Aviation Australia CASR Part 42 PDF

The holder of the Type Certificate or Production Certificate under which such a propeller, blade or hub is manufactured must: Legibly mark the information on it by a fireproof method, or Attach to it a manufacturer’s data plate on which that information is legibly marke...

The holder of the Type Certificate or Production Certificate under which such a propeller, blade or hub is manufactured must: Legibly mark the information on it by a fireproof method, or Attach to it a manufacturer’s data plate on which that information is legibly marked by a fireproof method, and If information is marked on a propeller, blade or hub, it must be marked in a way that ensures it is not likely to be defaced. If a manufacturer’s data plate is attached to a propeller, blade or hub, the plate must be attached to a non‑critical surface in a way that ensures the plate is not likely to be defaced or become detached during normal service, nor to be lost in an accident. Propeller identification A person must not remove or alter a manufacturer’s data plate from an aircraft propeller, propeller blade or propeller hub if the person does not have CASA’s written approval to do so. 2024-10-01 B-10c Aviation Legislation Page 250 of 328 CASA Part 66 - Training Materials Only  Part 42 of CASR 1998 Part 42 CASR Part 42 sets out Continuing Airworthiness requirements, including requirements for carrying out maintenance on aircraft and aeronautical products. It covers the requirements for a Continuing Airworthiness Management Organisation (CAMO) and authorises CASA to issue a MOS for CASR Part 42. At this stage, CASR Part 42 is applicable only to Australian aircraft and their aeronautical products when they are operated under a Regular Public Transport (RPT) Air Operator’s Certificate (AOC). The CAMO, the AOC holder and the Registered Operator may all be the same person. © Aviation Australia Continuing airworthiness 2024-10-01 B-10c Aviation Legislation Page 251 of 328 CASA Part 66 - Training Materials Only  Legislative Documents The two CASR Part 42 legislative documents are: CASR Part 42 – The regulation Part 42 Manual of Standards (MOS) – The requirements These two legislative documents are supported by: The Acceptable Means of Compliance and Guidance Material (AMC/GM), and Advisory Circulars (AC). GM is identified by grey shaded text. Guidance material Part 42 is part of a suite of CASRs for aircraft maintenance; it provides the overall policy direction for the entire maintenance suite of the CASRs. It is based on EASA’s Part M. Part 42 provides for all the requirements necessary to ensure any actions performed support the continuing airworthiness of Australian aircraft. The mention of a Commission Regulation is a cross-reference to a similar provision in Part M of the European Commission Regulation on the continuing airworthiness of aircraft and aeronautical products, parts and appliances and on the approval of organisations and personnel involved in these tasks. 2024-10-01 B-10c Aviation Legislation Page 252 of 328 CASA Part 66 - Training Materials Only  Part 42 Subparts Part 42 Structure CASR Part 42 is divided into subparts (Subpart A to Subpart O). Subparts are further divided into divisions. Part 42 subparts 2024-10-01 B-10c Aviation Legislation Page 253 of 328 CASA Part 66 - Training Materials Only  CASR Subpart 42.A: Preliminary CASR Part 42 was written to set out Continuing Airworthiness requirements, including requirements for carrying out maintenance for aircraft and aeronautical products, and to provide CASA with the power to issue a MOS for Part 42. CASR Part 42 is applicable to Australian aircraft classified as large aircraft and their aeronautical products when they are operated under an AOC. An A380 parked in storage CASR Subpart 42.B Requirements for Registered Operators Continuing Airworthiness requirements Record-keeping requirements in relation to authorisations under Regulation 42.630. Subpart 42.B sets out the Continuing Airworthiness requirements that apply to the Registered Operator (RO) of the aircraft. It details Continuing Airworthiness requirements to be ensured by the RO before permitting an aircraft to fly. 2024-10-01 B-10c Aviation Legislation Page 254 of 328 CASA Part 66 - Training Materials Only  CASR Subpart 42.C Continuing Airworthiness Management Requirements for the Person Responsible for Continuing Airworthiness for Aircraft Subpart 42.C sets out requirements relating to the continuing airworthiness of an aircraft that apply to the person responsible for continuing airworthiness for the aircraft, including: Continuing Airworthiness management tasks Continuing Airworthiness records – all aircraft Continuing Airworthiness records system Information about aircraft Substantiating documents Flight technical log Record of next maintenance due to be carried out Record of utilisation information Retention and transfer of records Major defects—reporting and investigating. If the CAMO becomes aware that there is a defect on the aircraft, the defect must be rectified unless aircraft operation with the defect is permitted by: The Minimum Equipment List (MEL) for the aircraft The Configuration Deviation List (CDL) for the aircraft An SFP is issued for the flight. 2024-10-01 B-10c Aviation Legislation Page 255 of 328 CASA Part 66 - Training Materials Only  CASR Subpart 42.D Maintenance Subpart 42.D covers Continuing Airworthiness requirements for maintenance. Requirements for carrying out maintenance on an aircraft or an aeronautical product include: Permissions for Section 20AB of the Act – aircraft and aeronautical products. The requirements for critical control system maintenance include: Requirements for independent inspections after critical control system maintenance Requirements for dealing with defects Reporting of defects. Requirements for recording maintenance of aircraft or aeronautical products include: Requirements for making and keeping records for an AMO which carries out maintenance on an aircraft or aeronautical product. CASR Subpart 42.E Aeronautical Products Subpart 42.E covers Continuing Airworthiness requirements for aeronautical products: Requirements for fitting parts and using materials Requirements for controlling unserviceable and unsalvageable parts Requirements for controlling unapproved parts 2024-10-01 B-10c Aviation Legislation Page 256 of 328 CASA Part 66 - Training Materials Only  Unapproved Parts A part is unapproved if: The part is counterfeit; The part has not been approved; The part not a standard part, and Has been produced other than under an authorisation (however described) granted by CASA or a NAA, or Maintenance has been carried out on the part other than in accordance with an authorisation (however described) granted by CASA or an NAA. The part has been modified other than in accordance with a design for which there is a Part 21 approval. The part is unserviceable or unsalvageable. The part has been fraudulently represented as serviceable or the part is accompanied by a fraudulent document. Control of Unapproved Parts If a person becomes aware that a part is unapproved, they must ensure that steps are taken within 2 days after they first became aware that the part was unapproved. The steps are: Applying a label, or attaching a tag, to the part recording sufficient information to identify the part, including the part’s name, part number and serial number (if any). Determining the origin of the part, including any information about the aircraft or aeronautical product from which the part has been removed, if relevant and if known to the person. Determining the reason that the part is unapproved. Storing the part, and any documents that accompanied the part, separately from serviceable aeronautical products and in a secure location. Making a report about the part. 2024-10-01 B-10c Aviation Legislation Page 257 of 328 CASA Part 66 - Training Materials Only  Reporting Unapproved Parts The person must give a report about the part to: CASA, and If the person knows that the part was fitted to an aircraft or aeronautical product – the Type Certificate Holder or Foreign Type Certificate Holder for the aircraft or aeronautical product, and If the person knows that the part was fitted to an aircraft – the person responsible for continuing airworthiness for the aircraft. The report must be made to CASA on Form 1058. Action by CASA following a Report of Unapproved Parts If CASA receives a report about a part, CASA may, by notice in writing, require the person who made the report to give CASA further information in relation to the part within a period specified in the notice or tell the person who made the report that the part does not have to be kept. 2024-10-01 B-10c Aviation Legislation Page 258 of 328 CASA Part 66 - Training Materials Only  Action Required If Parts Are Not Required to Be Kept If CASA has given a person a notice in relation to a part, the person must, within 2 days after receiving the notice: If the person is not the owner of the part – give the part to the owner of the part or store the part, and any documents that accompanied the part, separately from serviceable aeronautical products and in a secure location or mutilate the part, or arrange for the part to be mutilated, in a manner that ensures the part cannot be used in aviation If the owner of a part receives the part, the owner must, within 2 days of receiving the part, store the part separately from serviceable aeronautical products and in a secure location or mutilate the part, or arrange for the part to be mutilated, in a manner that ensures the part cannot be used in aviation. CASR Subpart 42.E covers Continuing Airworthiness requirements for aeronautical products 2024-10-01 B-10c Aviation Legislation Page 259 of 328 CASA Part 66 - Training Materials Only  CASR Subpart 42.F Requirements for 42.F Approved Maintenance Organisations (AMO) Subpart 42.F covers Continuing Airworthiness requirements for AMOs: Approval of Subpart 42.F Organisations Changes to Subpart 42.F Organisations Requirements and offences for Subpart 42.F Organisations. CASR Subpart 42.G Continuing Airworthiness Management Organisations (CAMOs) CASR Subpart 42.G covers Continuing Airworthiness Management Organisations (CAMOs): Approval of CAMOs Changes to CAMOs Authorisation of pilot licence holders and authorisation to provide maintenance services Requirements for and offences by CAMOs A CAMO may issue an authorisation to provide specified maintenance services for the specified type and model of aircraft it manages to a pilot licence holder. 2024-10-01 B-10c Aviation Legislation Page 260 of 328 CASA Part 66 - Training Materials Only  CASR Subpart 42.H Maintenance Certification and Certificate of Release to Service (CRS) This subpart covers Continuing Airworthiness requirements for maintenance certification and CRS: Maintenance certification for maintenance carried out on aircraft (and aeronautical products) Responsibility for maintenance certification Requirements for performing maintenance certification Performance of maintenance certification CRS for aircraft Responsibility for issuing a CRS Requirements for issuing a CRS Form, content and issue of a CRS Record‑keeping. This subpart provides for a two-tier system of certification for completion of maintenance on aircraft or aeronautical products. The two elements of the system are: Maintenance certification and Certificate of Release to Service (CRS). Maintenance certification must be performed after completion of a maintenance task on an aircraft. A CRS must be issued before an aircraft or an aeronautical product is released to service after maintenance. It effectively combines the ‘certification of co-ordination’ and ‘final certifications’ and is issued on completion of all maintenance, before the aircraft flies. 2024-10-01 B-10c Aviation Legislation Page 261 of 328 CASA Part 66 - Training Materials Only  CASR Subpart 42.I Airworthiness Reviews and Airworthiness Review Certificates (ARCs) Subpart I covers the ARC issuance process, including: Issuance of ARCs Extensions to ARCs Airworthiness review procedure Administration. There is a relationship between the ARC and the CofA: all large aircraft and all aircraft that operate under an AOC must have an ARC. The basis of the ARC is a periodic airworthiness review by the CAMO. Airworthiness Review Certificate The Airworthiness Review must be carried out by the CAMO to determine the airworthiness of the aircraft. An ARC is an official statement by the CAMO that an aircraft is airworthy. An aircraft may not operate without a valid ARC. If an ARC ceases to be in force under this regulation, then the action required to restore the ARC is related to the action required to restore the CofA, e.g. if the CofA is cancelled, then the ARC is also effectively cancelled, a full Airworthiness Review must be carried out and a new ARC must be issued before the aircraft may be operated again. If the ARC is suspended and the certificate expires within the duration of the suspension, then a full Airworthiness Review must be carried out and a new ARC must be issued before the aircraft may be operated again. ©Aviation Australia All large aircraft and all aircraft that operate under an AOC must 2024-10-01 have B-10c an Legislation Aviation ARC Page 262 of 328 CASA Part 66 - Training Materials Only  CASR Subpart 42.J Approval of Maintenance Programs and Variations of Approved Maintenance Programs This subpart covers Continuing Airworthiness requirements for approval of Maintenance Programs and variations to Approved Maintenance Programs: Approval of Maintenance Programs by CAMOs Approval of Maintenance Programs by CASA Approval of variations to Approved Maintenance Programs by the CAMO (and CASA). A CAMO for an aircraft is permitted to approve a proposed maintenance program if the aircraft is not authorised to operate under an air transport AOC and if the organisation’s approval permits it to approve the program. The program must be approved on behalf of the organisation by an individual who is a maintenance program approval employee. CASR Subpart 42.K Directions to Vary Approved Maintenance Programs This subpart covers continuing airworthiness requirements for directions to vary Approved Maintenance Programs. It gives CASA the power to issue directions to vary Approved Maintenance Programs. CASR Subpart 42.L Approval of Reliability Programs and Variations of Approved Reliability Programs This subpart covers Continuing Airworthiness requirements for approval of reliability programs and variations of Approved Reliability Programs: Approval of reliability programs Approval of variations of Approved Reliability Programs. 2024-10-01 B-10c Aviation Legislation Page 263 of 328 CASA Part 66 - Training Materials Only  CASR Subpart 42.M Continuing Airworthiness Requirements for Pilots The pilot in command of an aircraft is required to ensure that a pre-flight inspection of the aircraft is carried out. The pilot in command of an aircraft for a flight must ensure that, before the next flight, the following information is recorded in the flight technical log: The aircraft’s time in service for the flight Details of any defect of which the pilot becomes aware during the operation of the aircraft Any abnormal instrument indication that occurred during the flight Any abnormal handling of the aircraft noted by the pilot during the flight Any abnormal behaviour by the aircraft during the flight If required, utilisation information Any instance of exceeding an operating limit specified in the aircraft’s flight manual during the flight. The pilot in command must ensure that a pre-flight inspection is carried out 2024-10-01 B-10c Aviation Legislation Page 264 of 328 CASA Part 66 - Training Materials Only  CASR Subpart 42.N Record‑Keeping Requirements This subpart covers Continuing Airworthiness record-keeping requirements. If a person is required to record information or to ensure that information is recorded, the person must ensure that: The record is written in a legible form in English The record will remain legible for the time for which it is required, by the regulations, to be kept The record is securely kept in a system that allows the record to be easily retrieved. CASR Subpart 42.O Copying or Disclosing Cockpit Voice-Recording Information This subpart covers Continuing Airworthiness requirements for copying or disclosing cockpit voice- recording information: The persons authorised to copy and disclose cockpit voice recorder information are: Transport safety investigators, and Maintainers approved to inspect and test on behalf of an AMO whether the equipment is functioning and reliable. 2024-10-01 B-10c Aviation Legislation Page 265 of 328 CASA Part 66 - Training Materials Only  CASR Part 42 Manual of Standards Introduction to the Manual of Standards Currently, CASR Part 42 MOS covers the following: Requirements for CAMOs Requirements for maintenance programs for large aircraft and aircraft operated under an AOC Requirements for Approved Reliability Programs Carrying out maintenance on Australian aircraft outside Australian Territory Carrying out maintenance on an aeronautical product for an Australian aircraft outside Australian Territory Aviation industry standards Aeroplanes and helicopters of a particular type and model that are specified as large aircraft Aeroplanes and helicopters of a particular type and model that are specified as small aircraft Documents issued under the law of a foreign country that are authorised release certificates. ©Aviation Australia CASR Part 42 MOS include the requirements for a CAMO 2024-10-01 B-10c Aviation Legislation Page 266 of 328 CASA Part 66 - Training Materials Only  CAMO Requirements Certain requirements must be met by a CAMO for the issue and continuation of an approval to provide Continuing Airworthiness Management services for aircraft. The CAMO must have an exposition that includes statements regarding: The Accountable Manager The Responsible Manager The Continuing Airworthiness Manager The Quality Manager Facilities and equipment Continuing Airworthiness Management employees The Airworthiness Review employee The Maintenance Program Approval Employee Instructions for Continuing Airworthiness Maintenance data for carrying out maintenance A Quality System Internal review Appropriate record-keeping. 2024-10-01 B-10c Aviation Legislation Page 267 of 328 CASA Part 66 - Training Materials Only  CAMO Exposition The CAMO must have an exposition that contains at least the following information: A statement signed by the Accountable Manager to confirm that the CAMO will provide Continuing Airworthiness Management services in accordance with Part 42. Detailed scope of the Continuing Airworthiness Management services the CAMO is approved to provide. CASA Form 004 is the form approved by CASA for the nomination of key personnel listed below: Accountable Manager Continuing Airworthiness Manager Responsible Manager Quality Manager A list of Airworthiness Review employees A list of Maintenance Program approval employees. The exposition also requires: A chart showing the CAMO’s structure and associated chains of responsibility of individuals within the CAMO A description of the CAMOs facilities and equipment at each location Procedures for making changes to the exposition Procedures that specify how the CAMO ensures compliance with Part 42. 2024-10-01 B-10c Aviation Legislation Page 268 of 328 CASA Part 66 - Training Materials Only  CAMO Accountable Manager The Accountable Manager is ultimately responsible for ensuring: That the CAMO complies with CASR Part 42, the Part 42 MOS, its approval and its exposition That the CAMO has adequate resources to provide Continuing Airworthiness Management services in accordance with its exposition That if the CAMO is an air transport AOC holder, they have the corporate authority for managing and financing the operation under the AOC That if the CAMO is not an air transport AOC holder, they have the corporate authority for managing and financing the CAMO. Image by National Business Aviation Association CAMO management group Responsible Manager The CAMO must appoint at least one individual as the Responsible Manager, responsible for ensuring that the CAMO complies with CASR Part 42, the CASR Part 42 MOS and the CAMO’s exposition. A responsible manager must have: At least five years’ experience in matters for which they are responsible, or At least two years’ experience in matters for which they are responsible, provided they have at least three years’ experience in civil aircraft maintenance. 2024-10-01 B-10c Aviation Legislation Page 269 of 328 CASA Part 66 - Training Materials Only  A Responsible Manager must have a comprehensive knowledge of: The regulations and standards and the CAMO’s exposition relating to matters for which they are responsible. A Responsible Manager, whose responsibility includes ensuring the CAMO’s compliance with CASR Part 42, the Part 42 MOS and the CAMO’s exposition in relation to providing Continuing Airworthiness Management services for an aircraft, must have a comprehensive knowledge of the following: The aircraft’s certification basis, The aircraft’s structure and systems, If applicable, the parts of the AOC holder’s operations manual that have Continuing Airworthiness implications, The aircraft’s certification basis, The aircraft’s structure and systems, If applicable, the parts of the AOC holder’s operations manual that have Continuing Airworthiness implications. The CAMO must keep copies of all documents that demonstrate each Responsible Manager has the appropriate qualifications, experience and knowledge for two years after the person ceases to be a Responsible Manager. PRESENTERMEDIA, used with permission. A CAMO must appoint at least one individual as the Responsible Manager 2024-10-01 B-10c Aviation Legislation Page 270 of 328 CASA Part 66 - Training Materials Only  Continuing Airworthiness Manager If a CAMO is an air transport AOC holder, the CAMO must appoint an individual as the Continuing Airworthiness Manager who is responsible for ensuring that the CAMO complies with CASR Part 42, the Part 42 MOS and the CAMO’s exposition in relation to providing Continuing Airworthiness Management services for the aircraft authorised to operate under the AOC. The Continuing Airworthiness Manager reports directly to the Accountable Manager. The Continuing Airworthiness Manager must: Hold, or have held, an aircraft engineer licence in Category B1, B2 or C, or equivalent, or Have a formal qualification in aircraft maintenance to at least Certificate IV level, or Hold an engineering qualification to at least diploma level in an engineering discipline in aeronautical, avionics, mechanical, electrical or electronics. The Continuing Airworthiness Manager must have at least three years’ experience in Continuing Airworthiness Management of aircraft. The Continuing Airworthiness Manager must have a comprehensive knowledge of the following: The regulations and standards applicable to airworthiness and the operation of aircraft The CAMO’s exposition The relevant parts of the AOC holders’ operations manual The CAMO’s Quality Management System. 2024-10-01 B-10c Aviation Legislation Page 271 of 328 CASA Part 66 - Training Materials Only  Maintenance Carried Out on an Aircraft and Aeronautical Products The Registered Operator of an aircraft must ensure that maintenance is carried out by a person who is permitted to carry out the maintenance according to: Subpart 42.300 (individuals not working for AMOs), or Subpart 42.301 (organisations under an NAA arrangement). The Registered Operator of an aircraft must ensure that maintenance carried out on an aeronautical product for the aircraft is carried out by a person who is permitted to carry out the maintenance according to: Subpart 42.305 (permitted persons), or Subpart 42.306 (foreign organisations approved by the NAA). The registered operator of an aircraft must ensure that maintenance is carried out by an AMO 2024-10-01 B-10c Aviation Legislation Page 272 of 328 CASA Part 66 - Training Materials Only  Continuing Airworthiness Requirements: All Aircraft The flight crew of the aircraft must not commence a flight unless a CRS has been issued for the most recent maintenance carried out on the aircraft. The procedures for flight crew to ensure this may be included in the flight technical log for aircraft or, in the case of an AOC holder, in the AOC holder’s operations manual. The flight crew of an aircraft should not commence a flight with a defect in the aircraft unless: Operation of the aircraft for the flight with the defect is permitted by the MEL or the CDL for the aircraft or by an SFP. The rectification of the defect is deferred in accordance with Part 42 by an individual on behalf of an AMO, or The defect is in an item of operational or emergency equipment that is not required by the certification basis for the aircraft and is not required by or under these regulations for the operation of the aircraft for the flight. The Registered Operator of an aircraft is to enter in the flight technical log for the aircraft the following defects before the aircraft commences a flight: Any defect the rectification of which is not required under the MEL or the CDL for the aircraft, and A defect in an item of operational or emergency equipment fitted to the aircraft. Flight crew should ensure defects are entered in the flight technical log for aircraft 2024-10-01 B-10c Aviation Legislation Page 273 of 328 CASA Part 66 - Training Materials Only  Applicable National and International Requirements in Maintenance I (10.7) Learning Objectives 10.7.1.1 Describe aircraft maintenance management programs and the conduct of maintenance checks and inspections (Level 2). 10.7.1.2 Describe the purpose of Master Minimum Equipment Lists, Minimum Equipment Lists and Dispatch Deviation Lists and how they are created (Level 2). 10.7.1.3 Describe the purpose of Airworthiness Directives and their compliance obligation (Level 2). 10.7.1.4 Describe the origin and general information contained in Service Bulletins and other manufacturer's service information (Level 2). 10.7.1.5 Describe how modifications and repair schemes are authorised and performed in a Part 145 AMO (Level 2). 10.7.1.6 Describe how maintenance documentation, including maintenance manuals, structural repair manuals, illustrated parts catalogue etc., are produced and distributed, and managed within organisations (Level 2). 2024-10-01 B-10c Aviation Legislation Page 274 of 328 CASA Part 66 - Training Materials Only  Regulations and Guidelines Introduction The following publications are additional to the regulations; these are published by CASA and other NAAs to ensure the continued airworthiness of aircraft. Publications Authority Airworthiness Directives (ADs) Issued by NAAs Advisory Circulars (ACs) FAA Civil Aviation Advisory Publications (CAAPs) CASA (CASR 1998) Airworthiness Advisory Circulars (AACs) CASA (CASR 1998) Safety Information Notices (SINs) EASA Airworthiness Bulletins (AWBs) CASA ©Aviation Australia NAA regulations and guidelines 2024-10-01 B-10c Aviation Legislation Page 275 of 328 CASA Part 66 - Training Materials Only  Approved Maintenance Programs Introduction to Approved Maintenance Programs An Approved Maintenance Program is a document which describes the specific scheduled maintenance tasks and their frequency of completion. It relates to procedures, such as a Reliability Program, necessary for the safe operation of those aircraft to which it applies. The aircraft should be maintained only according to one Approved Maintenance Program at any given point in time. When an owner or operator wishes to change from one approved program to another, a transfer check or inspection may be necessary. Approved maintenance programs 2024-10-01 B-10c Aviation Legislation Page 276 of 328 CASA Part 66 - Training Materials Only  System of Maintenance A System of Maintenance is developed from the aircraft manufacturer’s Maintenance Planning Document (MPD), Aircraft Maintenance Manuals (AMM) and, for Transport and Commercial category aircraft, the operator’s maintenance documents. The system of maintenance must also meet any special requirements of CASA or other NAAs. A system of maintenance means a document that includes: What maintenance must be carried out When maintenance must be carried out Scheduled and non-scheduled maintenance and guidance on how the maintenance is to be carried out. System of maintenance 2024-10-01 B-10c Aviation Legislation Page 277 of 328 CASA Part 66 - Training Materials Only  System of Maintenance Documents Maintenance documents required in a System of Maintenance include: Aircraft Maintenance Manuals (AMM) Structural Repair Manuals (SRM) Illustrated Part Catalogues/Lists (IPC/IPL) Policy and Procedures Manuals MEL and Dispatch Deviation List/Guide (MEL and DDL/DDG) Maintenance Schedules. Flight Safety Foundation Aircraft Maintenance Manuals 2024-10-01 B-10c Aviation Legislation Page 278 of 328 CASA Part 66 - Training Materials Only  Maintenance Schedules A large aircraft (IAW CASR Part 42) requires an approved System of Maintenance, which is included in the aircraft’s maintenance program. Class B aircraft (aircraft other than large aircraft) require an approved maintenance schedule in accordance with CAR 41. A Class B aircraft is an Australian aircraft that is a small aircraft and not flown commercially. Class B aircraft The Registered Operator (RO) is responsible for the maintenance of their aircraft. Regulations require an aircraft to be maintained well enough to keep it airworthy. For the purpose of the regulations, there are two types of maintenance schedules: Manufacturer’s maintenance schedules, and CASA maintenance schedules (Schedule 5 of the CARs). 2024-10-01 B-10c Aviation Legislation Page 279 of 328 CASA Part 66 - Training Materials Only  Aviation Australia Civil Aviation Advisory Publication (CAAP) example Manufacturer’s Maintenance Schedules Different manufacturers present their schedules in different documents, even for a single aircraft type. The maintenance schedule might be found in these approved documents: Aircraft Maintenance Manual Airworthiness Limitations Section Instructions for Continued Airworthiness Maintenance Review Board Report Maintenance Planning Data Continuing Airworthiness Program Supplemental Inspection Document Corrosion Prevention and Control Program Other documents. 2024-10-01 B-10c Aviation Legislation Page 280 of 328 CASA Part 66 - Training Materials Only  CASA Maintenance Schedules The CASA maintenance schedule is found under Schedule 5 of CAR 1988 Vol. 4. The CASA maintenance schedule does not replace or relax the manufacturer’s maintenance schedule. The main purpose of the CASA maintenance schedule is as a check against inadequate manufacturer schedules. A list of aircraft types with inadequate maintenance schedules can be found in CAO 100.5. Maintenance schedules 2024-10-01 B-10c Aviation Legislation Page 281 of 328 CASA Part 66 - Training Materials Only  Approved Maintenance Data Types of Approved Maintenance Data Approved maintenance data as stated in CASR Part 42, are listed in order of precedence: Data included in or required by an AD Data included in or required by a direction by CAR 35 Data included in or required by a condition placed on a maintenance release or a CRS, whichever is applicable Data included and approved during Type Certification (TC) Instructions issued by the manufacturer of an aircraft, aircraft components or materials, specifying how maintenance is to be carried out Instructions issued by the designers of approved modifications to aircraft or aircraft components, specifying how maintenance is to be carried out Any other instructions issued by CASA for the purpose of ensuring safety. Maintenance Data Aircraft Maintenance Organisation Requirements Under Part 145, an Aircraft Maintenance Organisation (AMO) must show how it accesses the maintenance data. The Exposition must show how it ensures that the maintenance data is current. Sources of data may be the Registered Operator (RO), vendors, subscription services or an aircraft owner. An AMO is deemed to hold maintenance data if it has subscribed to an online provider for that maintenance data. The AMO must be able to demonstrate that whenever access to the data is required by maintenance employees, it is available. 2024-10-01 B-10c Aviation Legislation Page 282 of 328 CASA Part 66 - Training Materials Only  AMO-Generated Maintenance Data An AMO may generate new maintenance data for maintenance tasks only when no data currently exists (in any form) for the maintenance. The generated maintenance data must not involve creating or setting wear limits pertaining to the aeronautical product or any part of the product. An AMO may only alter maintenance data for its own use, if: The maintenance can be carried out in a more practical or efficient manner; or the maintenance data cannot be complied with by following the existing maintenance instructions, or the alteration of the maintenance data is for the use of tools or equipment not specified in the data. a process is in place to notify the details of the new maintenance data to a manufacturer, TC holder, STC holder or holder of the design or repair approval where applicable. The alteration of the maintenance data is made in accordance with a procedure specified in the AMOs exposition that includes a process for approval of the alteration by the AMOs Quality Manager after an assessment establishes that the alteration provides an equivalent or improved maintenance standard. 2024-10-01 B-10c Aviation Legislation Page 283 of 328 CASA Part 66 - Training Materials Only  Master Minimum Equipment Lists The Master Minimum Equipment List (MMEL) is a document which lists the equipment that may temporarily be inoperative. The MMEL is generated by the TC holder and must: Meet certain conditions Maintain an acceptable level of safety. Each MMEL is specific to an aircraft type. Master minimum equipment list: Electronic An MMEL is approved by the NAA which issued the Type Certificate. An MMEL establishes the aircraft equipment allowed to be inoperative under certain conditions. It forms the basis for an operators Minimum Equipment List (MEL). 2024-10-01 B-10c Aviation Legislation Page 284 of 328 CASA Part 66 - Training Materials Only  Master minimum equipment list: Beechcraft 2024-10-01 B-10c Aviation Legislation Page 285 of 328 CASA Part 66 - Training Materials Only  Minimum Equipment Lists The Minimum Equipment List (MEL) is a document approved by CASA and developed from the TC holder’s MMEL. It contains the conditions under which a specified aircraft may operate, with items of equipment inoperative, at the time of dispatch. The MEL provides a time interval for the rectification of the faulty item, relevant to the operational significance of the item. It is carried on board the aircraft and provides guidance regarding whether the particular flight should or should not proceed. The MMEL and associated MEL are relieving documents. Their purpose is not, however, to encourage the operation of aircraft with inoperative equipment. It is undesirable for aircraft to be dispatched with inoperative equipment and such operations are permitted only as a result of careful analysis of each item to ensure that the acceptable level of safety, as intended in the applicable CASA or equivalent requirement, is maintained. A fundamental consideration is that the continued operation of an aircraft in this condition should be minimised. ©Aviation Australia Minimum Equipment List 2024-10-01 B-10c Aviation Legislation Page 286 of 328 CASA Part 66 - Training Materials Only  MEL Rectification Intervals Inoperative items or components, deferred in accordance with the MEL, must be rectified at or prior to the rectification (repair) interval categories: Category A No standard interval is specified; where a time period is specified, it shall start at 00:01 on the calendar day following the day of discovery. Category B Items must be repaired within three consecutive calendar days, starting at 00:01 on the calendar day following the day of discovery. Category C Items must be repaired within 10 consecutive calendar days, starting at 00:01 on the calendar day following the day of discovery. Category D Items must be repaired within 120 consecutive calendar days, starting at 00:01 on the calendar day following the day of discovery. © Aviation Australia Example of MEL, Section 2 of the Dispatch Deviation List/Guide 2024-10-01 B-10c Aviation Legislation Page 287 of 328 CASA Part 66 - Training Materials Only  Dispatch Deviation List/Guide The Dispatch Deviation List (DDL), also called the Dispatch Deviation Guide (DDG), is a document which contains the MEL and Configuration Deviation List (CDL). This document is carried on the flight deck of large Transport category aircraft. The DDL/G is an approved publication subject to review and amendment. 747 400 dispatch deviation guide 2024-10-01 B-10c Aviation Legislation Page 288 of 328 CASA Part 66 - Training Materials Only  Configuration Deviation List The Configuration Deviation List (CDL) identifies any external parts of an aircraft which may be missing at the commencement of flight. The CDL contains information associated with: Operating limitations, and Aircraft performance corrections where necessary. It is established by the TC holder, approved by the State of Design, published as part of the Aircraft Flight Manual and found in the DDL/G along with the MEL. Example of an Airbus A330 CDL 2024-10-01 B-10c Aviation Legislation Page 289 of 328 CASA Part 66 - Training Materials Only  Service Bulletins Service Bulletins (SBs) alert the owner or operator to pending serviceability problems. They are issued by the manufacturer of aircraft, engine, propeller and aircraft parts and appliances. If the Service Bulletin relates to an airworthiness safety problem, the regulator will issue an AD. Example of a manufacturer’s service bulletin 2024-10-01 B-10c Aviation Legislation Page 290 of 328 CASA Part 66 - Training Materials Only  Airworthiness Bulletins An Airworthiness Bulletin (AWB) contains essential information not considered mandatory. It is informative only. AWBs are issued by CASA to disseminate information as quickly and as clearly as possible. CASA Airworthiness Bulletin Airworthiness Directives An Airworthiness Directive (AD) is a notification to owners and operators of certified aircraft that a known safety deficiency in a particular model of aircraft, engine, avionics or other system exists and must be corrected. CASA and other NAA's issue Airworthiness Directives and compliance is mandatory. An AD may be issued for an aircraft, or for an aeronautical product, if: An unsafe condition exists in an aircraft or aeronautical product, and The condition exists, or is likely to exist, or could develop, in other aircraft or aeronautical products. 2024-10-01 B-10c Aviation Legislation Page 291 of 328 CASA Part 66 - Training Materials Only  The AD must: Be in writing, and State the kind of aircraft or aeronautical product to which it relates, and State that a known safety deficiency exists in a model of aircraft, engine, avionics or other system and must be corrected. The AD may require a person to comply with either or both of the following: A Directive (a Foreign Directive) mentioned in the AD that: Is issued by the NAA of a foreign country, and Is of the same nature as an AD, An instruction, direction or requirement that: Is issued by the manufacturer of aircraft or aeronautical products to which the Airworthiness Directive relates, and Is mentioned in the AD. A person must not operate an Australian aircraft that is covered by an AD or that is fitted with an aeronautical product covered by an AD. ©Aviation Australia CASA Airworthiness Directive (AD) Example 2024-10-01 B-10c Aviation Legislation Page 292 of 328 CASA Part 66 - Training Materials Only  Modifications and Repairs Under CASR Part 42, the person responsible for continuing airworthiness for an aircraft must ensure that the aircraft is not modified unless: There is a Part 21 approval for the design of the modification The modification is compatible with the configuration of the aircraft The person responsible for continuing airworthiness must ensure that a repair that involves a change to the approved design of the aircraft is not made unless there is a Part 21 approval. A person or organisation repairing an aircraft or component should assess the damage against approved repair data. The action to be taken if the damage is beyond the limits or outside the scope could involve any one or more of the following options: Repair by replacement of damaged parts Requesting technical support from the following: Type Certificate holder The approved Part 21 organisation An agency approval of the particular repair data. Modifications and repairs 2024-10-01 B-10c Aviation Legislation Page 293 of 328 CASA Part 66 - Training Materials Only  Maintenance Documentation Aircraft Logbooks The holder of the Certificate of Registration for an Australian aircraft must keep a logbook for the aircraft and make the logbook, and other documents referred to in the logbook, available to CASA and to persons engaged in maintenance of the aircraft. The logbook must have provision for the recording the following: Maintenance and certification of maintenance carried out A record of when any time-lifed components were installed or removed A record of compliance with all applicable ADs A summary of any changes to the empty weight of the aircraft. All logbook sections incorporating certification pages must be bound and sequentially numbered. Aircraft logbook 2024-10-01 B-10c Aviation Legislation Page 294 of 328 CASA Part 66 - Training Materials Only  Aircraft Logbook Statement Under CAR 50A, an aircraft logbook must make statements that: Identify the aircraft and the type and model of engine and propeller fitted to the aircraft State whether the aircraft is equipped for Instrument Flight Rules (IFR) operations, Visual Flight Rules (VFR) Day operations or VFR Night operations. Alternative Aircraft Logbook CASA may approve the use of an alternative to an aircraft logbook or to a particular section of an aircraft logbook. Alternative logbook means a logbook used as an alternative to those sold by CASA. The alternative logbook must be made available to CASA and to persons engaged in maintenance of the aircraft. An example of an alternative aircraft logbook is the AOC holder’s aircraft technical log. Alternative aircraft logbook 2024-10-01 B-10c Aviation Legislation Page 295 of 328 CASA Part 66 - Training Materials Only  Maintenance Records Maintenance records form part of the Continuing Airworthiness records for an aircraft. The AMO must have control processes for identification, legibility, storage, protection, archival, retrieval and retention of all maintenance records Records must be protected from any possibility of damage or destruction by fire, flood or interference and tampering. The following aircraft maintenance records must be retained for a period of 1 year following the end of the aircraft’s operating life or its withdrawal from service: Aircraft Logbook Engine Logbook Propeller Logbook Major Assembly History Card Component History Card Maintenance Release or CRS, whichever is applicable, and Maintenance Records If an Australian aircraft is exported from Australia, the aircraft’s maintenance records must accompany it. Maintenance records 2024-10-01 B-10c Aviation Legislation Page 296 of 328 CASA Part 66 - Training Materials Only  Applicable National and International Requirements in Maintenance II (10.7) Learning Objectives 10.7.1.5 Describe how modifications and repair schemes are authorised and performed in a Part 145 AMO (Level 2). 10.7.2.1 Define continuing airworthiness and how it is managed (Level 1). 10.7.2.2 State the need for test flights, the various types of test flights and their minimum equipment requirements (Level 1). 10.7.2.3 State ETOPS/EDTO flight planning allowances and typical maintenance and dispatch requirements for ETOPS/EDTO operation (Level 1). 10.7.2.4 State how all weather operations, including category 2 and 3 operations are approved and managed, including aircraft minimum equipment requirements (Level 1). 2024-10-01 B-10c Aviation Legislation Page 297 of 328 CASA Part 66 - Training Materials Only  Continuing Airworthiness Requirements for All Aircraft Defect Reporting Commercial operators, maintenance organisations and manufacturers must submit a report for each malfunction, failure or defect that occurs under the reportable categories. In addition, each commercial operator and AMO must report any other malfunction, failure or defect in an aircraft that occurs or is detected at any time, if under the opinion that the malfunction, failure or defect has endangered or may endanger the safe operation of an aircraft. Aircraft gas turbine engine with the cowls damaged from an incident 2024-10-01 B-10c Aviation Legislation Page 298 of 328 CASA Part 66 - Training Materials Only  System Outcomes The current aircraft population is too large to achieve full knowledge of all potential safety problems solely through inspection. The Service Difficulty Reporting (SDR) system assists in effective decision- making, resource utilisation and enhancement of safety. A properly implemented SDR system provides the intelligence needed to assess defects, institute early corrective action and thus assist in accident prevention. The SDR is a feedback system which provides a database for effective decisions on matters of reliability and airworthiness. The level of sophistication of the SDR can vary from NAA to NAA. CASA’s SDR is coupled with the FAA and Transportation Canada’s SDR systems. Further development of the SDR system internationally will result in worldwide sharing of SDR information. Most failures in aircraft parts are random. In some cases, service time between intervals can be increased if based on proper statistics that are obtainable from data, including data from a working SDR system. Determining inspection periods should result from proper inspection rationalisation based on statistical records resulting from full defect reporting. Conversely, SDR information may be used to convince operators that reliability of certain aeronautical products must be improved. System Feedback An effective SDR system provides information that enables CASA to make sound regulatory decisions and to provide an improved advisory service to the operator. The Maintenance Standards Branch uses the following documents to circulate this information: Airworthiness Directives Advisory Circulars Airworthiness Bulletins Flight Safety Magazine Alerts CAR 51 Reporting of Defects in Australian Aircraft—General states: ‘Where a person engaged in the maintenance of an Australian aircraft becomes aware of the existence of a defect, the person shall report the defect to his or her employer’. Continuing Airworthiness Requirements The Registered Operator of an aircraft is to enter in the flight technical log for the aircraft and the following defects before the aircraft commences a flight: Any defect rectification which is not required under the MEL or the CDL for the aircraft A defect in an item of operational or emergency equipment fitted to the aircraft. 2024-10-01 B-10c Aviation Legislation Page 299 of 328 CASA Part 66 - Training Materials Only  Major Defects Introduction to Major Defects A major defect is described as a defect that has caused, or that could cause: A primary structural failure A control system failure An engine structural failure A fire in an aircraft. CASA states that if a person connected to the operation or the carrying out of maintenance discovers a major defect in the aircraft, the person must report the defect to the Certificate of Registration (CofR) holder and to CASA. If a person discovers a defect in an aircraft in the course of complying with an AD, the person must report the defect to CASA. A person must not prevent another person from reporting a major defect. © Aviation Australia CASA Online Defect Reporting Portal Link to the CASA Defect Reporting Service (DRS). 2024-10-01 B-10c Aviation Legislation Page 300 of 328 CASA Part 66 - Training Materials Only