the mainplane and

empennage (including canards) of the aircraft:

(a) inspect the skins for evidence of wrinkles, buckles,

sheared or loose rivets, corrosion, disbonds and

general damage;

(b) if the skin is fabric, check the strength of the fabric;

(c) inspect the internal structures and spars;

(d) inspect the lift struts, interplane struts, jury struts,

spreaders, chafing discs and bracing wires;

(e) inspect the flight control surfaces, slats, spoilers, tabs,

flaps, mass balance weight attachments, hinge brackets,

tracks and rollers;

(f) inspect the flight control system bellcranks, push pull rods,

torque tubes, cables, fairleads, turnbarrells and pulleys;

(g) inspect the wing and empennage to fuselage

attachments and surrounding structure;

(h) lubricate as necessary.

(3) Take the following action in relation to the fuselage:

(a) inspect the fuselage skin for evidence of wrinkles,

buckles, sheared or loose ri vets, corrosion, disbonds

and general damage;(b) inspect the areas around cut-outs (such as windows

and inspection apertures) for cracks and inspect the

sealing and fit of all doors and emergency exits;

(c) inspect the interior;

(d) inspect the strength of the fabric covering on surfaces;

(e) inspect the internal structure;

(f) inspect the locks, latches and hinges of doors, canopy,

windows which may be opened and direct v ision

windows;


(g) check that the windshields and windows are clean and

free from crazing, cracking, discoloration, delamination

and scratches;

(h) inspect the seats, seat attachments, seat adjustment

mechanisms, seat stops, seat belts, safety harnesses

and inertia reels;

(j) inspect the control wheels, control columns, rudder

pedals, control levers, control system bellcranks, push

pull rods, torque tubes and cables;

(k) operate all trim controls through the complete range

of travel and check them for correct trim position

indication;

(l) inspect the brake master cylinders, brake lines,

reservoirs, parking brake linkage and mechanical brake

system operating mechanisms;

(m) check the cabin fire extinguisher for correct charge,legibility of operating instructions and condition of

locking pin or seal and ensure that the extinguisher has

not reached its expiry date;

(n) inspect the heating and fresh air system ducting and

outlets and the airflow control valves;

(p) inspect the emergency and flotation equipment and ensure

that the equipment has not reached its expiry date;

(q) lubricate as necessary.

(4) Jack the aircraft so that the landing gear is clear of the

ground and take the following action:

(a) inspect the undercarriage attachment to the airframe;

(b) inspect the structural members, drag and side braces,

compression members, oleo struts, bracing struts and

torque links;

(c) inspect the leaf or tube spring shock absorbing units

and bungee rubber;

(d) inspect the flexible hoses;

(e) inspect the main wheels and tyres and the nose or tail

wheels and tyres;

(f) clean the wheel bearings, check that they are free from

scoring and brinelling, re-lubricate them, re-install them

and adjust the bearing pre-load;

(g) inspect the brake linings or pads and the brake drums

or discs;

(h) inspect the brake lines and flexible hoses;

(j) inspect the nosewheel or tailwheel steering mechanism

and the shimmy dampener;

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(k) inspect the landing gear retraction mechanism, the door

and the door operating linkage;

(l) carry out an operational check of the landing gear and

doors and ensure that the adjustment of downlocks,

overcentre links, uplocks and spring tensions are within

the manufacturers specified limits;

(m) lubricate as necessary.

(5) Take the following action in relation to the fuel system:

(a) inspect the fuel tanks (where visible), lines, drains,

vents, signs, filler caps, filler cap securing chains or

cables, filler cap seals and scupper drains;

(b) inspect the fuel selector valves;

(c) inspect the fuel selector valve operating linkage.

(6) Take the following action in relation to the hydraulic system:

(a) remove, clean, and refit the hydraulic system filter element,or if it is unserviceable, install a new filter element;

(b) inspect the hydraulic system reservoirs, powerpack,

accumulators, selector valves, hand pump, pipelines

and flexible hoses.

(7) Inspect the anti-icing and de-icing systems.

(8) Inspect the air-conditioning evaporator, condenser and

compressor and the air-conditioning ducting, pipelines and

units.

(9) Inspect the pressurisation control system and indication

system.

(10) Take the following additional action if the aircraft is used in

agricultural operations:

(a) inspect the hopper, hopper lid and fasteners, baffles

and internal braces;

(b) inspect the spreader, spreader gate and controls;

(c) inspect the spray pump fan, fan mount, fan brake,

spray pump lines, booms and boom supports;(d) inspect the emergency dump doors and dump controls.

(11) Take the following additional action if t he aircraft is a

seaplane:

(a) inspect the external covering and internal structure of

the floats or hull;

(b) drain the bilge compartments, refit and re-lock the drain

plugs;

(c) inspect the float attachment struts, bracing wires and

attachment fittings;


(d) inspect the water rudders, water rudder attachments

and water rudder controls, operate and check them for

full and free movement in t he correct sense and for

correct locking;

(e) inspect the protective treatment and finish.

Section 2: The engine(1) Check the external and internal required placards.

Note Reference should be made to the aircraft flight manual


(2) Take the following action in relation to the cowls:

(a) remove, clean and inspect the cowls, cowl flaps and

fastenings.

(3) Inspect, and record the compression of, each cylinder.

(4) Take the following action in relation to the engine oil system:(a) drain the sump or tank and refit the plug and lockwire;

(b) drain the oil cooler and refit and secure the hose;

(c) either:

(i) remove, inspect, clean and refit the pressure filter

and lockwire; or

(ii) remove, open and inspect the cartridge full flow

filter and fit a new cartridge and lockwire;

(d) inspect the oil cooler, oil temperature control valves, oil

tank and attachment fittings;

(e) inspect all oil lines, fittings, breather pipe and the oil

cooler shutter;

(f) refill the sump or tank with the recommended grade

and quantity of oil.

(5) Take the following action in relation to the ignition system:

(a) remove the spark plugs, clean and inspect them, check

the spark plug electrode gap, test the spark plugs and

renew them if required;

(b) inspect the spark plug high tension leads and ceramics;

(c) inspect the magneto housing;

(d) inspect the breaker compartment and cam follower;

(e) inspect the breaker points for serviceability and check

the breaker points gap, magneto engine timing and

synchronisation;

(f) inspect the switch and earth leads;

(g) refit and torque the spark plugs;

(h) refit the spark plug high tension leads.

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(6) Take the following action in relation to the fuel system:

(a) place the fuel selector in the off position;

(b) remove, inspect, clean and refit the fuel strainers and

screens and lockwire;

(c) drain and flush the carburettor fuel bowl and refit the

plug and lockwire;

(d) inspect the carburettor or fuel injection components;

(e) inspect the throttle and mixture shafts;

(f) inspect all fuel lines and fittings;

(g) move the fuel selector from the off position;

(h) inspect the auxiliary fuel pump for operation;

(i) pressurise and purge the fuel system and inspect it for

leaks.

(7) Take the following action in relation to the induction

system:

(a) remove the air filters, clean them, inspect them and

refit or renew them;

(b) inspect the hot and alternate air systems for the

integrity of seals and for serviceability of valves, shafts,

bearings, magnets and hinges;

(c) inspect the induction manifold and hoses.

(8) Take the following action in relation to the exhaust system:

(a) inspect the exhaust system;

(b) remove the muffler shroud, inspect the muffler and refit

the shroud;

(c) inspect the muffler internally for security of baffle

cones;

(d) inspect the cabin heat flexible hoses.

(9) Take the following action in relation to the engine cylinders

and baffles:

(a) inspect the cylinder assemblies;

(b) inspect the cylinder base to the crankcase area;(c) inspect the rocker covers;

(d) inspect the push rod housing seals.

(10) Take the following action in relation to the crankcase,

accessory housing and firewall:

(a) inspect the engine for evidence of oil leakage;

(b) inspect the accessories and drive belts;

(c) inspect the engine mounts and engine mountbolts;

(d) inspect the engine mount frame;

(e) inspect the firewall, including seals and sealant.


(11) Inspect the following controls for full and free movement in

the correct sense:

(a) throttle, mixture and propeller;

(b) alternate air and carburettor heat;

(c) engine bay fuel strainer controls;

(d) oil cooler shutter and cowl flap;

(e) turbocharger.

(12) Take the following action in relation to the propeller:

(a) inspect the propeller for static track;

(b) inspect the propeller hub, spinner and backplate;

(c) inspect the wooden propeller attachment bolts;

(d) inspect the blades;

(e) inspect the counterweights;

(f) lubricate the propeller hub;

(g) service the propeller hub with air.

(13) Take the following action in relation to the turbocharger:

(a) remove the heat shield and inspect the turbocharger

housing for cracks and oil leaks from the inlet and

outlet ports;

(b) inspect the compressor and turbine wheel;

(c) inspect the rotating assembly bearing for end float;

(d) inspect the turbocharger mount;

(e) inspect the transition assembly, the induction and

exhaust components and the clamps;

(f) inspect the upper deck pressure manifold and hoses;

(g) lubricate the waste gate linkages and the butterfly

valve;

(h) inspect the flexible oil lines;

(j) inspect the controllers and actuators;

(k) inspect the compressor by-pass door;

(m) refit the heat shield.

(14) Take the following action in relation to the refitting of the

cowls:

(a) check that no tooling, rags or other foreign objects

remain in the compartment;

(b) inspect the latches and fasteners for correct tension;

(c) inspect the inlet and cooling air ducting;

(d) inspect the landing and taxi light wiring;

(e) inspect the cowl flap linkage and engine drain lines.

18 19


11/89

(15) Chock the wheels and check the brake operation, then set

the park brake, start the engine and take the following

action to determine satisfactory performance in accordance

with the manuracturers recommendations:

(a) stabilise the engine temperatures and pressures;

(b) check the idle speed, mixture and the magneto switch

operation at low engine revolutions per minute;

(c) check the carburettor heat or alternate air operation;

(d) check the gyro or vacuum pressure indication;

(e) inspect the generator or alternator;

(f) check any unusual engine vibration or noises;

(g) check the engine response to throttle application;

(h) check each magneto and propeller governor for operation;

(j) check the static engine revolutions per minute, manifold

pressure and fuel flow;(k) check the idle cut-off operation.

(16) After taking the action described above, remove the cowls,

inspect the engine for oil, fuel or other fluid leaks, then replace

the cowls.

Section 3: The electrical system(1) Check the external and internal required placards.

Note: Reference should be made to the aircraft flight manual


(2) Take the following action in relation t o the air-conditioning

system:

(a) inspect the distribution system electrical components

and interwiring;

(b) inspect the heating and temperature control system;

(c) inspect the reon system electrical components and

interwiring;

(d) inspect the air cycle system electrical components and

interwiring.

(3) Take the following action in relation to the electrical power:

(a) inspect the AC generation system (including the

generator, invertor, regulator, interwiring, control relays

and switching);

(b) inspect the AC distribution system;

(c) inspect the DC generation system (including the

generator, regulator, transformer or rectifier units,

interwiring, control relays and switches);

(d) inspect the DC distribution system (including the busses,

circuit breakers or fuses, relays, switches and interwiring);


(e) inspect the starter generator;

(f) inspect the indication systems;

(g) inspect the batteries;

(h) inspect the external power system.

(4) Take the following action in relation to electrical equipment

and furnishing:

(a) inspect the flight compartment (including any spare

bulbs and fuses);

(b) inspect the passenger compartment (including any

spare bulbs and fuses);

(c) inspect the buffet or galley electrical systems, the

lavatory compartment electrical systems and the cargo

compartment electrical systems.

(5) Take the following action in relation to the following fire

protection systems:

(a) inspect the engine fire detection system;

(b) inspect any other fire and smoke detection systems;

(c) inspect the engine fire extinguishing system;

(d) inspect any other fire extinguishing systems.

(6) Inspect the electrical components and interwiring of the

following flight control systems:

(a) the trim and flap system;

(b) the lift dump and spoiler system;

(c) the lift augmenting system.


fuel distribution and dump system.


main and auxiliary hydraulic systems.


following ice and rain protection systems:

(a) the anti/de-ice systems;

(b) the ice detection and indication systems.

(10) Inspect the systems and components that give audible or

visual warnings.


following landing gear systems:

(a) the extension and retraction systems;

(b) the wheels, brakes and anti-skid system;

(c) the nose wheel steering system;

(d) the position and warning system;

(e) the anti-retract system.

20 21


12/89

(12) Inspect lights in or on the following areas:

(a) the flight compartment, the passenger compartment

and the cargo and service compartment;

(b) the exterior and emergency systems.

(13) Inspect the electrical components and interwiring of

pneumatic systems.

(14) Inspect the electrical or electronic control panels,

equipment racks and junction boxes.

(15) Inspect the electrical components and interwiring of

passenger, crew and cargo doors.


propeller control and anti/de-ice systems.

(17) Inspect the electrical harnesses, excluding the ignition

harness.


engine fuel and engine control systems.

(19) Take the following action in relation to the ignition:

(a) inspect the electrical power supplies;

(b) inspect the booster coils, vibrator systems and high

energy ignition systems;

(c) inspect the switching, including by performing an

insulation check of the magneto switch leads.

(20) Inspect the engine starting system.

Section 4: The instruments(1) Check the external and internal required placards.



(2) Take the following action in relation to the auto-flight

system:

(a) inspect the autopilot or the automatic flight control

system, including the flight director and stability control

augmentation;

(b) inspect the yaw damper system;

(c) inspect the speed-attitude correction system, including

the auto-trim and mach-trim.

(3) Inspect the flight control surface indication systems.

(4) Inspect the fuel pressure and quantity indication systems.

(5) Inspect the hydraulic power indication system.

(6) Inspect the ice protection indication system.

(7) Take the following action in relation to indicating and

recording systems:

(a) inspect the instrument and control panels;


(b) inspect the independent instrument systems, including

the inclinometers, indicators and clocks;

(c) inspect the recorders, including the flight data

recorders, performance or maintenance recorders.

(8) Take the following action in relation to navigation systems:

(a) inspect the flight environment data system, including:

(i) the central air data system; and

(ii) the pitot/static system, including instruments; and

(iii) the stall warning system;

(b) inspect the attitude and direction systems, including:

(i) the magnetic compass; and

(ii) the vertical attitude gyro system; and

(iii) the directional gyro system, including the magnetic

referenced systems; and

(iv) the electronic flight instrument system and multi-function displays;

(c) inspect the independent position determining systems,

including:

(i) the inertial navigation and reference systems; and

(ii) the ground proximity warning systems;

(d) inspect the flight management system, including the

flight management and performance management

systems.

(9) Take the following action in relation to oxygen systems:

(a) inspect the crew, passenger and portable systems;

(b) inspect the indicating systems.

(10) Inspect the pneumatic indicating systems, including the

pressure gauge and warning indicators.

(11) Take the following action in relation to the instrument

pressure or vacuum system:

(a) inspect the distribution system, including the filters,

manifolds, regulating valves, check valves and

plumbing;

(b) inspect the indicating system, including the pressure

gauge and warning system.

(12) Inspect the engine indicat ing systems, including fuel flow,

temperature and pressure.

(13) Take the following action in relation to the engine

indicating systems:

(a) inspect the power indicating system;

(b) inspect the temperature indication system;

(c) inspect the integrated engine instrument system.

22 23


13/89

(14) Inspect the oil indicating systems, including quantity,

pressure and temperature.

(15) Inspect the water injection indicating system.

Section 5: The radio system(1) Check the interior and exterior required placards including

frequency charts.



(2) Take the following action in relation to communication and

navigation systems:

(a) inspect the accessible interwiring, plugs and sockets;

(b) inspect the microphones, headsets and cords;

(c) inspect the fuses for adequacy of spares;

(d) inspect the antennae and antenna insulators;

(e) inspect the Emergency Location Transmitter/CrashLocation Beacon batteries for electrolyte leakage and

check that the battery lif e has not expired;

(f) inspect the removable units, mounting racks, vibration

isolators and bonding straps;

(g) inspect the switches and controllers;

(h) inspect the radio panel lamps for adequate illumination;

(j) inspect the radio indicators for legibility.

(3) Take the following additional action in relation to

communicat ion systems in aircraft equipped for I.F.R. flight:

(a) inspect the HF communication system, including for

correct performance by communication with ground

stations or by other means;

(b) inspect the VHF communication system, including for

correct performance by communication with ground

stations or by other means;

(c) inspect the audio system, including for correct

operation of all distribution and amplifying systems in

all modes of operation.(4) Take the following action in relation to navigation systems

in aircraft equipped for I.F.R. flight:

(a) check the ADF system for accuracy and correct

performance in all modes of operation within the limits

specified in section 108.34 of the Civil Aviation Orders;

(b) check the VOR system for correct performance within

the limits specified in section 108.34 of the Civil

Aviation Orders;

s y s t e m s o f m a i n t e n a n c e24

Civil AviationAdvisoryPublicationAugust 1996

This publication is

only advisory but

it gives the CASA

preferred method

for complying with

the Civil Aviation

Regulations.

It is not the only

method, butexperience has

shown that if

you follow this

method you will

comply with the

Civil Aviation

Regulations.

Always read

this advice in

conjunction with

the appropriate

regulations

Contents...

Systems of

maintenance

Independentinspections

Log book

requirements


(c) check the localiser system for correct performance

within the limits specified in section 108.34 of t he Civil

Aviation Orders;

(d) check the glideslope system for correct performance

within the limits specified in section 108.34 of t he Civil

Aviation Orders;

(e) check the marker system for correct performance in all

modes: an approved simulator may be used for these

tests;

(f) inspect the DME system;

(g) inspect the Omega/VLF system;

(h) inspect the Doppler navigation system;

(j) inspect the weather radar system;

(k) check the ATC transponder system for correct

performance in all modes using the self test facility:

select code 0101 for this test;

(l) inspect the radio altimeter system;

(m) inspect the ground proximity warning system; and

(n) inspect the electronic flight instrument system.

Part 3: Post inspection check3.1 On completion of each section of the inspection, check to

ensure that all tools, maintenance equipment or rags have

been removed from the aircraft and all panel, access doors,

detachable fairings and fillets have been correctly secured.

24 25


14/89

Revised CAAP 41-2(1)

Maintenance programsfor class B aircraftThe relevant regulations and other references

Part IVA of Civil Aviation Regulations (CARs), particularly

Subdivision B, CARs 41, 42, 42A, 42B and 42C dealing with

maintenance programs for class B aircraft

CARs 2A, 42V, 42ZC, 42ZE and 42ZP

The CASA Maintenance Schedule as set out in Schedule 5

of the CARs

Civil Aviation Order (CAO) 100.5, General Requirements in

respect of Maintenance of all Australian Aircraft

CAAP No. 42-1, Inappropriate maintenance programs for

class B aircraft.

Who this CAAP applies to Certificate of Registration holders for class B aircraft

Certificate of Approval holders for class B aircraft

maintenance

Licensed Aircraft Maintenance Engineers

Holders of an Airworthiness Authority

Why this publication was writtenRegulation 41 of the CARs requires that a maintenance program

must be in force for the maintenance of a class B aircraft.

This publication gives guidance on maintenance programs,

identifies the maintenance schedules acceptable to CASA as

defined by regulation 42, 42A, 42B and 42C and the appropriate

certification requirements under regulation 42ZE for the

certification for the completion of maintenance for this class of

aircraft.

Status of this CAAPThe format and layout of t his CAAP has been completelyrevised and replaces CAAP 41-2(0) dated 1 March 1992.

For further informationContact the CASA Airworthiness District Office closest to you.

Civil Aviation Advisory Publication

April 1996


The Certificate of Registration holder for a class B aircraft must

not fly the aircraft and must ensure that the aircraft does not start

a flight unless there is a maintenance program for the aircraft and

the program includes provision for the maintenance of all aircraft

components fitted to or provided in the aircraft.

The Regulations provide for one of three maintenance program

options which may be based on either:

the manufacturer s maintenance schedule, under CAR 42A; or

the CASA Maintenance Schedule 5, under CAR 42B; or

a maintenance program developed by the Certificate of

Registration holder and approved by CASA or an authorised

person under CAR 42M.

In providing these options, CASA expected that industry would

recognise the manufacturers maintenance schedule as the most

appropriate for aircraft maintenance.

Many Certificate of Registration holders, however, have elected to

use the CASA Maintenance Schedule 5 believing that compliance

with the CASA Schedule 5, the applicable Airworthiness Directives

(ADs) and the Airworthiness Limitations would satisfy all the

necessary maintenance required for continued airworthiness.

While election of the CASA Maintenance Schedule 5 meets

the minimum requirements set by CASA, the schedule does

not address supporting material contained in the instructions

issued by manufacturers for continued airworthiness, such as

special inspections, structural integrity inspections, corrosion

control programs and continuing airworthiness inspection

programs provided by the manufacturer. Nor does it address the

requirements for those persons carrying out maintenance to do so

in accordance with approved maintenance data (CAR 2A) which is

a consideration of how maintenance tasks shall be performed, e.g.

an inspection.

In the absence of a requirement for a major inspection, the

importance of the instructions issued by manufacturers for

continued airworthiness are not only relevant but essential when

considering that many class B aircraft in Australia are over twenty

(20) years old.

The Certificate of Registration holder for a class B aircraft must

ensure that any maintenance required to be carried out on the

aircraft (including aircraft components fitted to or provided in the

aircraft) by the aircrafts maintenance program is carried out at

intervals determined in accordance with schedules which form part

of that program.

26 27


15/89

The Certificate of Registration holder for a class B aircraft is

responsible for establishing a maintenance program for the

aircraft, which is to be specified in the aircrafts Log Book

Statement, and which may consist of one of t he following

programs applicable to the aircraft:

A program which includes the manufacturers maintenance

schedule, and:

as necessary, CASA Maintenance Schedule 5 instruments

and radio (avionics) inspections;

the manufacturers Airworthiness Limitations;

Australian Airworthiness Directives;

Consideration should, for the purposes of continuing

airworthiness, also include:

special inspections - (manufacturers/modifications/

repairs,etc.);

the manufacturers continuing airworthiness inspection

program;

the manufacturers supplementary and corrosion

inspection programs;

A program which includes the CASA Maintenance Schedule

5, and:

the manufacturers Airworthiness Limitations;

Australian Airworthiness Directives;

Consideration should, for the purposes of continuing

airworthiness, also include:

special inspections - (manufacturers/modifications/

repairs,etc.);

the manufacturers continuing airworthiness inspection

program;

the manufacturers supplementary and corrosion

inspection programs;

A program which consists of an approved maintenance

program under CAR 42M.

MORE THAN ONE MANUFACTURERSMAINTENANCE SCHEDULEIf more than one manufacturers maintenance schedule is available

for the aircraft, e.g., periodic or progressive care, you should take

care to nominate, and remain with one schedule only. There

should be no mix and matching. Also in selecting your schedule,

make sure that the schedule addresses the fit-out of your aircraft

and that it relates to the latest revision of the instructions of the

manufacturer for continued airworthiness.


DEFICIENT INSTRUCTIONS/INFORMATIONDeficiencies in instructions issued by manufacturers, or in

manufacturers schedules, generally relate to lack of information

concerning optional instrument and radio systems and roll

equipment. The periodic maintenance of such systems and

associated equipment is best undertaken by reference to the CASA

Maintenance Schedule 5 for when to do it and in accordance

with the approved maintenance data (CAR 2A) for how to do it.

MAINTENANCE RELEASE PERIODAll maintenance required at the nominated inspection for

maintenance release issue must be certified prior to the

maintenance release issue. The periodic maintenance release

inspection must not exceed 100 hours time-in-service or a calendar

period of twelve months, whichever occurs first. To ensure that

no maintenance will be overlooked between periodic inspections,

all maintenance required to be carried out between periodic

inspections are to be endorsed on the Maintenance Required

section of the maintenance release.

CASA MAY GIVE DIRECTIONS FOR INADEQUATEMANUFACTURERS MAINTENANCE SCHEDULESIf CASA thinks t he elected manufacturers maintenance

schedule does not adequately provide for the continued

airworthiness of the aircraft, CASA may, to remedy the

inadequacy, give directions requiring the Certificate of

Registration holder to do either or both of the following, in

addition to comply with the schedule:

take the action described in the directions; and/or

prepare documents containing requirements specified in

the directions that are to be complied with.

Once the direction has been given to take particular action, the

direction then forms part of the aircrafts maintenance program.

CASA MAY DECLARE MANUFACTURERS

MAINTENANCE SCHEDULE INADEQUATECASA may direct under Regulation 42A (6), in the interests of

the safety of air navigation, that the manufacturers maintenance

schedule for a type or model of aircraft must not be used as the

maintenance schedule [see also CAO 100.5]. In this case the

Certificate of Registration holder cannot elect the schedule, but

must either adopt the CASA Maintenance Schedule 5 or develop

and seek approval of a maintenance program.

28 29


16/89

Certificate of Registration holders should be aware that

selection of the CASA Maintenance Schedule 5 is limited in its

application in that t he schedule:

may not be used for helicopters;

in many cases, may not address all relevant periodic

maintenance requirements (schedules, etc.) for a particular

aircraft; and

will not cover the requirements for continuing

airworthiness (eg, service bulletins, service letters, etc.).

For this reason, notwithstanding legislative requirements, CASA

recommends Certificate of Registration holders and/or Certificate

of Approval holders (approved organisations) will need to carefully

evaluate the aircraft manufacturers manuals, in particular the

associated maintenance schedule, and in the absence of any

justifiable reason why the maintenance program cannot be used,

elect and maintain the aircraft to that maintenance program.

ADDITIONAL INSTRUCTIONS TURBINE ENGINESFITTEDIf an aircrafts maintenance schedule is the CASA Maintenance

Schedule 5 and the aircraft has a turbine engine, then all

instructions issued by the engine manufacturer for the continued

airworthiness of the engine must be included and form part of the

aircrafts maintenance program.

Once an election has been made and the Certificate of Registration

holder becomes aware that the maintenance schedule contained

in the aircrafts maintenance program becomes inadequate or

defective and does not adequately provide for the continuing

airworthiness of the aircraft the holder must report the matter

to CASA as required by CAR 42. The Certificate of Registration

holder must then either choose to replace the aircraft maintenance

schedule with another schedule or request CASA or an authorised

person to approve a maintenance program for the aircraft. Such an

election must be made in writing to your local CASA Airworthiness

District Office.

Where the Certificate of Registration holder desires under CAR

42J, or is directed by CASA under CAR 42K/CAR 38, to develop

a maintenance program for the aircraft, that program must

be approved by CASA or an authorised person and should

contain, as a minimum, the following:


the name of the Certificate of Registration holder;

the type, model and registration mark of the aircraft to

which the maintenance program applies;

schedules which set out:

- the maintenance to be carried out at specified intervals

and the intervals between maintenance;

- the identity of the inspection to be complied with for the

issue of a maintenance release;

- structural integrity inspections;

- special inspections, including corrosion control,

independent, and weight and balance inspections;

- components subject to overhaul and the intervals

between overhauls;

- components subject to retirement and their retirement

life;

- continuing Airworthiness Inspection Programs;

the maintenance required following lightning strikes, or

when abnormal flight or ground loads have been imposed

on the aircraft;

MEL control procedures (if MEL is approved for the

aircraft); and

amendment procedures for the maintenance program.

Those parts of the maintenance program required by the schedules

and the maintenance required following a lightning strike, etc.,

are to comply with the requirements specified in the approved

airworthiness/maintenance data for the aircraft, unless otherwise

approved or directed by CASA.

Where the details in items above are identical to the

recommendations contained in the approved airworthiness/

maintenance data for the aircraft, the maintenance program need

only contain a reference to the documents in Logbook Statement

Part 1, containing those details.

REQUESTING APPROVAL OF ALTERATIONS TO ANAPPROVED MAINTENANCE PROGRAMThe Certificate of Approval holder may request CASA or an

authorised person to approve proposed alterations to the

maintenance program.

CASA or the authorised person will take into account the aircrafts

relevant manufacturers maintenance schedule (if any) when

considering the approval of the alterations.

30 31


17/89

CASA MAY DIRECT CHANGES TO AN APPROVEDMAINTENANCE PROGRAMCASA may give directions requiring the Certificate of Registration

holder to alter the approved maintenance program or correct any

inadequacies in the program.

All instructions issued by manufacturers, including service bulletins

(refer CAR 2A) that deal with how to carry out maintenance must

be complied with, unless CASA or an appropriately authorised

delegate has explicitly approved an alternative procedure. This

applies regardless of the maintenance program that has been

chosen for the aircraft. Please also see CAR 42V regarding use of

approved maintenance data and CAR 42ZP regarding certification

only to be made where maintenance has been carried out in

accordance with approved data.

ASSESSING MANUFACTURERS DATAThe Certificate of Registration holder needs to confirm thatwhen assessing the instructions issued by manufacturers and

the associated schedules, the data addresses the continuing

airworthiness of the aircraft. The Certificate of Registration holder is

responsible for considering the data to confirm whether an elected

manufacturers maintenance schedule is deficient or otherwise.

If the assessment indicates that the elected schedule is deficient,

then the Certificate of Registration holder is responsible for the

reporting and rectification action as required by CAR 42 - Defective

or inappropriate maintenance program.

As part of the maintenance control function, Certificate of

Registration holders are required to compile a Log Book Statement

Part 1 identifying the aircrafts maintenance program and other

inspections to be complied with. [refer CAR 50A and CAO 100.5]

As previously discussed, there are three maintenance program

options available to the Certificate of Registration holder. The

following typically represent log book statements for each of the

three options that should be considered when compiling the log

book statement:

TYPICAL LOG BOOK STATEMENT CONSIDERATIONSWHEN USING THE CASA MAINTENANCE SCHEDULE 5This aircraft is to be maintained in accordance with the following:

the CASA Maintenance Schedule 5.

the schedule of Airworthiness Limitations contained in the

latest revision of the manufacturers maintenance manual

applicable to this aircraft for all time-lifed components.

all Airworthiness Directives (ADs) applicable to this aircraft.


ADs indicating compliance at major inspection are to be

complied with at intervals not greater than three years, or one-year

intervals for aircraft used in agricultural operations.

all inspections which are listed in the:

- approved maintenance/airworthiness data relating to

modifications/repairs incorporated in this aircraft; and

- approved maintenance/airworthiness data relating to

modifications/repairs incorporated in components installed in

this aircraft.

any other requirements recommended by the aircraft or

component manufacturer for the continuing airworthiness of

the aircraft or component. e.g. Corrosion Prevention Control

Programs (CPCPs), or Continuing Airworthiness Inspection

Programs (CAIPs).

TYPICAL LOG BOOK STATEMENT CONSIDERATIONSWHEN USING THE MANUFACTURERSMAINTENANCE SCHEDULEThis aircraft is to be maintained in accordance with the following:

the instructions issued by the manufacturer and the associated

maintenance schedule contained in the latest revision of the

manufacturers maintenance manual.

any instructions for the continued airworthiness of the aircraft

specified by the aircraft or component manufacturer from time

to time;

the CASA Maintenance Schedule 5 for instrument and radio

components and systems not adequately covered by the

manufacturers schedule, as appropriate;

the schedule of Airworthiness Limitations contained in the

latest revision of the manufacturers maintenance manual

applicable to the aircraft for all time-lifed components.

ADs indicating compliance at major inspection, are to be

complied with at intervals not exceeding three years, or one

year intervals for aircraft used in agricultural operations.

all inspections which are listed in the:

approved airworthiness/maintenance data relating to

modifications/repairs incorporated in this aircraft; and

approved airworthiness/maintenance data relating to

modifications/repairs incorporated in components installed

in this aircraft.

any other requirement recommended by the aircraft or

component manufacturer for the continuing airworthiness of

the aircraft or component. e.g. Corrosion Prevention Control

Programs (CPCPs), or Continuing Airworthiness Inspection

Programs (CAIPs).

Civil AviationAdvisoryPublicationAugust 1997

This publication is

only advisory but

it gives the CASA

preferred method

for complying with

the Civil Aviation

Regulations.

It is not the only

method, but

experience has

shown that if

you follow this

method you will

comply with the

Civil Aviation

Regulations.

Always read

this advice in

conjunction with

the appropriate

regulations.

Contents...

Systems of

maintenance

Independentinspections

Log book

requirements

32 33


18/89

TYPICAL LOG BOOK STATEMENT CONSIDERATIONSFOR AN APPROVED MAINTENANCE PROGRAMThis aircraft is to be maintained in accordance with the following:

the current approved maintenance program.

state where located

Note: The approved maintenance program may be attached to the

log book attachment, Log Book Statement Part 1 or alternatively

may be held as an independent document by the Certificate of

Approval holder (maintenance organisation) normally responsible

for the carrying out and certifying for completion of maintenance

on the aircraft.

CertificationRegulation 42ZE requires that a person who carries out

maintenance on an aircraft must ensure that completion of

the maintenance is certified in accordance with an approvedsystem of certification or the CASA system of certification

(Schedule 6 of the CARs) as applicable.

Separate certifications relating to each inspection shall be

made in the appropriate sections of the aircraft log books

pursuant to the pertinent CARs.


CAAP No: 39-1 (1)

Maintenance requirementsfor class A aircraft

The relevant regulations and other referencesThis publication should be read in conjunction with Civil

Aviation Regulations 39 (1), 42ZE and Schedule 6 of the CARs.

Who this CAAP applies to Certificate of Registration Registered Operators for class A

aircraft

Holders of a Certificate of Approval for maintenance

of class A aircraft

LAMEs and Maintenance Authority holders

Pilots and flight engineers engaged in RPT operations or

who operate transport category aircraft

Why this CAAP was writtenRegulation 39 of the CARs requires that class A aircraft must

have in force a system of maintenance approved by CASA. This

publication describes the preferred procedures to be followed for

the development and approval of that system of maintenance and

the certification requirements of regulation 42ZE.

Status of this CAAPThis is the second issue of CAAP 39-1. It has been amended

to clarify the maintenance requirements for class A aircraft

by deletion of one sentence. The sentence referred to

maintenance options available to class B aircraft and could

have caused confusion.

This is an interim amendment to rectify this aspect of the CAAP

only. CASAs extensive regulatory review process may result in

further changes to this and other CAAPs.

Systems of maintenanceThe Certificate of Registration holder of a class A aircraft is

required, by regulation 39 of the CARs, to submit for approval,

to CASA or an authorised person, a system of maintenance.

The system of maintenance is to be referred to in the aircrafts

Log Book Statement Part 1 or an approved alternative and

should include, as applicable:

the name of the Certificate of Registration holder;

the type, model and registration mark of the aircraft to

34 35


19/89

which the system applies;

maintenance schedules which include:

- maintenance tasks to be performed at specified intervals

and the intervals between the maintenance;

- the identity of the inspection to be completed for the issue

of a maintenance release;

- structural inspections;

- a list of components subject to an overhaul life

and the intervals between the overhauls, based

upon the manufacturers recommendations and the

recommendations contained in the Maintenance Review

Board (MRB) document for the aircraft;

- a list of components subject to retirement and the

retirement life.

the maintenance required following a lightning strike or

abnormal flight or ground loads;

amendment procedures for the system of maintenance;

servicing procedures including specification and grade of

fluids;

maintenance practices and procedures; and

if not covered by a Maintenance Control Manual:

- MEL control procedures;

- maintenance control procedures, including the planning

system to ensure that all maintenance is completed and

certified for on or before the due time-in-service or date.

If the Certificate of Registration holder is using approved

maintenance data as the system of maintenance, the system

need only contain a reference to that data.

Maintenance schedules are, unless otherwise approved or

directed by CASA or an authorised person, to comply with the

requirements specified in the approved maintenance data or, if

applicable, the current Australian Maintenance Requirements

Documents (AMRD) for the aircraft.

Where a class A aircraft is used in extended range operations

approved under CAO 20.7.1B, the system of maintenance

must also include provision for t he practices and procedures

required to comply with the additional airworthiness

requirements, including those specified in the latest issue of

airworthiness directives and other approved maintenance data.


Independent inspectionsAs the system of maintenance will be assessed against the

requirements of the current edition of the manufacturers

instructions, CARs and CAOs, it is advisable to use these

documents as guidance when developing the system.

The definition for Approved Maintenance Data, in CAR 2A,

specifies data that is in force from time to time. This means

that the data used when performing maintenance must be the

current edition in force at the t ime the maintenance was being

performed.

Regulation 42G of the CARs requires an independent

inspection, to ensure correct assembly and f unction of

the flight control systems of an aircraft, t o be carried out

and certified prior to the certification being made for the

completion of maintenance of any part of an aircraft control

system involving:

assembly;

adjustment;

repair;

modification; or

replacement.

Correct assembly and function means:

that the control system and its components have been

correctly assembled and adjusted;

locking devices have been made safe; and

the controls have full and free movement, in the correct

sense, throughout their operating range.

For the purposes of independent inspections, the flight control

system of an aircraft includes:

the main control surfaces;

lift and drag devices;

trim and feel systems;

flight control lock systems;

collective pitch system;

cyclic pitch system;

yaw system;

associated operating mechanisms and/or control systems,

including servo systems; and

ballonet systems in airships.

36 37


20/89

Log book requirements

The first inspection will be performed and certified by the

holder of a:

valid appropriate AME licence; or

valid appropriate maintenance authority.

The second inspection will be performed and certified by

a person, other than the person who performed the first

inspection, who is the holder of :

a valid appropriate AME licence;

a valid appropriate maintenance authority; or

a current pilot licence, other than a student pilot licence, or

a current flight engineer licence, rated for the aircraft t ype

concerned.

Where adjustments of a control system are required

following either the first or second inspection, the appropriate

inspections should be repeated and certified.

The independent inspection and certification requirements

are not required for the connection and disconnection of

optional dual controls which are normally converted from one

configuration to another without the use of tools.

Unless using an approved alternative recording system

under regulation 50B, the instructions issued by CASA for the

compilation of the aircrafts log book are to be complied with.

Regulation 50A requires the Certificate of Registration holder

to keep a log book for the aircraft. Reference to the aircrafts

maintenance schedule will be specified in t he aircrafts Log

Book Statement Part 1. Approved variations to this schedule

will be in the aircrafts Log Book Statement Part 2, and any

exemptions granted will be contained in the aircrafts Log Book

Statement Part 3. If using an approved alternative to the log

book, the alternative records must contain reference to t he

aircrafts system of maintenance.

The Certificate of Registration holder will complete 2 copies of

a Log Book Statement Part 1 (available from any CASA District

Office) nominating the maintenance schedules, inspection

schedules, maintenance release period, maintenance release

inspection and ownership details. When completed, the

Certificate of Registration holder will attach one copy of the

Log Book Statement Part 1 to the front of the aircrafts log book

and submit the second copy to the airworthiness office having

administrative control of the aircrafts records within 7 days of

commencing operations. These schedules must be updated to

38

Civil AviationAdvisoryPublication

March 1992

Contents...

1 Daily Inspection

Schedule

2 Periodic Inspection

Schedule

Systems of

maintenance


reflect the latest information available from t he manufacturer

and CASA.

Serial numbered items contained, or referred to, in the

schedule for time-lifed components may also have a Lifed

Component Control Record card contained in the body of

the aircrafts log book. This record card is t o be used as a

maintenance planning document and does not replace the

Component History Card also contained in the aircrafts log

book.

The Recurring Airworthiness Directive Control Record and

the Recurring Maintenance Control Record are maintenance

planning documents and do not replace the requirement for

compliance and certification to be made in the Aircraft or

Engine Maintenance Certification Log sections of the log book.

s y s t e m s o f m a i n t e n a n c e38 39


21/89

CAAP No: 42B-1 (0)

CAA Maintenance Schedule

IMPORTANTWhen the Certificate of Registration holder elects to use the

CAA Maintenance Schedule the election includes both the Daily

and the Periodic Inspection Schedules.

The time-in-service between Periodic Inspections is to be 100

hours aeroplane time-in-service or 12 months, whichever

is the earlier, and for aeroplanes below 5700 kg engaged in

private operations this inspection may be performed annually

irrespective of hours flown. The completion of this inspection,

along with any defect rectifications performed as a result of

this inspection, is to be certified for in the aeroplanes log book.

PURPOSERegulation 42B of the CARs provides that the Certificate of

Registration holder of class B aeroplanes may use the CAA

Maintenance Schedule. This publication contains that schedule

as a reprint of the original schedule contained in the CARs,

modified to include provision for the certification of each task

and a final category and co-ordination certification. This will

allow this schedule to be copied and utilised as work sheets.

These schedules have been designed as an option to the

manufacturers maintenance schedules. Before the Certificate

of Registration holder elects t o use this schedule, however, it

is recommended that a study be made of the manufacturers

schedules as it is considered that these are generally more

appropriate for the maintenance of the aeroplane.

STATUSThis is the first issue of CAAP 42B-1, and will remain current

until withdrawn or superseded.

REFERENCESThis publication should be read in conjunction with Civil

Aviation Regulation 42B, and CAAP 41-2.

c i v i l a v i a t i o n s a f e t y a u t h o r i t y

HOW TO OBTAIN COPIES OF THIS PUBLICATIONCopies of this publication may be obtained from:

Civil Aviation Authority Publication Centre

P.O. Box 1986

Carlton South

Victoria 3053

1: DAILY INSPECTION SCHEDULE1.1 The daily inspection is to be carried out, and certified,

before the first flight on each day the aircraft is operated.

1.2 The Daily Inspection Schedule has been prepared tocover various types of aeroplanes and refers to a number

of different design features and types of construction.

Only those items applicable to the aeroplane type being

inspected are to be observed. It is not necessary to open

inspection panels, other than those associated wit h engine

oil or dipsticks for this inspection, but where the powerplant

has quick access cowlings, it is recommended that use

should be made of the increased accessibility to the engine

in completing this inspection.

1.3 The person performing the daily inspection must be an

appropriate person authorised to do so and must certify, in

accordance with the approved system of certification, on

the aircrafts maintenance release for the completion of this

inspection. Appropriate persons for daily inspections are:

(a) the pilot-in-command;

(b) a person holding a valid pilot licence endorsed for the

aircraft type;

(c) the holder of a valid appropriate aircraft maintenanceengineer licence;

(d) the holder of a valid appropriate maintenance authority

covering the aircraft being inspected; or

(e) provided that person has sufficient knowledge and

experience to carry out the inspection, the holder of an

AME licence in either the airframe or engine category but

not necessarily rated for the aircraft or engine type or

group, in respect to all AME licence categories.

s y s t e m s o f m a i n t e n a n c e40 41

Telephone (008) 331676

(008) 334191

(03) 342 2000

Fax (03) 347 4407


22/89

ITEM SCHEDULE1. Check that ignition switches are OFF.

2. Check propeller blades are free from cracks, bends and

detrimental nicks, that the propeller spinner is secure and

free from cracks, there is no evidence of oil or grease

leakage from the propeller hub or actuating cylinder and

that the propeller hub, where visible, has no evidence of any

defect which would prevent safe operation.

3. Check that induction system and all cooling air inlets are free

from obstruction.

4. Check the engine, where visible, for fuel and oil leaks and

that the exhaust system is secure and free from cracks.

5. Check that oil quantity is within the limits specified by

the manufacturer for safe operation and that oil filler cap,

dipstick and inspection panels are secure.

6. Check that engine cowlings and cowl flaps are secure.

7. Check that landing gear tyres are free from cuts or other

damage, have no plies exposed and by visual inspection are

adequately inflated.

8. Check that landing gear oleo extensions are within normal

static limits and that landing gear doors are secure.

9. Check wing, fuselage, empennage and, if applicable, canard

surfaces are free from damage, ensure inspection panels,

flight control surfaces and devices are secure.

10. Check interplane and centre section struts are free from

damage and that bracing wires are of correct tension.

11. Check pitot heads and static ports are free from obstruction

and that pitot cover is removed or is free to operate.

12. Check fuel tank filler caps, chains, vents and associated

access panels for security and condition.

13. Check that all flight controls, trim systems and high lift

devices have full and free movement in the correct sense.

14. Check that all radios and antennae are secure and that wherevisible, radio units and interwiring are secure.

15. Check that all drain holes are free from obstruction.

16. Remove any deposits of frost, snow or ice from wings, tail

surfaces, canards, propeller and windscreen.

17. Check that each tank sump and fuel filter is free from water

or foreign matter by draining a suitable quantity of fuel into

a clean transparent container.

18. Check windscreen for cleanliness and condition.

19. Check instruments are free from damage, for legibility and

security.

c i v i l a v i a t i o n s a f e t y a u t h o r i t y

20. Check that seat belts, buckles and inertia reels are free from

damage, secure and function correctly.

ADDITIONAL ITEMS FOR AGRICULTURALAEROPLANES21. Check that agricultural equipment (e.g. hopper, hopper lid

and fasteners, spray tanks, spray pump and lines, booms

and boom supports, dump doors, fan and fan brake) are

secure.

22. Check that dump and f an brake mechanisms are free from

obstructions and operate correctly.

ADDITIONAL ITEMS FOR SEAPLANES23. Check hull and floats are free from damage, corrosion and

water accumulation.

24. Check float attachment struts, bracing wires and