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AeroFix Aircraft Maintenance Organisation Policy and Procedures Manual About this manual This manual is for training purposes only. It has been produced for the fictitious aircraft maintenance organization AeroFix. The manual simulates a PPM and is generally consistent with CASA requirements. It is not a complete Aircraft Maintenance Organisation (AMO) manual, as only the sections required to support this Toolbox training package have been produced. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Manual structure An approved organisation’s PPM will normally include all the following parts. 1 A statement of corporate commitment by the accountable manager setting out the procedures to ensure that its management system is, or will be, used by all persons whose duties relate to the maintenance carried out by the organisation. 2 The structure of the organisation, including: (a) the name and position of: (i) the accountable manager; and (ii) each responsible manager; and (b) the areas of the organisation that report to each responsible manager; and (c) who will occupy the position of a person mentioned in subparagraph (a) (ii) if the person is absent. 3 The area of responsibility, the duties and the authority of: (a) the accountable manager; and (b) each responsible manager; and (c) each person or class of persons who is, or will be, permitted to sign for the return to service of an aircraft or aeronautical product; and (d) each person authorised to sign an authorised release certificate. 4 A statement describing each of the organisation’s locations and each rating that applies to the location, including a description of: (a) the facility at each location; and (b) the equipment, special tools and data that are used, or available for use, at each location; and (c) the kind of maintenance that is, or will be, carried out at each location, including: (i) a description of each kind of aircraft, engine or aeronautical product that is, or will be, maintained at the location; and (ii) a list showing each contract under which the organisation carries out maintenance for an AOC holder and the location where the maintenance will be carried out. 5 Any procedure that the organisation uses, or will use, to carry out maintenance away from a facility. 6 The procedure that the organisation uses, or will use, if it proposes to make a change to this manual. 7 The procedures that are, or will be, used for: (a) carrying out maintenance; and (b) controlling the carrying out of maintenance in accordance with regulations (or a reference to the data that describes those procedures). 8 The capability list of the AMO and the procedures for amending the list. 9 The procedures that the AMO will use to vary the maintenance that is described in a rating document or operation specification document. 10 Any procedure that the AMO uses, or will use, to fabricate parts. 11 The organisation’s management system (unless the same person carries out or directly supervises, and signs for, all maintenance). 12 If, in the organisation, the same person carries out or directly supervises, and signs for, all maintenance, the procedures for the organisation’s annual review. Page i © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 13 If the organisation carries out maintenance on an aircraft or aeronautical product for which the manufacturer specifies a tolerance, the procedure to ensure that equipment used is calibrated. 14 The training program for maintenance staff and pilots. 15 The procedures to deal with alcohol, drug or fatigue related problems of maintenance staff. 16 The procedures to control all contracted activities. 17 If non-AMO contract maintenance is, or will be, carried out for the organisation, the procedure to ensure that: (a) non-AMO contract maintenance is carried out to standards appropriate to the maintenance being carried out; and (b) an aeronautical product on which non-AMO contract maintenance is carried out is used only after it has been determined to be serviceable by the AMO. 18 If the organisation carries out, or will carry out, maintenance in accordance with the AMP of the registered operator of an aircraft, the procedure for that maintenance. 19 If the organisation carries out, or will carry out, maintenance on foreign registered aircraft under a technical arrangement between CASA and the NAA of the country in which the aircraft is registered, the procedures for identifying, documenting and complying with the specific maintenance requirements of the country. 20 The procedures for: (a) storage, examination and inspection of equipment, tools and aeronautical products; and (b) handling defective or incorrectly labelled aeronautical products. 21 The procedures to authorise the AMO’s maintenance staff to carry out and sign for, on behalf of the AMO, maintenance. 21A The procedures for the coordination of maintenance to meet the requirements of the regulations. 22 The procedure for examining salvaged or stored aeronautical products for damage, before they are used. 23 The organisation’s record-keeping system (including those associated with the training program referred to in item 14) and the records it keeps, or will keep, together with: (a) a sample of each form that the organisation uses, or will use, to keep records of maintenance, and a description of the way in which each form must be filled in and signed (or otherwise certified); or (b) if the organisation has a forms manual, a copy of the forms manual. 24 The organisation’s major defect reporting procedure via an Irregularity Report form. 25 The procedure for amending the organisation manual, including the person or persons who may approve an amendment. 26 The organisation’s procedure for internal communication about to the maintenance it carries out 27 Any procedures or policy that relate to maintenance and that have not been described in another item. Page ii © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual List of Effective Pages This section of the PPM is not required for the Toolbox; therefore it has not been included. This page intentionally left blank Page iii © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Abbreviations used in this manual AD: Airworthiness Directive AME: Aircraft Maintenance Engineer AMO: Aircraft Maintenance Organisation (AeroFix) CASA: Civil Aviation Safety Authority CASR: Civil Aviation Safety Regulation CE: Chief Engineer EEO: Equal Employment Opportunity IAW: In accordance with LAME: Licensed Aircraft Maintenance Engineer NAA: National Airworthiness Authority NDT: Non Destructive Testing OH&S: Occupational Health and Safety PPM: Policy and Procedures Manual (this book) SB: Service Bulletin MR: Maintenance Release Page iv © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Contents AeroFix Aircraft Maintenance Organisation ......................................................................... i Policy and Procedures Manual............................................................................................... i About this manual ................................................................Error! Bookmark not defined. List of Effective Pages ......................................................................................................... iii Abbreviations used in this manual ....................................................................................... iv 1 - Corporate Statement ........................................................................................................ 1 2 - Organisational Structure .................................................................................................. 2 3 - Duty Statements ............................................................................................................... 4 4 - Staff Policy and Procedures ............................................................................................. 9 5 - Facility Location Statement ........................................................................................... 15 6 - Procedures for work carried out off base....................................................................... 16 7 - Procedures to obtain a new rating.................................................................................. 17 8 - Maintenance Policy and Procedures .............................................................................. 18 9 - Forms ............................................................................................................................. 34 Form 1A - Work and Survey Sheet (single tasks) ...................................................... 37 Form 1B - Additional Work Sheet .............................................................................. 39 Form 2 – Work Package Summary ............................................................................. 41 Form 3 - Maintenance Due List .................................................................................. 43 Form 4 - CASA Airworthiness Directives .................................................................. 45 Form 5 - Trade Identification Sheet ............................................................................ 47 Form 6 - Independent Inspection of Controls ............................................................. 49 Form 7 - Category Co-Ordination Certification Sheet ............................................... 51 Form 8 - Maintenance Release (CASA form 194) ..................................................... 53 Form 9 - Manual Change Request .............................................................................. 55 Form 10 - Authorised Release Certificate .................................................................. 57 Form 11 - Major Defect Reporting (CASA Form 404) .............................................. 59 Form 11a – Irregularity Report ................................................................................... 63 Form 12 – List of Accountable Documents ................................................................ 65 Page v © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 1 - Corporate statement 1.1 Corporate commitment by Chief Engineer – AeroFix Aircraft Maintenance The Chief Engineer (CE), as the owner of AeroFix Aircraft Maintenance, is committed to running AeroFix as an adequate and cost-effective maintenance facility providing first class service to customers. In providing the service, the CE commits to using proven and effective maintenance methods as described by CASA, the aircraft manufacturer, the vendor product manufacturer and any authorised maintenance authority as specified by the aircraft owner, and in compliance with other relevant government regulations. The CE commits to having adequate staffing arrangements for all levels, classifications and types of maintenance. Where AeroFix does not have the specialist coverage to perform an activity, these specialists will be contracted from CASA approved organisations that have this coverage. The CE also commits to adequate planning of maintenance activities, correct implementation of the activities, correct certification of the activities and the update of all records attributed to the maintenance activities. Page 1 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 2 - Organisational structure Organisational chart – AeroFix Aircraft Maintenance Chief Engineer AeroFix Maintenance Controller/ Planner LAME: management of aircraft activities Office staff LAME Mechanical Support Quality Coordinator AME Mechanical AME Structures Trade Apprentice Page 2 LAME Avionics Support Supply Officer AME Avionics Trades Assistant © Commonwealth of Australia | Licensed under AEShareNet – S Licence Trade Apprentice Aeroskills Toolbox 2008 Policy and Procedures Manual List of organisation staff Name Position Rating Ian Shearer Chief Engineer (CE) Responsible Manager, LAME Ben Redman Maintenance Controller / Planning and management of activity, LAME Planner Steve O’Rourke Supply Officer Allan Teal LAME Mechanical Quality Coordinator Others Support LAME Arman Jaeger LAME Avionics Wally Gardner AME Avionics Colin Sheldon AME Mechanical David Petrie AME Structures Vince Jacana Trades Assistant Painting Office staff Secretary, record keeping Trevor Milson Trade Apprentice Mechanical Rebecca Wren Trade Apprentice Avionics Page 3 Support © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 3 - Duty statements 3.1 Management personnel The CE, as the owner of AeroFix, is the accountable Manager and is supported by the following staff positions. Management staff: Maintenance Controller/Planner (LAME with certification for aircraft type in maintenance LAME Mechanical. LAME Avionic Support staff: AME Avionics tradesperson AME Mechanical tradesperson AME Structures tradesperson aircraft trade assistants office staff Apprentices. Contracted when required: CASA approved NDT specialist with eddy current and ultra sonic coverage Design Engineer. 3.2 Duties and responsibilities of management personnel 3.2.1 Chief Engineer (CE) The CE, as the owner, is accountable for the correct maintenance procedures being carried out in all maintenance activities performed by AeroFix and organisations subcontracted to assist AeroFix to perform this maintenance. The CE controls all maintenance activities performed on a day-to-day basis and ensures that correct tooling and equipment is available for all activities. The CE ensures that suitably qualified persons carry out all activities. The CE leads regular staff meetings to discuss all issues associated with the business of the organisation, including: Page 4 OH&S CASA regulation reforms newly issued data such as ADs, SBs, alerts problems with any maintenance activity any other item pertinent to the safe and efficient running of the organisation. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 3.2.2 Quality Coordinator The LAME secondary role as the Quality Coordinator is responsible for providing the necessary expertise to ensure that the organisation is in a position to develop and implement quality procedures. The Quality Coordinator will achieve the following objectives: a. develop and maintain a robust audit system to ensure organisational compliance with the PPM b. manage the implementation of quality practices into the organisation c. develop new systems to meet the requirements of quality standards d. maintain a staff awareness of any changes to the PPM e. coordinate internal quality training programs as required f. implement and monitor a quality system across the organisation g. conduct internal audits h. prepare updates for the PPM i. promote organisation best practice j. maintain most up to date maintenance data k. liaise with the CASA on all items of interest and concern to both organisations l. ensure the implementation of all ADs, SBs and other maintenance data to the time lines specified in that data in all maintenance activities performed and all aircraft types under full control of AeroFix m. maintain staff awareness of the quality program n. induct new employees to the PPM o. maintain a register of personnel qualifications and notify the CE of relevant changes to this register. 3.2.3 3.2.3.1 Licensed Aircraft Maintenance Engineers (LAMEs) Maintenance Controller LAME (management of aircraft activity) The Maintenance Controller LAME is responsible to the CE for the performance under the approvals and privileges as specified in the CASA regulations pertaining to them, implement, supervise and perform maintenance activities in accordance with (IAW) all Maintenance Data associated with those activities. The Maintenance Controller LAME will, for those tasks for which he/she does not have approvals or privileges under the CASA regulations, delegate tasks to suitably qualified persons and supervise to ensure that the appropriate levels of certification have been obtained. Page 5 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual The Maintenance Controller LAME can delegate maintenance activities for which he/she does have approvals and privileges to other suitably qualified LAMEs for them to supervise and certify. The Maintenance Controller LAME is responsible for making sure all the required maintenance activities are certified IAW this PPM and CASA regulations and relevant maintenance records are dealt with IAW procedures of recording and filing. The Maintenance Controller LAME is responsible for the activities of all staff under their control on the maintenance activity. The Maintenance Controller LAME will be responsible for the ultimate safe return to service of the aircraft in their control, ensuring: all items under the maintenance schedule have been completed and correctly certified all aircraft records and logs and rotatable items records and logs have been updated to include all activities covered by the maintenance activity Maintenance Release has been issued IAW organisation procedures and CASA regulations. 3.2.3.2 Support of aircraft maintenance activities LAME The LAME/s will be responsible to the Maintenance Controller LAME for maintenance activity for all tasks delegated to them as a suitably qualified person for which they have the approvals or privileges under the CASA regulations. The LAME/s responsibility will be that all maintenance activities delegated to them are certified and relevant paper trails are dealt with IAW procedures of recording and filing. The LAME/s will be responsible for the activities of all staff under their control for the maintenance activity. The LAME will certify for any maintenance that they carryout or for maintenance carried out by personnel that they supervise, consistent with the skills and experience and the privileges of their license. When delegated, the LAME/s will be responsible for the ultimate safe return to service of the aircraft in their control, ensuring: all items under the maintenance schedule have been completed and correctly certified all aircraft records and logs and rotatable items records and logs have been updated to include all activities covered by the maintenance activity Maintenance Release has been issued IAW organisation procedures and CASA regulations. 3.2.3.3 Maintenance Controller LAME (Planner activity) The Maintenance Controller secondary role as Planner is responsible to for all maintenance data to be available for the intended maintenance activity. They will also ensure that adequate materials, tooling and spares are available. The Maintenance Controller/Planner will liaise with maintenance staff at all times and at all levels of the maintenance to help prioritise tasks for the most efficient outcomes. Page 6 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual The Planner will ensure that there will be tracking of any incomplete ‘Maintenance Due’ items on AeroFix aircraft or aircraft contracted to AeroFix for maintenance to ensure that any incomplete maintenance is planned to be completed prior to the exhaustion of any remaining hours. 3.2.4 Aircraft Maintenance Engineers (AMEs) The AME/s will be defined as an aircraft tradespersons with skills and experience to carryout maintenance and repair tasks as directed on AeroFix aircraft. The AME shall carry out all tasks within the limits of his/her skills base and shall follow all reasonable instructions of his employer. The AME normally works under the guidance of the LAME and will at all times act professionally and diligently. The AME/s will at all times carryout maintenance on the aircraft or its components consistent with the approved data. The AME will sign for his/her own work. Typical sources of approved data are defined in this manual. 3.2.5 Apprentice Aircraft Maintenance Engineers The Apprentice will be defined as trainee aircraft tradespersons. The apprentice will receive training in the maintenance and repair tasks on AeroFix aircraft. The Apprentice shall carry out all tasks within the limits of his/her skills base and shall follow all reasonable instructions of his employer. The Apprentice normally works under the guidance of the LAME and or the AME and will at all times act professionally and diligently. The Apprentices will at all times carryout maintenance on the aircraft or its components consistent with the approved data and under instruction from qualified personnel. Typical sources of approved data are defined in this manual. 3.2.6 Trade Assistant (TA) The Trade Assistant (TA) shall carry out all tasks within the limits of his/her skills base and shall follow all reasonable instructions of his employer. The TA always works under the guidance of LAME/s and or the AME/s and will at all times act appropriately. The TA’s tasks will include lubrication, paint stripping, sanding, cleaning and simple disassembly and reassembly tasks or any other tasks as directed. The TA will at all times carryout Tasks on the aircraft or its components consistent with the approved data and always under instruction from qualified personnel. 3.2.7 Records Staff Records personnel will ensure that AeroFix as an approved organisation will at all times meet its obligations with regard to correct retention and storage of aircraft maintenance records. Records personnel will maintain the aircraft maintenance records of AeroFix consistent with the procedures laid out in this manual. Page 7 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 3.2.8 Supply Officer The AeroFix Supply Officer will manage the supply store consistent with the procedures laid out in this manual. The Supply Officer’s duties shall include stock ordering, stock rotation, part shortages, receiving and despatching of stock and correct packaging of all aircraft spares and consumables. The Supply Officer shall liaise with the maintenance controller and other maintenance personnel to ensure the timely provision of parts and consumables for all aircraft maintenance activity. The supply officer will only seek parts from reputable sources and only accept items for aircraft fitment with a GRN supplied. Page 8 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 4 - Staff policy and procedures 4.1 Safety, wellbeing and rehabilitation policy AeroFix is committed to providing a healthy and safe environment within its premises for its employees, contractors and visitors. Under the OH&S legislation, responsibility rests with the CE, Maintenance Controller and supervisors. Additionally, all employees have a responsibility, as far as is reasonably practicable, to ensure that their work environment is safe. AeroFix will: take reasonable steps to reduce and eliminate health and safety risks establish and maintain safe systems of work provide information and guidance on safety and rehabilitation policies and procedures consult and communicate with stakeholders for improvements in health and safety ensure staff in leadership positions are held accountable for decisions affecting health and safety ensure supervisors are proactive within the organisation’s operations be informed of, and take action as required on, incidents and accidents that occur develop monitoring processes for staff wellbeing encourage the early reporting of symptoms of any injury or disease related to work assist injured employees to remain at work or return to work as soon as possible. AeroFix has a health and safety plan that sets out the objectives and the key measures, and identifies particular projects to improve the organisation’s health and safety outcomes. Health and safety is a shared responsibility between employees and contractors. Everyone must ensure the safety of their individual and collective environment by cooperating with policy and procedures, and reporting unsafe conditions or hazards. 4.2 Equity and diversity policy 4.2.1 Policy objective AeroFix is committed to promoting equity and diversity, aiming for a discrimination and harassment free work environment, and embracing a community of increasingly diverse needs and backgrounds. Scope The policy applies to every staff member, contractor and visitor. It applies to all aspects of employment, employment conditions and benefits, eg training, promotion, work allocation and leave arrangements. It also applies when staff are working off site and after hours; that is, wherever people are as a result of their work. Page 9 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 4.2.2 Policy statement The concept of workplace diversity includes the principle of EEO. AeroFix is committed to the principles of EEO and believes that EEO is an integral part of good management practice. EEO in the workplace matters because it: helps attract and retain the best talent enhances an organisation’s productivity and innovation improves workplace relationships helps to attract and retain a broader 'customer' base reduces the organisation’s risk. EEO means that all staff have equal access to the opportunities available at work, are treated with fairness and respect and are not subject to discrimination or harassment in the workplace. It requires that everyone be given an equal chance to use their skills and capabilities. A wide range of Commonwealth and State Government laws make it unlawful to discriminate against someone on the basis of: race, colour, nationality or ethnic origin sex or gender, lawful sexual activity, sexual preference, gender identity, marital status, pregnancy or potential pregnancy, breastfeeding, or status as a parent or carer religious or political belief or activity, industrial activity, union membership or nonmembership age, physical features, disability (past, present or imputed), medical record. All staff have a right to raise a genuine concern in relation to discrimination and or harassment issues without being victimised or punished. Vexatious, malicious or false complaints in relation to discrimination and/or harassment issues against one or more individuals will not be tolerated. 4.3 AeroFix Code of Conduct 4.3.1 Introduction This Code of Conduct outlines the standard of behaviour expected of employees of AeroFix. It is designed to help you to understand your responsibilities and obligations. It is also designed to provide guidance if you are faced with an ethical dilemma or conflict of interest in your work. A Code of Conduct cannot cover every situation. If you are unsure what action to take in a particular situation, discuss the matter with your supervisor and refer to the relevant AeroFix procedures. Staff who breach the standards of this Code will be subject to disciplinary action which for serious breach could involve summary dismissal, and in the case of suspected criminal act(s) may involve reference of the matter to the relevant law enforcement authority. Page 10 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 4.3.2 Principles As an organisation, AeroFix uses the following Code of Conduct principles: impartiality – treat all people fairly; base actions, decisions and advice on a consideration of all relevant facts, and implement relevant government policy and programs equitably integrity – maintain public trust by acting in the public interest and reporting any unethical behaviour at work accountability – achieve results through the best use of AeroFix’s financial, physical and human resources responsive service – provide a relevant and timely service to clients; provide information to which a person is entitled, promptly and in an easily understood form, and make sure it is accurate, current and complete. The AeroFix Code of Conduct includes required standards under a number of broad categories. These are: 4.3.2.1 Customers 4.3.2.2 Confidential information 4.3.2.3 Ethics 4.3.2.4 Behaviour of managers and staff 4.3.2.5 Outside employment 4.3.2.6 Performance. 4.3.2.1 Customers 4.3.2.1.1 Providing excellent customer service is the way in which AeroFix develops and improves its business. In your work at AeroFix, your customers may be external or internal (eg other staff at AeroFix). You should treat all people with whom you have contact in the course of your work fairly, equitably, professionally, and with courtesy and sensitivity. You should endeavour to demonstrate these attributes in your actions. 4.3.2.1.2 All AeroFix staff should value customer feedback as a means of identifying business improvement opportunities. In relation to customer feedback, staff should take appropriate action in conjunction with their manager. 4.3.2.1.3 All staff should be helpful and courteous when dealing with customers, giving prompt and satisfactory service to reasonable requests and managing sensitive issues with due care and consideration. 4.3.2.1.4 When providing advice to customers, ensure the advice is timely, accurate and based on the most current information. Page 11 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 4.3.2.2 Confidential information 4.3.2.2.1 You must not, either during or after your employment with AeroFix, use or disclose, or allow others to use or disclose, confidential information obtained during your employment with AeroFix. Confidential information includes information which, by reason of: (a) the nature of the information; (b) the employment position held by the employee, as a result of which the employee has access to the information; and/or (c) the general circumstances in which the employee becomes aware of the information is reasonably understood to be treated as confidential. 4.3.2.2.2 Without limiting the circumstances in which clause 4.3.2.1 will be breached, a breach of clause 4.3.2.2.1 will occur where an employee uses or discloses confidential information: (a) with the intention of directly or indirectly gaining an advantage for themselves, or someone else, or causing detriment to AeroFix; or (b) negligently or recklessly when the use may result in themselves or someone else directly or indirectly gaining an advantage, or cause detriment to AeroFix. 4.3.2.2.3 Confidential information includes any information constituting or relating to: (a) institute contract or commercial dealings (b) AeroFix correspondence or other internal or external communications conducted on a private basis. 4.3.2.3 Ethics 4.3.2.3.1 You are required to always act with honesty and integrity in all aspects of your work for AeroFix. 4.3.2.3.2 You should report any unethical behaviour or wrong doing by another staff member to your immediate manager. Where such a report relates to your immediate manager, you should approach the person to whom your immediate manager reports (‘the manager once removed’). If you suspect such wrong doings, you should also discuss these matters confidentially with your manager or the manager once removed. 4.3.2.3.3 All lawful directions relating to workplace ethics given by your manager or another manager should be complied with promptly. Page 12 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 4.3.2.4 Behaviour of managers and staff 4.3.2.4.1 All staff should work together to pursue AeroFix’s goals. Below is a non-exhaustive list of guidelines to assist AeroFix staff to maintain good working relationships with other staff and to maintain acceptable behaviour when conducting oneself in the workplace. 4.3.2.4.2 You should: (a) respect the professional opinions of colleagues in their areas of competence and acknowledge their contribution (b) support and encourage other staff members’ new ideas, learning and personal development (c) endeavour to support and assist other staff members in developing new skills (d) if you manage or supervise staff, treat them fairly; involve them in decisions that affect them, and provide them with equal opportunity to develop their skills (e) respect diversity and recognise it as an organisational strength; attempt at all times to support AeroFix’s emphasis on managing diversity, which involves understanding, anticipating and managing the needs and issues that emerge from demographic and cultural diversity (f) attempt to create a supportive environment for all staff, regardless of their gender, culture, age, location, disability or disadvantage (g) act in accordance with relevant sections of AeroFix policies and procedures that are available on AeroFix’s Intranet. 4.5 Outside employment 4.3.2.5.1 If you are a full-time employee, you must advise your manager if you are regularly employed or self-employed in another position outside AeroFix. 4.3.2.5.2 You should not be in any way involved with the conduct of a business, regardless of whether you are a full-time, part-time or casual employee, trade or profession, outside your employment with AeroFix where it interferes with the proper performance of your work, or where it could give rise to a conflict of interest with your position at AeroFix. Page 13 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 4.3.2.6 Performance 4.3.2.6.1 In relation to the performance of your work duties for AeroFix you are expected to: (a) perform your work diligently, impartially, responsively and to regulatory requirements and standards, to the best of your ability (b) observe relevant OH&S requirements (c) bring to the attention of your manager any situation, which is, or may be, a health or safety hazard (d) only be absent from work with permission (e) avoid waste and extravagance in the use of resources (f) if possible, identify improvements to administrative systems and procedures and communicate these to your manager (g) ensure that in financial matters, including the handling of moneys, you are fully accountable in relation to any advice or transaction in which you are involved; if you have financial responsibilities you are required to observe the relevant legislative and regulatory requirements. 4.3.2.6.2 You must not harass anyone or discriminate on the grounds of sex, sexual preference, age, marital status, pregnancy, the state of being a parent, childless or a de facto spouse, race, colour and national extraction, lawful religious or political belief or activity, or impairment. The principles of Victorian and Commonwealth EEO and anti-discrimination legislation are fully supported. 4.3.2.6.3 Your activities outside working hours at AeroFix must not diminish public or industry confidence in AeroFix, or your ability to perform your duties. 4.3.2.6.4 The consumption of alcohol or improper use of drugs or other substances must not adversely affect your work performance or official conduct. In particular, you must not be under the influence of alcohol or any other substance that hinders your ability to perform the requirements of your position with AeroFix. 4.3.2.6.5 If you are charged with any criminal offence punishable by imprisonment during your employment at AeroFix, you must advise the CE immediately. 4.3.2.6.6 You must comply with the requirements of all AeroFix policies and procedures, and all other applicable standards, legislation, guidelines, codes or regulations relevant to your position and duties, and those governing the terms and conditions of your employment including the terms of this document. AeroFix’s policies and procedures are available on AeroFix’s Intranet and should be referred to for further clarification. Page 14 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 5 - Facility location statement AeroFix is a fictitious approved maintenance organization and this PPM forms part of that approval. AeroFix’s main place of Business is; Hangar 1131, 26 Bristol Ave Tribone Airport Australia 9797. The Terms of this PPM apply to all AeroFix personnel or any contractors engaged by AeroFix. If aircraft maintenance activities are being conducted offsite, by AeroFix personal on AeroFix aircraft or on aircraft contracted to AeroFix for maintenance, then the terms of AeroFix’s approval and this PPM will continue to apply. This page intentionally left blank Page 15 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 6 - Procedures for work carried out off base This section of the PPM is not required for the Toolbox; therefore it has not been included. This page intentionally left blank Page 16 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 7 - Procedures to obtain a new rating This section of the PPM is not required for the Toolbox; therefore it has not been included. This page intentionally left blank Page 17 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 8 - Maintenance policy and procedures AeroFix maintenance policy It is a CASA and an AeroFix requirement that any and all maintenance, whether planned or unscheduled, that is carried out on AeroFix or customer aircraft, must be carried out in accordance with approved data. All maintenance activities are to be fully recorded and documented in accordance with the forms and procedures of this manual. Only approved serviceable aircraft parts supplied with a valid general release note number/s (GRNs) are to be fitted to any aircraft that AeroFix maintains. Maintenance will be performed for each aircraft as per the appropriate approved maintenance schedule. Approved data Approved data is defined but not limited to data issued by the aircraft or vendor manufacturer. It includes the maintenance manual, illustrated parts catalogue, SBs, component overhaul manual/s, structural repair manual/s, flight manual, aircraft operation manual, service letters, and any other data the manufacturer may issue from time to time to support their aircraft, engine or equipment etc. CASA authorised/issued approved data includes this manual, Airworthiness Directives, CASA regulations, Civil Aviation Advisory Publications(CAAPs) data issued by foreign NAAs when endorsed for use by CASA and data issued by duly recognised and CASA approved design signatory/s. Page 18 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Gippsland Aeronautics GA8 Airvan For the Gippsland Aeronautics GA8 Airvan, the following maintenance schedule is adapted from the Gippsland Aeronautics Model GA8 Airvan Service manual (PN: C01-00-03 Chapter 5 is used). All formatting and terminology is as per the Airvan manual. All references to other GA8 Airvan service manual chapters will be used. All references to Vendor information (Engine, Propeller, and other items), shall be used MAINTENANCE SCHEDULES Section Title Page 5-00-00 General ................................................................................................................... 7-3 5-00-10 Pilot Preventative Maintenance ............................................................................. 7-3 5-10-00 Time Limits ............................................................................................................ 7-3 5-20-00 Scheduled Maintenance Checks ............................................................................. 7-4 5-30-00 Maintenance Schedules. ......................................................................................... 7-4 5-40-00 Unscheduled Maintenance .................................................................................... 7-15 5-40-10 Inspection after Abnormal Flight Loads ............................................................... 7-15 5-40-20 Inspection after Heavy Landings .......................................................................... 7-16 5-40-30 Inspection after Lightning Strike .......................................................................... 7-16 Page 19 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 5-00-00 GENERAL Although the applicable regulations in the country of registration of the aircraft may vary the requirements somewhat, the aircraft will normally be required to undergo mandatory annual/100 hour inspection and maintenance performed in accordance with approved maintenance schedules. In addition, some components, in particular the propeller, engine and its accessories, will be subject to complete overhaul based on time in service (refer to paragraph 5-10-00). Gippsland Aeronautics recommends that all Mandatory Inspection and Maintenance Requirements be conducted in accordance with the Gippsland Aeronautics GA8 MAINTENANCE SCHEDULES using the procedures and techniques specified in this GA8 SERVICE MANUAL. From time to time other mandatory inspections may be required in the light of in service experience. In this event airworthiness directives relating to the airframe, engine, propeller or other components/equipment as appropriate will be issued. It is the responsibility of the owner/operator to ensure compliance with all applicable airworthiness directives and, when the inspections are repetitive, to take appropriate action to prevent inadvertent non-compliance. All maintenance carried out must be correctly recorded and certified for in the relevant logbooks and other maintenance documents. 5-00-10 Pilot Preventative Maintenance There are no unusual features of the GA8 that prevent a suitably licensed pilot from conducting preventative maintenance as allowed by the applicable regulations in the country of registration of the aircraft. 5-10-00 TIME LIMITS The following components are time-lifed. Gippsland Aeronautics recommends that they be replaced/overhauled as indicated: Component Life Requirement Engine In accordance with Engine Manufacturer’s requirements Overhaul or Replace Engine Accessories Same as Basic Engine Overhaul or Replace Propeller In accordance with Propeller Manufacturer’s requirements Overhaul or Replace Fuel and oil flexible hoses forward of firewall 5 years; or a time in service no greater than the engine overhaul/replacement hours, whichever occurs first. Replace No components other than those listed above are subject to specific replacement or overhaul periods, but should be maintained on an ‘on condition’ basis. Airworthiness Directives may be issued from time to time that vary the above lives or alternatively impose lives on additional components. In this case the requirements/lives specified in the Airworthiness Directives will take precedence over those given above. Page 20 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 5-20-00 Scheduled maintenance checks Unless specifically approved otherwise by the appropriate airworthiness authorities, the replacement or overhaul requirements for time-lifed components as listed in paragraphs 4-10-00 and 5-10-00 of this service manual must be complied with. Additionally, any special techniques required by this manual, the component manufacturer’s service manual or an AD are to be complied with as appropriate. Where the requirement is optional, compliance is also optional. The inspections required by these schedules shall be a thorough functional and visual check of the nominated system, component, assembly and/or installation. The inspection should be conducted making extensive use of inspection panels, access doors, detachable fairings and fillets. Adequate lighting is to be used and, where necessary, inspection aids such as mirrors, torches, work stands etc. Surface cleaning of individual components may also be required. The inspection of the nominated system, component, assembly and/or installation must be adequate to determine continued airworthiness or to establish that repair or replacement is required. All items are to be inspected for GENERAL CONDITION together with specific requirements where nominated. The term GENERAL CONDITION includes, but is not limited to the following: correct operation, full and free movement in the correct sense correct rigging, alignment and tension appropriate lubrication correct fluid quantities or levels correct air pressures security and cleanliness wear is within acceptable limits no loose or missing fasteners vents are free from obstruction correct clearance bonding straps correctly positioned, undamaged and secure freedom from excessive: o leakage o corrosion, deterioration of protective treatments o cracking and disbonds o deformation, wear, scoring, chafing, flat spots and fraying o obstruction or other obvious damage, or o burning, arcing or heat damage, and that hoses are within inspection and testing periods. Unless specifically approved or directed otherwise, the procedures and limits specified in this manual are to be adhered to. It is highly recommended that an engine ground run be performed prior to carrying out the inspection. 5-30-00 MAINTENANCE SCHEDULES The maintenance schedules required by Gippsland Aeronautics for the scheduled maintenance of the GA8 at each 100 hour / annual inspection, or as otherwise noted, form the remainder of this chapter. Unless otherwise approved by the applicable national airworthiness authority, all inspections listed in Maintenance Schedules are to be carried out in accordance with the procedures contained in this Service Manual. Page 21 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual GA8 MAINTENANCE SCHEDULES Page 1 CATEGORY - AIRFRAME Aircraft Registration: ....................... AME LAME REQUIRED PLACARDS External and Internal Note: Reference should be made to Chapter 11 of the Service Manual and applicable airworthiness directives for required placards WINGS AND EMPENNAGE – INSPECT Skins for evidence of wrinkles, buckles, sheared or loose rivets, corrosion, disbonding of GRP fairings and general damage. Internally through normal inspection panels for corrosion, disbonds, distortion and damage to spars & internal structures. Lift struts, horizontal stabiliser and fin. Flight control surfaces, flaps, mass balances, hinges and hinge brackets. Check freeplay per 27-10-00, 27-20-00 and 27-30-00. Wing and empennage to fuselage attachments and surrounding structure for damage, distortion, corrosion, GRP fairing disbonds, cracks and loose or sheared rivets or bolts. Lubricate all flight control system pivot points and hinges as per 12-20-30. FUSELAGE – INSPECT Skins for evidence of wrinkles, buckles, sheered or loose rivets, corrosion, disbonding of GRP fairings and general damage. Areas around cut-outs such as inspection apertures for cracks and the sealing and fit of all doors/windows. Aircraft interior for damage and security of installed equipment, internal structure. Locks, latches and hinges of doors. Windshields and windows for cleanliness, freedom from crazing, cracking, discolouration and scratches. Seats, attachments, adjustment mechanisms and stops, safety harnesses and buckles. Control columns, rudder pedals, control levers, control system bellcranks, push-pull rods, torque tubes and cables. Operate trim controls through complete range of travel and check for correct trim position indication. Brake master cylinders, lines, reservoirs for leaks and adequate fluid quantity, parking brake cable and brake system operating mechanisms. Page 22 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual GA8 MAINTENANCE SCHEDULES Page 2 CATEGORY - AIRFRAME Aircraft Registration: ....................... AME Cabin fire extinguisher for correct charge, legibility of operating instructions and condition of locking pin or seal; ensure that extinguisher has not reached expiry date. Fresh air system ducting and outlets, airflow control valves. Emergency and flotation equipment (if carried), ensure that equipment has not reached expiry date. Lubricate as per 12-20-30. LAME LANDING GEAR – INSPECT Jack aircraft so that landing gear is clear of the ground. Undercarriage attachment to airframe structural members. Nose wheel for security and condition. Main and nose wheel tyres. Clean wheel bearings and inspect for condition, re-lubricate, re-install and adjust pre-load per 32-40-00. Brake pads and discs. Brake lines and flexible hoses. FUEL SYSTEM – INSPECT Fuel tanks, lines, drains, vents, placards, filler caps/seals. Emergency shut-off valve system for correct operation. AIR CONDITIONING – INSPECT (IF INSTALLED) Air conditioning (if installed) evaporator, condenser and compressor, ducting, pipelines and units. Cabin heating and defrost. POST INSPECTION CHECK On completion of the inspection, check to ensure that no tooling, maintenance equipment or rags have been left in the aircraft and all panels, access doors, detachable fairings and fillets have been correctly secured. CERTIFICATION: I hereby certify that all maintenance in AIRFRAME CATEGORY has been completed. LAME:...................................................... Lic:....................... Date:................................. NOTE: This certification does not replace the requirement for a category certification in aircraft log book. Page 23 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual GA8 MAINTENANCE SCHEDULES Page 3 CATEGORY - ENGINE Aircraft Registration: ....................... AME LAME COWLS Remove as required, clean, check cowls and fastenings. COMPRESSION CHECK CYLINDER: #1 #2 #3 #4 #5 #6 RESULT: Compression test method used:......................................... OIL SYSTEM Drain sump, refit plug and lock-wire. Remove pressure filter, cut open and inspect for foreign and abnormal particles, replace with new filter and lock-wire. Remove and inspect suction screen for foreign and abnormal particles. Clean, reinstall and lock. Oil cooler condition, security, cooling fins (clean as required) and ducting. Oil temperature control valves, oil lines, fittings and breather. Refill sump with recommended grade and quantity of oil. IGNITION SYSTEM Remove spark plugs, clean, inspect, gap, test or renew as required. Spark plug high tension leads and ceramics. Inspect magneto housings. Check ignition timing and inspect magnetos in accordance with slick magneto products maintenance schedule 100hr inspection (and 500hr inspection if due). Switch and earth leads. Apply anti-seize to threads, refit and torque spark plugs. Clean insulators and refit high tension leads. Page 24 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual GA8 MAINTENANCE SCHEDULES Page 4 CATEGORY - ENGINE Aircraft Registration: ....................... AME LAME FUEL SYSTEM WARNING Do not perform any sort of maintenance on the fuel system in conjunction with maintenance on the electrical system. The escape of fuel fumes under the floor and/or in the aircraft may cause an explosion. Pull emergency shut-off to OFF. Remove, inspect, clean and refit fuel strainers and screens, refit lockwire. Caution – ensure service taps are turned OFF prior to removing fuel strainer lids. Inspect fuel injector components. Inspect throttle and mixture shafts and operating cables. Inspect all fuel lines and fittings. Push emergency shut-off to ON position, ensure service taps are fully ON when filter lid retainers are fitted. Carry out functional check of warning system per 28-40-10, electric fuel pump operation and emergency shut-off. Purge fuel system and check for leaks. INDUCTION SYSTEM Remove, inspect, refit or replace air filter. Alternate air system for integrity of seals, serviceability of valves, shafts, bearings and actuating cable connections. Cabin heat flexible ducts. EXHAUST SYSTEM Remove heat exchanger outer shroud and inspect exhaust pipe. Inspect carbon monoxide detector. ENGINE CYLINDERS AND BAFFLES Inspect cylinder assemblies for loose thread inserts, cracks, cracked and broken fins, worn or damaged baffles, baffle seals for serviceability. Inspect cylinder base to crankcase area for evidence of fretting and loss of torque on retention nuts. Inspect rocker covers and push rod housing seals. Inspect baffle seals for condition and sealing. Page 25 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual GA8 MAINTENANCE SCHEDULES Page 5 CATEGORY - ENGINE Aircraft Registration: ....................... AME LAME CRANKCASE, ACCESSORY HOUSING AND FIREWALL Inspect engine for evidence of oil leakage. Inspect all accessories and drive belts. NOTE: If alternator drive belt requires replacement, a tension check is to be carried out within 10–20 hours of installation. Inspect engine mounts (rubbers) for delamination and set, engine mount bolts. Inspect engine mount frame for condition and signs of overheating. Inspect firewall including seals and sealant. CONTROLS Inspect the following controls for full and free movement in the correct Sense. Throttle, mixture and propeller. Alternate air. PROPELLER Note: For further details refer to the Propeller Owner’s Manual. Propeller for blade track. Propeller hub, spinner and backplate. Attachment bolts for looseness and locking. Blades for nicks, backlash, creep and dimensions within limits. Lubricate propeller hub and service with air iaw manufacturer instructions (if applicable). REFIT COWLS Ensure that no tooling, rags or other foreign objects remain in the engine compartment before proceeding. Latches and fasteners for correct tension. Inlet and cooling air ducting. Engine drain lines. Baffle seals forward facing and correct. GA8 MAINTENANCE SCHEDULES Page 6 Page 26 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual CATEGORY - ENGINE Aircraft Registration: ....................... AME LAME ENGINE GROUND RUNS Carry out an engine ground run. Functionally check, operate and observe the following. Cowls should all be in place and secured. Start engine and stabilise engine temps and pressures. Alternator charging, voltage correct. Record maximum static rpm, manifold pressure, fuel flow, oil temperature and pressure, and cylinder head temperature. Recorded values Airfield pressure height and OAT Max. static RPM Manifold pressure Fuel flow Oil temperature Oil pressure Cylinder head temperature Idle speed, mixture and magneto switch operation at low RPM – momentarily check for dead cut. Operate alternate air and check warning light. Note any unusual engine vibration or noises and rectify as required. Check engine response to throttle application, smooth acceleration with no hesitation. Magneto RPM drop check and prop governor operation. Idle cut-off operation, then Open cowls, check for oil and fuel leaks, secure cowls. CERTIFICATION: I hereby certify that all maintenance in ENGINE CATEGORY has been completed. LAME:...................................................... Lic:....................... Date:................................. NOTE: This certification does not replace the requirement for a category certification in aircraft log book. Page 27 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual GA8 MAINTENANCE SCHEDULES Page 7 CATEGORY - ELECTRICAL Aircraft Registration: ....................... AME LAME WARNING Do not perform any sort of maintenance on the electrical system in conjunction with maintenance on the fuel system. The escape of fuel fumes under the floor and/or in the aircraft may cause an explosion. REQUIRED PLACARDS External and Internal, including terminal labelling per 24-00-50 Note: Reference should be made to Chapter 11 of the Service Manual and applicable airworthiness directives for required placards. AIR CONDITIONING (IF INSTALLED) Inspect distribution system electrical components and interwiring. Inspect heating and temperature control system. Inspect freon system electrical components and interwiring. ELECTRICAL POWER Inspect for security, freedom from damage and proper function. DC generation system (includes alternator, regulator, transformer/rectifier units, interwiring, control relays and switches). DC distribution system (includes buses, circuit breakers, relays, switches and interwiring). Starter. Battery general condition. External power system (if installed). Functional test of alternator/capacitor system per 24-00-30. FUEL Inspect electrical components and interwiring associated with fuel pump and warning system. STALL WARNING SYSTEM Functional test of stall warning system. LIGHTS inspect cockpit, navigation, landing and anti-collision(if fitted). ENGINE AND IGNITION Inspect for security and freedom from damage. Electrical harnesses, excluding ignition harness. Ignition switching, including insulation check of magneto switch leads. Page 28 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual GA8 MAINTENANCE SCHEDULES Page 8 CATEGORY - AIRFRAME Aircraft Registration: ....................... AME LAME ENGINE STARTING Inspect for correct starter operation, solenoid and relay operation and adequacy of high current operations. Cranking system. Test starter solenoid and relay per 80-10-30. POST INSPECTION CHECK On completion of the inspection, check to ensure that no tooling, maintenance equipment or rags have been left in the aircraft and that all panels, access doors, detachable fairings and fillets have been correctly secured. CERTIFICATION: I hereby certify that all maintenance in ELECTRICAL CATEGORY has been completed. LAME:...................................................... Lic:....................... Date:................................. NOTE: This certification does not replace the requirement for a category certification in aircraft log book. Page 29 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual GA8 MAINTENANCE SCHEDULES Page 9 CATEGORY – INSTRUMENT Aircraft Registration: ....................... AME LAME REQUIRED PLACARDS External and Internal Note: Reference should be made to Chapter 11 of the Service Manual and applicable airworthiness directives for required placards. FUEL SYSTEM Inspect fuel pressure and quantity indication systems. INDICATING AND RECORDING Inspect instrument panel and instruments. NAVIGATION Inspect pitot/static system, including associated instruments. Functional test of pitot-static caution system per 34-10-00. Inspect magnetic compass. INSTRUMENT VACUUM SYSTEM Inspect distribution system and filter. ENGINE INSTRUMENTS Inspect tachometer, manifold pressure and fuel flow (if fitted). Inspect oil temp, oil pressure. CAUTION/WARNING LIGHTS Functional test of caution/warning light system, POST INSPECTION CHECK On completion of the inspection, check to ensure that no tooling, maintenance equipment or rags have been left in the aircraft and that all panels, access doors, detachable fairings and fillets have been correctly secured. CERTIFICATION: I hereby certify that all maintenance in INSTRUMENT CATEGORY has been completed. LAME:...................................................... Lic:....................... Date:................................. NOTE: This certification does not replace the requirement for a category certification in aircraft log book. Page 30 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual GA8 MAINTENANCE SCHEDULES Page 10 CATEGORY – AIRFRAME Aircraft registration: ....................... AME LAME REQUIRED PLACARDS External and Internal, including frequency charts. Note: Reference should be made to Chapter 11 of the Service Manual and applicable airworthiness directives for required placards. COMMUNICATION & NAVIGATION Operation and function of all installed radio systems. ATC transponder system (if installed) for correct performance in all modes using the self test facility. Select code 0101 for this test. Accessible interwiring, plugs and sockets. Microphones, headsets (helmets) and cords. Antennas and antenna insulators. ELT/ELB (if installed) batteries for electrolyte leakage and remaining battery life. Removable units, mounting racks and bonding. Switches and controllers. Radio panel lamps for adequate illumination, and Radio indicators for legibility. POST INSPECTION CHECK On completion of the inspection, check to ensure that all tools, maintenance equipment or rags have been removed from the aircraft and that all panels, access doors, detachable fairings and fillets have been correctly secured. CERTIFICATION: I hereby certify that all maintenance in RADIO CATEGORY has been completed. LAME:...................................................... Lic:....................... Date:................................. NOTE: This certification does not replace the requirement for a category certification in aircraft log book. Page 31 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 5-40-00 UNSCHEDULED MAINTENANCE Unscheduled maintenance includes those inspections required after the report of abnormal flight loads due to severe air turbulence or manoeuvres exceeding flight limitations, heavy landing or lightning strike. If damage is found, this inspection must be extended to its logical conclusion as loads sufficient to produce damage or distortion at one point may be expected to have caused damage elsewhere. 5-40-10 Inspection after Abnormal Flight Loads Abnormal flight loads result from severe turbulence or incidents where the aircraft is upset and subjected to excessive acceleration and/or the ‘never exceed’ speed is exceeded. The defects that may result from such manoeuvres include structural distortion, usually indicated by skin wrinkles in the wings or fuselage, and damage at or near main assembly points. The following items detail the inspections required after the report of such occurrences. Inspect the control elements (tail surfaces and ailerons) together with flaps for general condition. Check the flap push-rod and operating lever for signs of deformation or damage. Check all mass balances for security of attachment. Operate all flight and engine control systems for full and free movement. If increase in static friction or backlash is noted, the system must be checked from end to end to ascertain the cause. Inspect the wing internally (through normal inspection panels) and externally, particularly in the region of the wing root at the front spar and in the vicinity of the front spar strut attachment, for evidence of wrinkles, buckles, sheared or loose rivets. Inspect the integral fuel tank for signs of leaks. Note: Cracked or flaking paint may be an indication of permanent deformation. Inspect lift struts, horizontal stabiliser and fin for signs of deformation. Remove wing and strut attachment bolts and inspect for deformation. Inspect engine mounts and fittings for evidence of permanent deformations and cracks. Inspect main spar, rear spar and strut carry-through structure. Inspect attachment of components such as the battery. Page 32 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 5-40-20 Inspection after Heavy Landing The effects of heavy landings are usually more locally concentrated than in the case of abnormal flight loads. The impact of a hard landing transmits an upward force through one or more of the undercarriage components according to which takes the impact, into the fuselage structure above, a corresponding inertia load is applied to the remainder of the structure. If the undercarriage and attachments give indications of heavy landing damage, a more thorough inspection of the aircraft, including all items of section 5-40-10, must be completed. Jack the aircraft so the wheels are clear of the ground and perform the following inspections. Inspect main and nose landing gear legs for distortion and security of attachment. Remove attachment bolts as required and examine for signs of shearing. Remove wheels and examine for damage; hubs for signs of cracking, distortion or damage. Examine axle for bowing and attachment bolts for shearing. Examine tyres for creep, damage to outer casings, bulges etc, and general signs of casing fractures. Inspect all structure around the main undercarriage and nose wheel attachment points for signs of permanent deformation. 5-40-30 Inspection After Lightning Strike Most lightning strikes show evidence of entering or leaving the tips of propeller blades. In some instances the area is dark in colour and erosion is present. Generally, the material around the area is annealed. The other area that is damaged is the thrust bearing for the blades. Arcing sometimes occurs and is evident on the race balls of the bearing. In every case, all steel parts are magnetized due to the flow of the current. In the event of a propeller lightning strike; act in accordance with the Propeller and Engine Owner’s Manuals. Perform a complete airframe inspection if there is evidence to suggest lightning has struck the wings or fuselage, typically indicated by scorch marks and erosion at the point of impact. In addition to a complete airframe inspection, particular attention should be paid to control surface hinge bolts for erosion and other damage caused by arcing. Also inspect the fuel vent system plenum, located on the cabin roof between wing/fuselage pickups, for erosion along the trailing edge and burn marks on the paint. Page 33 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 9 - Forms Table of contents 1 Introduction 2 Control of forms 3 Maintenance and record forms 4 Description of forms 5 Retention of documents Page 34 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Forms 1. 2. Introduction A. The forms listed in this section are part of the approved Maintenance Records System, System of Certification or Maintenance Release. The forms are presented as training versions only. B. Miscellaneous forms and control documents of an administrative or commercial nature are not included. Control of forms A. All forms used by AeroFix are controlled by the Quality Assurance Officer, who keeps a computer register of the forms and retains the master copy of all computer generated forms. B. Applications for new forms or changes to existing forms are covered by raising a Manual Change Request (Form 9). C. Some of the forms used are CASA forms that normally are downloaded from the CASA website or purchased directly from CASA. Included here are training versions of these forms. Note: The forms contained in this manual are for training only and are not to be used for any other purpose. 3. Maintenance and record forms Form No. Page 35 Title 1A Work and Survey Sheet (single tasks) 1B Additional Work Sheet 2 Work Package Summary 3 Maintenance Due List 4 Airworthiness Directives List 5 Trade Identification Sheet 6 Independent Inspection of Controls 7 Category Coordination Certification Sheet 8 Maintenance Release 9 Manual Change Request 10 Authorised Release Certificate 11 Major Defect Report (CASA Form 404) 11A Irregularity Report 12 List of Accountable Documents © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual 4. 5. Page 36 Description of forms A. The following pages contain summarised descriptions of the purpose, procedures and filing/retention of forms used for aircraft maintenance, together with a facsimile of each form. B. Chapter 3, paragraph 2 contains a brief description of the various certification documents used in the system of maintenance. Retention of documents A. At the completion of work, the Maintenance Coordinator will photocopy a set of all completed documents and forward to the Technical Services Section for filing. These documents will be retained for a period of five (5) years. B. The original completed documents are passed onto the owner/operator. C. The signed Maintenance Release must be placed in the aircraft log in the aircraft cockpit prior to the aircraft returning to service at the completion of maintenance. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Form 1A – Work and Survey Sheet (single tasks) 1. Purpose/description A. 2. 3. Procedure summary A. Details of the work required are entered on the Work and Survey Sheet (Form 1A). B. The form is issued to Maintenance and accounted for on the Work Package Summary (Form 2). C. On completion of the work, each item is certified on the Work and Survey Sheet (Form 1A) by an appropriately licensed AME or a person holding an appropriate authority. Filing/retention A. Page 37 Used by the Maintenance Controller or his/her delegate to list all scheduled maintenance, modifications and special inspections, record defects found during scheduled maintenance, and/or subsequent additional work etc to be accomplished on the aircraft during a particular lay-up; including previously deferred defects requiring rectification. This form is used for single tasks only. See Form 1B for multiple tasks. Filed with the aircraft records, retained for a period for five (5) years. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 1A – WORK AND SURVEY SHEET A/C registration Date Raised by Page of Job no Dash no Client fax no Faxed (date) Work required Cost estimate of replacement parts Client approval required AUD Manhours estimate Parts estimate Approval and date YES/NO Action taken Component replacement Component OFF Component ON Posn P/N S/N P/N S/N P/N S/N P/N S/N GRN LAME certification I hereby certify, pursuant to the requirements of CASA that all maintenance has been properly performed. Signature License no Date Airframe Engine Elect/inst Radio Page 38 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Form 1B – Additional Work Sheet 1. Purpose/description A. 2. 3. Procedure summary A. Details of the work required are entered on the Additional Work Sheet (Form 1B). B. The form is issued to Maintenance. C. On completion of the work, each item is certified on the Additional Work Sheet (Form 1B) by an appropriately licensed AME or a person holding an appropriate authority. Filing/retention A. Page 39 Used by the Maintenance Controller to list all scheduled and unscheduled maintenance, modifications and special inspections, record defects found during scheduled maintenance, and/or subsequent additional work etc where a multiple task sheet is required. Work is to be accomplished on the aircraft during a particular layup, including previously deferred defects requiring rectification, or for unscheduled lay-ups. Filed with the aircraft records, retained for a period for five (5) years. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 1B – ADDITIONAL WORK SHEET Document serial no ...................................................................... Job no ......................... Aircraft type 1. Item Aircraft registration ............................................ Aircraft serial no ................................................................... ....................................................................................................................................... 2. Inspection or task required 3. Action taken Page .......... of ............. 4. Component details 5. Sign auth no and date P/N OFF AME S/N OFF LAME P/N ON S/N ON Hours Landings R/N P/N OFF AME S/N OFF LAME P/N ON S/N ON Hours Landings R/N P/N OFF AME S/N OFF LAME P/N ON S/N ON Hours Landings R/N A certification in Column 5 above constitutes a certification pursuant to the requirements of CASR part 43 subpart F that all maintenance has been properly performed. A coordination and final certification Page 40 Licence no © Commonwealth of Australia | Licensed under AEShareNet – S Licence Date Aeroskills Toolbox 2008 Policy and Procedures Manual Form 2 – Work Package Summary 1. Purpose/description A. 2. 3. Procedure summary A. Form 2 is raised whenever the aircraft is scheduled for maintenance. B. Form 2 will list all relevant inspection schedules, AD’s, Service Bulletins, relevant forms etc. and details of the new Maintenance Release. C. When maintenance has commenced, the Maintenance Coordinator/Planner or his/her delegate ensures any additional documents, inspections etc are raised during the maintenance activity are recorded on Form 2. At the completion of the maintenance, the Coordinator or his/her delegate records the new Maintenance Release details on the Form 2 or deletes those sections if no Maintenance Release is to be issued. The Coordinator or his/her delegate will ensure that all documents raised during the check are accounted for on Form 2 and sign the Co-ordination Certification Statement in accordance with the requirements of Chapter 3 of this manual and return the form with the completed work package to AeroFix’s records section at the completion of the maintenance activity. D. Once the aircraft has been received for maintenance any additional maintenance or inspection work requirements raised, are considered to be supplementary to the original work package and are to be recorded in the next vacant task field on this form, if all the fields are exhausted then another blank Form 2 to is raised and appended to the original and its serial number is referenced on the list of accountable documents; Form 12. Filing/retention A. Page 41 Used to coordinate and record all documentation raised during scheduled maintenance. Filed with the aircraft records, retained for a period for five (5) years. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 2 – WORK PACKAGE SUMMARY Document serial no Page Aircraft Reg: Aircraft serial no Issue date: Task no/ defect no of Aircraft type Issued by: Description Corrective action status AME sign LAME sign Licence Date no 1 2 3 4 5 6 7 Co-ordinator’s statement All the required maintenance has been carried out, completed and duly certified. All documents have been accounted for and a Maintenance Release has been issued. Date Page 42 Signature Licence no OR employee approval no © Commonwealth of Australia | Licensed under AEShareNet – S Licence Maintenance Release issued Aeroskills Toolbox 2008 Policy and Procedures Manual Form 3 – Maintenance Due List 1. Purpose/description A. To itemise maintenance that will be due in the life of the issued Maintenance Release. This form allows for a more comprehensive list of tasks than what is allowed for on the Maintenance Release; Maintenance Required section. More than one form can be raised if required. 2. Procedure summary A. The Maintenance Due List (Form 3) will accompany the Maintenance Release. All due maintenance and deferred maintenance will be listed on this form and when cleared will be certified to show the clearance. B. At the completion of any maintenance activity if any items of maintenance on this list have not been completed and have hours remaining, the aircraft planner is to track the outstanding items on this list to ensure the maximum hours before rectification is not exceeded. 3. Filing/retention A. Filed with the aircraft records, retained for a period for five (5) years. A copy is sent to the aircraft planner. Page 43 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 3 – MAINTENANCE DUE LIST VH - Serial no Sheet of Phase checks …………………………… carried out at Maintenance Release issue. The following work is required to be carried out during the validity of Maintenance Release no ……………………. Issued at TTIS Lands Maintenance Release # Date #1 eng hrs #2 eng hrs #1 cycles #2 cycles is valid until or total hours Work due Item Work required TTIS Work completed Lands Date * cert lame no Date cert *A signature in this column for the completion of maintenance shall constitute a certification required by CASA.. Page 44 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Form 4 – Airworthiness Directives List 1. Purpose/description A. 2. 3. Procedure summary A. The list is compiled from AD lists published on CASA website and is updated as new ADs are issued. B. The list is continually updated and, at the completion of each maintenance phase, a new list is implemented to show the status of all ADs. Filing/retention A. Page 45 Used to list all applicable ADs required for the aircraft. Keep with the aircraft documentation for the life of the aircraft. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 4 – AIRWORTHINESS DIRECTIVES LIST Aircraft serial no ……………………………………………..… VH-………………….. CASA mandated Ads. Aust AD no Page 46 Description Compliance © Commonwealth of Australia | Licensed under AEShareNet – S Licence Certification Aeroskills Toolbox 2008 Policy and Procedures Manual Form 5 – Trade Identification Sheet 1. Purpose/description A. 2. Procedure summary A. 3. The Quality Coordinator ensures all required details are entered on the sheet prior to signing the Maintenance Release. Filing/retention A. Page 47 Provides a record of persons certifying for work with a cross-reference to the license number and signature. Filed with the aircraft records, retained for a period for five (5) years. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 5 – TRADE IDENTIFICATION SHEET Aircraft reg ........................... Surname Page 48 Initials Inspection ............................................. Signature Licence or authority no Job no ............................. Category © Commonwealth of Australia | Licensed under AEShareNet – S Licence Expiry date Tick () if category coordinator Aeroskills Toolbox 2008 Policy and Procedures Manual Form 6 – Independent Inspection of Controls 1. Purpose/description A. 2. Used to record and certify for an initial inspection of controls/systems disturbed during maintenance by the LAME who performed the work and for a second, independent inspection. Procedure summary A. The person who initiates or performs the work is responsible for recording details of the maintenance being carried out on the Independent Inspection of Controls (Form 6) in accordance with the requirements of this manual. B. On completion of the work, a second independent inspection for correct assembly and operation of the affected system is made. C. First inspection will be carried out and certified by the holder of a valid appropriate AME licence or valid appropriate maintenance authority. Second inspection shall be carried out and certified by a person, other than the person who performed the first inspection, who is the holder of a: valid appropriate AME licence; valid appropriate maintenance authority; or current pilot licence, other than a student pilot licence, that is valid for the aircraft. 3. Filing/retention A. Page 49 Filed with the aircraft records, retained for a period for five (5) years. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 6 – INDEPENDENT INSPECTION OF CONTROLS Aircraft type Aircraft reg Job no Date Flight or engine control system or portion of control system affected 1. 2. 3. 4. 5. 6. 7. 8. I hereby certify that the assembly and locking of that portion of the control systems which have been subject to adjustment or replacement have been correctly carried out. I have verified that all affected controls have full, free and correct movement through their specified operating ranges. First inspection: LAME signature * Lic./auth no Date Lic./auth no Date Second inspection: LAME/pilot signature * *A signature in this section for the completion of maintenance shall constitute a certification as required by CASR part 43 subpart D. NOTE 1 First inspection will be carried out and certified by the holder of a valid appropriate AME licence or valid appropriate maintenance authority. Second inspection shall be carried out and certified by a person, other than the person who performed the first inspection, who is the holder of a: valid appropriate AME licence; valid appropriate maintenance authority; or current pilot licence, other than a student pilot licence, that is valid for the aircraft. Page 50 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Form 7 – Category Coordination Certification Sheet 1. Purpose/description A. 2. Procedure summary A. 3. The Category Coordination Certification Sheet (Form 7) is issued with the work package required for a particular scheduled inspection or other maintenance function, or used by the Maintenance Category Coordination Certification or Dual Category Coordination Certification of a particular maintenance task(s). Filing/retention A. Page 51 Used to record Category Coordination Certification or Dual Category Coordination Certification of scheduled inspections and other maintenance tasks. The form has the provision for Category Coordination Certification of all trades categories involved in a scheduled inspection, and individual task Dual Category Coordination Certification. Filed with the aircraft records, retained for a period for five (5) years. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 7 – CATEGORY COORDINATION CERTIFICATION SHEET Aircraft registration Inspection/check Job no Trip no Category coordination certification I hereby certify that all work in the applicable category has been completed and certified or properly deferred in accordance with the requirement of the Maintenance Control Manual. Category Signature Licence no Date Airframe Engine Electrical Instruments Radio Dual category coordination certification I hereby certify that, in relation to the task item(s) listed below, the required work in the applicable categories has been completed and properly certified. Task/item no Page 52 Signature Category Licence no © Commonwealth of Australia | Licensed under AEShareNet – S Licence Date Aeroskills Toolbox 2008 Policy and Procedures Manual Form 8 – Maintenance Release (CASA form 194) 1. Purpose/description A. 2. the signature of the Maintenance Coordinator indicating all maintenance has been completed and certified (2) specifying the period of validity of the Maintenance Release (3) recording and certifying for any inspections or maintenance tasks required during the period of validity of the Maintenance Release (4) recording any defect or damage which has not been rectified, ie minor defects, permissible unserviceabilities, defects or damage covered by a Permit to Fly (5) certifying for the rectification of defects. Refer to detailed description provided in Coordination of Maintenance and Maintenance Release Issue in this manual. Filing/retention A Page 53 (1) Procedure summary A. 3. Has provision for the following: The form is made out in duplicate and distributed as follows: (1) white original – carried in the aircraft throughout the period of validity, retained with the aircraft records until five (5) years after completion of Contract LPD01058 or the aircraft is permanently withdrawn from service, or on sale of aircraft, transferred as directed by the new owner (2) pink carbon copy– retained by the Maintenance Coordinator who issued the Maintenance Release for minimum period of twelve (12) months. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 8 – MAINTENANCE RELEASE VH: ................................... AIRCRAFT TYPE: ................................... MAINTENANCE RELEASE ISSUED ON MR No. ………………………………… HOURS, CYCLES, LANDINGS AT CURRENT MAINTENANCE RELEASE ISSUE: MAINTENANCE RELEASE EXPIRES TTIS LH ENGINE TTIS RH ENGINE CYCLES TTIS AIRFRAME CYCLES TTIS APU LANDINGS OR TTIS DATE WHICHEVER IS THE EARLIER DATE DATE FROM TO T.O. TIME LAND TIME FLIGHT TIME Defect reported1400 AIRCRAFT TOTAL TIME IN SERVICE AIRCRAFT LANDINGS SINCE M.R. ISSUE Sign CREW CERTIFICATION* LICENCE NUMBER PRE FLIGHT POST FLIGHT Action taken FUEL ADDED REMAINING Certification * date / licence no Pilot LAME Maintenance required during validity of Maintenance Release and MEL items Item/MEL ref Category Due at Certification * date / licence no Outstanding items transferred to MR S/N This Maintenance Release has been issued by virtue of reg. 43.(7)(a) of the Civil Aviation regulations and except where it ceases to be in force by virtue of regulation 45 or 47 of the Civil Aviation regulations shall remain in force until: Issued by: ........................................... Approval no. Signed: ............................................... LAME no. ............................. Date: ............................. Time ............ PLACE: ................................ DATE: ……………………………… This aircraft is approved for IFR operations in the ................. category. OR ………………………………..TTIS ....................... AeroFix system of maintenance applicable to this aircraft. * A signature in this column, certifying for the completion of maintenance shall constitute a certification required by CASR part 43 Subpart F. Page 54 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Form 9 – Manual Change Request 1. Purpose/description A. 2. 3. Procedure summary A. Where manual amendments are called for, these shall show the amendment number. B. An amendment record page is provided. C. All amendments to the current issue of this manual shall be indicated by a vertical black line against the right hand margin of the applicable text and the amendment number in the page footer. D. After approval by the Maintenance Controller or CASA, as required, copies of the amendment will then be passed to all registered manual holders. E. It is the responsibility of the Quality Coordinator and the Maintenance Controller to maintain and amend this manual as required Filing/retention A. Page 55 Should the operator, maintenance organisation or CASA become aware that this manual is no longer appropriate or is defective, it is a requirement that they contact the Quality Coordinator as soon as practical, using a Manual Change Request (Form 9) stating the areas of concern. The Maintenance Controller shall hold on file the Manual Change Request (Form 9), with all relevant data including a copy of the amendment issued and a copy of the superseded pages. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 9 – MANUAL CHANGE REQUEST Manual / procedure no / form no Manual Controller Chapter Originator (print name) Page(s) MCR no Job no File no Change requested / reason for change Originator’s signature Date CASA approval required YES/NO Comments Signature Date Maintenance Controller comments Signature Date Note: If space insufficient to complete comments, continue overleaf. Authorised person approval Maintenance Controller Approved by CASA Letter reference no Date YES/NO Page 56 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Form 10 – Authorised Release Certificate 1. Purpose/description A. 2. 3. Page 57 Certifies that, unless otherwise specified, the work identified and described on this form was carried out in accordance with CASA regulations, with regard to Return to Service of Aircraft and Aeronautical Products, and in respect to that work the items are approved for return to service. Procedure summary A. The form is raised at the completion of all maintenance carried out on aeronautical items and components or items and aeronautical components inspected and deemed fit for aircraft use. B. No aeronautical component or item is to be installed on the aircraft without one of these forms being raised to assure its serviceability. Filing/retention A. The original is to travel with the component or item and, when installed on the aircraft, to be placed in the aircraft records. B. A copy is to be held on record in the workshop as evidence of work or inspection carried out. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 10 1. Approving NAA/country 3. Form tracking no AUTHORISED RELEASE CERTIFICATE 4. Organisation name and address 6. Item 7. Description 5. Work order/contract invoice no 8. Part no 9. Eligibility 10. Quantity 11. Serial/batch no 12. Status/work 13. Remarks 14. Certifies that the items above were manufactured in conformity to: approved design data and in a condition for safe operation; or non-approved design data specified in Block 13. 19. CASA part 43 Return to service Other regulations specified in Block 13 Certifies that, unless otherwise specified in Block 13, the work identified in Block 12 and described in Block 13 was carried out in accordance with CASA regulation, CASR part 43 subpart F Return to service of Aircraft and Aeronautical Products, and in respect to that work the items were approved for return to service. 15. Authorised signature 16. CASA approval no 20. Authorised signature 21. CASA certificate no 17. Name (printed or typed) 18. Date (DD/MM/YY) 22. Name (printed or typed) 23. Date (DD/MM/YY) User/installer responsibilities It is important to understand that the existence of this document alone does not automatically constitute authority to install the part/component/assembly. Where the user/installer works in accordance with the national regulations of a National Aviation Authority (NAA), different than the NAA of the country specified in Block 1, it is essential that the user/installed ensures that his/her NAA accepts parts, components and assemblies from the NAA of the country specified in Block 1. Statements in Block 14 and 19 do not constitute installation certification. In all cases the aircraft maintenance record must contain an installation certification issued in accordance with the national regulations by the user/installed before the aircraft may be flown. Page 58 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Form 11 – Major Defect Report (CASA Form 404) 1. 2. 3. Purpose/description A. Used by persons reporting aircraft defects, as required by CASA regulations. Helpful instructions for the use of this form are contained on page 3 of the form. B. Enquiries regarding the form may be directed to any CASA District Office. Procedure summary A. Refer to page 3 of the form for all procedures regarding this form. Note an up to date version of this form can be obtained from the CASA website under ‘forms’. B. A report will be submitted under one of the three categories following and follow up as stated must be adhered to. C. Notification of defect with complete investigation results – no further submissions are anticipated. D. Initial defect notification only – report that does not contain all of the required information or investigation results. A follow-up report is required to be submitted. E. Follow-up report from earlier defect notification – a report of investigation results or additional information following from an initial defect notification only. Filing/retention A. Page 59 This report is to be sent to CASA at the earliest convenient time. A copy will be kept on file with the aircraft records. The originator will also keep a copy for reference. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 11 – COPY OF CASA FORM 404 (Major Defect Report) Page 60 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Page 61 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Page 62 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Form 11a – Irregularity Report 1. Purpose/description A. 2. 3. Page 63 Used by AeroFix personnel to report: major defects operational irregularities or system anomalies events, actions or situations that may lead to potential hazards to aircraft safety in flight or on the ground which have, or may have, impact on air safety results of AD requirements or any special inspections. B. The Quality Coordinator is to assess the reported irregularity and notify the aircraft’s operator if it is a third party, or CASA via an SDR if it is an AeroFix operated aircraft, of the condition/defect identified. The manufacturer of the affected aircraft and/or its equipment is to be advised if relevant. C. Enquiries regarding the form may be directed to the Quality Coordinator. Procedure summary A. All the fields are to used as required, providing as much detail as available. B. The main body of the form is to be used for an accurate description of the irregularity, hand drawn pictures are acceptable and the reverse side of the form may used. Photos and/or video may be provided in hardcopy or electronic format. (Note: Any electronic support files are to be forwarded to [email protected] referencing the serial number of the Irregularity Report raised.) C. Once raised, the form must be serialised and accounted for. D. This form is raised in triplicate with a copy to be retained by the author. The second copy is provided to the Quality Coordinator and the remaining copy is to be sent to the CE. Filing/retention A. This report is to be faxed and sent to the Quality Coordinator and the CE at the earliest convenient time. A copy will be kept on file with the aircraft records. The originator will also keep a copy for reference B. The Quality Coordinator is to send a copy to the aircraft operator if they are a third party to AeroFix. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 11A – IRREGULARITY REPORT Complete this report in writing, including diagrams if necessary. Attach any photos, video and copies of any other reference material (provided material can be hard and/or electronic copy). This form is to be used by AeroFix personnel to report: major defects operational irregularities or system anomalies events, actions or situations that may lead to potential hazards to aircraft safety (in flight or on the ground) which have or may have impact on air safety results of AD requirements or any special inspections. Date Time Location/port Aircraft reg Aircraft S/N Engine S/N Affected part no Affected part S/N TSN TIS Cycles MM reference SB/AD reference Was there an in-flight shut down? Yes No Not applicable Describe irregularity below: Use reverse side if required or attach further pages. This form is raised in triplicate with a copy to be retained by the author, the second copy to be provided to the Quality Coordinator and the third copy is to be sent to the Chief Engineer. Any electronic copies of support files are to be forwarded to [email protected] Note: information provided on this form maybe used in completing CASA SDRs. Page 64 © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual Form 12 – List of Accountable Documents 1. Purpose/description A. 2. 3. Procedure summary A. Details of the serial numbers of any maintenance form used are entered on the List of Accountable Documents. B. This form is issued with a Maintenance Work Package Summary (Form 2). C. If all the available fields of the current List of Accountable Documents are completed, second and subsequent forms are raised as necessary. The latest form with vacant fields in use is considered the active list; all previous filled forms must also remain with the package until coordination is complete. D. Any form 12 with all fields exhausted then becomes the previous List of Accountable Documents. The serial number of the previous List of Accountable Documents is entered in the first vacant field of the next active form so it becomes accountable. E. CE, Maintenance Controller or LAME/s can raise any additional List of Accountable Documents during a maintenance activity. They must enter the serial number of the previous accountable form on to the active List of Accountable Documents. F. The person appointed to coordinate the Work Package Summary (Form 2) is to check that the List of Accountable Documents is present at the completion of any maintenance activity, and all forms entered on it are present, certified and accounted for. Filing/retention A. Page 65 Used by the Maintenance Controller and must be available during all scheduled or unscheduled maintenance, or any time that an accountable document has been raised or completed. Filed in accordance with filing and retention instructions. © Commonwealth of Australia | Licensed under AEShareNet – S Licence Aeroskills Toolbox 2008 Policy and Procedures Manual FORM 12 – LIST OF ACCOUNTABLE DOCUMENTS Document serial no Page Aircraft reg Aircraft serial no Issue date Issued by Date Document description Page 66 Document serial no of Aircraft type © Commonwealth of Australia | Licensed under AEShareNet – S Licence Pages Accounted for (initial) Aeroskills Toolbox 2008
