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TECHNICAL AIRWORTHINESS MANAGEMENT MANUAL

SECTION 2 LEAFLET 5

TECHNICAL AIRWORTHINESS REGULATION

REGULATION 5 AIRCRAFT MAINTENANCE AND MANAGEMENT PROCEDURES 5.1. CONDUCT OF MAINTENANCE 5.1.1. Maintenance Authority a. The Approved Maintenance Organisation (AMO) shall only conduct maintenance of State aircraft and aeronautical product to the scope and level stated in the AMO certification and associated Letter of Maintenance Authority. 5.1.2. Publications, Instructions, Orders and Data a. The AMO shall ensure that only Publications, Instructions, Orders and Data authorised by the DGTA are used in the conduct of maintenance on State aircraft and aeronautical product. b. The Senior Maintenance Manager (SMM) shall ensure that the AMO has, or has access to, DGTA and/or responsible AEO approved technical publications, instructions, orders and data required for the maintenance activities within their assigned scope and level. c. The AMO shall list all Publications and Instructions held by the AMO, either directly or by reference, in the Maintenance Management Plan (MMP). d. A system for management and review of Publications, Instructions, Orders and Data used for the maintenance of State aircraft and aeronautical product shall be documented, either directly or by reference, in the MMP. e. Publications and Instructions used for the maintenance of State aircraft and aeronautical products shall: (1) (2) (3) be complete and up to date, be maintained in good order, be accessible to personnel,

(4) be applicable to the scope and level of maintenance being conducted, (5) be supported by a master document or record allowing the amendment status and document completeness to be ascertained, and (6) contain or display: (i) (ii) (iii) (iv) their authority for use, document name, date of issue, and their sponsor.

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5.1.3. Foreign Source Data a. The AMO shall only use Foreign Source Data where it is authorised by DGTA 5.1.4. Maintenance Procedures a. The AMO shall use only maintenance procedures approved by DGTA to conduct maintenance on aircraft and aeronautical product. b. The AMO shall only use those maintenance policies, plans, and procedures applicable to the aircraft and/or aeronautical product being maintained, or as determined by DGTA c. The AMO shall report to DGTA as applicable any deficiencies in approved maintenance procedures. d. The AMO shall submit recommendations for changes to approved maintenance practices or procedures to DGTA. e. The SMM may authorise a local maintenance procedure to amplify or clarify AEO or DGTA authorised maintenance procedures. f. The SMM shall ensure that all local maintenance procedures authorised under 5.1.4.e are stated, either directly or by reference, in the MMP. 5.1.5. Maintenance Certification a. All maintenance performed shall be accurately and progressively documented and certified by the person who performed the maintenance. b. Only duly authorised persons shall certify maintenance on completion of the task. c. The person certifying maintenance shall ensure that the certification makes reference to the applicable technical instruction used in the conduct of the maintenance. d. Where an authorised person is responsible for supervising a person under training, the authorized person shall accept full responsibility for the maintenance performed and certify that maintenance. e. A person certifying the release of an aircraft or aeronautical product from maintenance shall ensure: (1) all required maintenance has been completed and certified, or a determination has been made in accordance with Regulation 5.1.11 to defer any maintenance required; (2) the aircraft configuration; and or aeronautical product is in an approved

(3) all tools and test equipment used during maintenance have been removed from the aircraft or aeronautical product and / or accounted for. 5.1.6. Independent Maintenance Inspections a. The SMM shall ensure that only personnel authorised in accordance with Regulation 4.5.6 (Maintenance Inspector/Supervisor) perform independent maintenance inspections. b. As a minimum and unless otherwise specified by the DGTA, Independent Maintenance Inspections shall be performed whenever any of the following safety-critical items or systems are replaced, adjusted or reconnected: www.dgta.gov.my 2.5 - 2 of 13 TERHAD

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(1) (2)

flying controls and associated equipment; engine controls and associated equipment; brake and steering controls, and

(3) undercarriage controls, associated equipment; (4) (5) (6)

installed airborne oxygen equipment; aircrew escape and survival equipment; and explosive ordnance and associated equipment.

c. The in-service DAR and/or the SMM shall specify additional independent maintenance inspections as required. d. Independent Maintenance Inspections performed in accordance with Regulation 5.1.6.a, b and c shall be performed to ensure that all items: (1) are correctly assembled, adjusted and locked; (2) operate with full range and freedom of movement, and in the correct sense; and (3) have no loose or foreign objects. e. Only authorised personnel who have not been involved in the maintenance task being inspected shall perform Independent Maintenance Inspections. f. Independent Maintenance Inspection requirements as detailed in this regulation shall be stated, either directly or by reference, in the MMP. 5.1.7. Maintenance of Aircraft During the Period of Operation a. Except as stated in Regulation 5.1.7.b, maintenance shall only be performed on aircraft after the aircraft captain has released the aircraft. b. Conduct of minor maintenance shall be permissible during the period of operation providing: (1) the maintenance procedure is authorised by the SMM or inservice DAR. (2) the maintenance to be performed is authorised by the aircraft captain; and (3) the SMM documents, either directly or by reference, in the MMP, maintenance tasks that are permissible during the period of operation. 5.1.8. Foreign Object Control a. The AMO shall have procedures documented, either directly or by reference, in the MMP, to prevent the ingress of foreign objects into, and the detection and removal of those objects from, aircraft and aeronautical product. 5.1.9. Safety a. The AMO shall observe all safety precautions detailed in the aircraft and aeronautical product technical publications and documents.

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5.1.10. Reserved 5.1.11. Carried Forward Unserviceability a. The AMO shall state, either directly or by reference, in the MMP the procedure to authorize deferment of maintenance required, allowing a subject aircraft to operate prior to rectification of the required maintenance. b. All Carried Forward Unserviceabilities shall be approved by the SMM, or personnel authorised by the SMM. c. The SMM shall define and state, either directly or by reference, in the MMP the minimum competency standards for personnel authorised to approve Carried Forward Unserviceabilities. d. Before approving a Carried Forward Unserviceability which affects the handling or operational characteristics of an aircraft, the SMM or authorised person shall obtain an operational endorsement from an appropriately authorised aircrew representative. e. Where the AMO does not have access to sufficient technical data pertaining to the unserviceability under consideration to ensure the adequacy and appropriateness of the decision before approving a Carried Forward Unserviceability, in-service DAR and ASR advice shall be obtained. f. Carried Forward Unserviceabilities shall be recorded and presented in a format that is visible to aircrew on acceptance of the aircraft. g. The SMM shall maintain a system to regularly review all Carried Forward Unserviceability decisions. h. Each Carried Forward Unserviceability shall have a specific period of deferment clearly identified. 5.1.12. Maintenance Test Flights a. Maintenance test flights shall be carried out whenever a flight-safetycritical item is changed, adjusted or maintained, and safe and correct operation cannot be proven by means of a workshop test or maintenance ground run. b. Where workshop tests and maintenance ground runs can be performed to prove partial, safe and correct operation, these workshop tests and maintenance ground runs shall be successfully performed before a maintenance test flight. c. AMOs shall provide aircrew with in-service DAR and ASR approved maintenance test flight schedule documentation covering the range of applicable functional tests and checks. d. The AMO shall confirm that only appropriately qualified pilots perform maintenance test flights. 5.1.13. Maintenance Ground Runs a. Maintenance ground runs shall be performed, unless specifically stated otherwise by the DAR, when the safe, full or partial correct operation of an aircraft or aeronautical product needs to be proven before the aircraft or aeronautical product is returned to service, or cleared for a maintenance test flight. b. Maintenance ground runs shall be performed in accordance with DARapproved procedures. www.dgta.gov.my 2.5 - 4 of 13 TERHAD

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c. Maintenance ground runs shall only be performed by appropriately authorised personnel. d. Engine ground runs of rotary wing aircraft with engaged rotors shall only be performed by appropriately qualified pilots. 5.1.14. Aircraft Ground Handling a. The SMM shall ensure procedures and equipment approved by the DAR are used when ground handling aircraft. b. Within the AMO, the SMM shall ensure that only appropriately authorised personnel perform aircraft ground handling. c. The SMM shall ensure that only marshalling signals approved and specified by DAR are used. d. Notwithstanding Regulation 5.1.14.c, the SMM, with agreement from the senior operational representative, may approve locally developed marshalling signals, which do not conflict with those approved by DAR. e. The SMM shall ensure that marshalling signals used by the AMO are stated, either directly or by reference, in the MMP. 5.1.15. Standard Repairs f. The AMO shall conduct standard repairs in accordance with the relevant aircraft or aeronautical product repair manuals. g. Full details of standard structural repairs applied to primary and secondary aircraft structure, including details of repair to primary and secondary structure by replacement, and other items designated by the DAR shall be forwarded to the relevant ASR. 5.1.16. Modifications a. Aircraft and aeronautical product shall only be modified in accordance with instructions authorised by the DAR. b. Incorporation of modifications shall be documented in accordance with Regulation 5.2 Maintenance Records and Documentation. 5.1.17. Weight and Balance a. The SMM shall ensure that accurate and current weight and balance information is maintained by the AMO for all aircraft and aeronautical product nominated by the DAR. b. Aircraft and aeronautical product shall be reweighed: (1) after any maintenance activity which is likely to significantly alter the aircraft or aeronautical products weight or Centre of Gravity; and (2) as otherwise nominated by the DAR. c. The AMO shall forward details of all aircraft and aeronautical product weighs to the DAR.

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5.1.18. Adhoc Non Destructive Testing a. In the absence of an ASR-approved Non Destructive Testing (NDT) procedure, and to meet an urgent operational requirement, a locally developed NDT procedure may be approved by the SMM or delegate. b. Where a requirement arises to use a non-AEO approved NDT procedure on a regular or ongoing basis for a component or structure, the SMM shall obtain from the relevant AEO approval of the specific NDT procedure and application. 5.1.19. Non-Standard Repairs a. The AMO shall submit all design details of non-standard repairs, developed by the AMO, to the in-service DAR prior to incorporation. b. Except as defined in Regulation 5.1.19.d, the AMO shall obtain approval from the ASR in accordance with Regulation 5.4 Deviations, prior to incorporation of non-standard repairs to: (1) (2) primary and secondary aircraft structure, and safety critical items or systems.

c. The AMO shall retain documentation disclosing all non-standard repairs in accordance with Regulation 5.2 Maintenance Records, Documentation and Data. d. The SMM may design and incorporate a non-standard repair to primary and secondary aircraft structure or flight-safety-critical systems prior to ASR approval only when: (1) there is a compelling and justifiable operational need to return the aircraft to service; and (2) specific approval for incorporation is granted by the Operational Commander after duly considering the following: (i) the non-standard repair is justified on an assessment of the risk involved, (ii) a precedent has been established where a similar repair has been approved, and (iii) the AMO is competent and capable of designing and conducting the repair. 5.1.20. Contingency Maintenance and Aircraft Battle Damage Repair a. Where a Contingency Maintenance (CMAINT) and Aircraft Battle Damage Repair (ABDR) capability is required due to the nature of aircraft operations, the AMO shall: (1) have documented CMAINT and ABDR procedures which are approved by the DAR; (2) ensure that the CMAINT and ABDR procedures are completely documented in accordance with the approved maintenance recording system; and (3) ensure that personnel are authorised, in accordance with Regulation 4.5 Personnel Requirements, to perform ABDR. b. Except for the circumstances defined in Regulation 5.1.20.d, CMAINT and ABDR procedures shall only be invoked for declared contingencies. www.dgta.gov.my 2.5 - 6 of 13 TERHAD

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c. Training in the application of ABDR techniques shall only be performed on training aids. d. Where there is an operational emergency and the risk can be justified in the opinion of the SMM, the SMM may, with approval from the operational commander, approve the use of practiced ABDR techniques and procedures to enable the recovery of a damaged aircraft to an appropriate maintenance location. e. The AMO shall provide details of all CMAINT and ABDR repairs to the DAR at the earliest possible opportunity. f. The AMO shall ensure that aircraft and aeronautical product subject to CMAINT and ABDR action are surveyed, as soon as contingency circumstances cease, to determine action required to recover technical integrity. g. The AMO shall ensure that aircraft and aeronautical product subject to CMAINT are returned to peacetime maintenance immediately contingency circumstances cease. 5.2. MAINTENANCE RECORDS and DOCUMENTATION 5.2.1. Maintenance Records and Documentation Requirements a. The AMO shall establish and maintain a system, documented, either directly or by reference, in the MMP, to clearly and accurately document all State aircraft and/or aeronautical product maintenance activities for which they are responsible. b. The SMM shall ensure that all personnel making entries in the aircraft and aeronautical product maintenance records are authorised to do so in accordance with Regulation 4.5 (Personnel Requirements) and perform the tasks in accordance with Regulation 5.1 (Conduct of Maintenance) and Regulation 5.5 (Tools, Equipment and Aeronautical Product). c. Reserved. d. The SMM shall ensure that all entries in maintenance documentation and records describing unserviceable conditions contain, as a minimum: (1) the name of the person making the entry, (2) an accurate and concise description of the unserviceable condition and the maintenance required, and (3) the date and time the unserviceable condition was entered. e. The SMM shall ensure that entries pertaining to the completion of maintenance: (1) accurately describe the activity(s)/corrective action(s) undertaken; (2) where appropriate, makes reference(s) to the relevant approved and authorised technical publication(s), instructions and orders the work was completed in accordance with; and (3) contain certifications that comply with Regulation 5.1.5 and: (i) identify the person who made the certification, (ii) stipulate the capacity in which the certification was provided, and (iii) record the date and time of certification.

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f. The SMM shall ensure that the maintenance documentation and records contain sufficient detail to show the make, model, identification number and/or serial number of the aircraft or aeronautical component being maintained. g. are: The SMM shall ensure that the maintenance documentation and records (1) (2) controlled (serially, where appropriate); legible and comprehensible;

(3) unable to be changed, either deliberately or inadvertently without leaving evidence that a change did take place and maintaining legibility of the original data; (4) stored and supported in such a manner as to retain readability (visual or electronic) for the required retention period; (5) appropriately protected against loss, damage and unauthorised alteration; and (6) 5.2.2. Reserved 5.2.3. Retention and Review of Maintenance Documentation and Records a. The SMM shall ensure that the AMO has a system for retention and review of maintenance documentation and records that meets the following criteria: (1) the required retention period is adhered to; and (2) a periodic review of record security, condition, completeness and accuracy is performed. 5.2.4. Falsification, Reproduction or Alteration of Maintenance Records a. The SMM shall ensure that only appropriately authorised personnel perform alterations to any record, document or report required under the Technical Airworthiness Regulations. b. The SMM shall ensure that no person shall make, or be caused to make: (1) any fraudulent or intentionally false entry in any record, document or report that is required to be kept or used to show compliance with any requirement of the Technical Airworthiness Regulations; (2) any reproduction, for fraudulent purposes, of any record, document or report required by the Technical Airworthiness Regulations; and (3) alterations, for fraudulent purposes, of any record, document or report required by the Technical Airworthiness Regulations. 5.3. REPORTING AND INVESTIGATION REQUIREMENTS 5.3.1. Reporting of Unserviceable Conditions a. Details of all unserviceable conditions discovered, experienced or reported during operation or maintenance shall be recorded at the first opportunity after identifying the condition, and at least before release of an aircraft or aeronautical product from maintenance. www.dgta.gov.my 2.5 - 8 of 13 TERHAD able to be secured.

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b. All unserviceable conditions shall be documented in a relevant and approved aircraft and aeronautical product maintenance record. c. All entries in the approved documentation describing unserviceable conditions shall be completed in accordance with the requirements defined in Regulation 5.2.1 d. d. When an SMM, or authorised delegate, judges that an unserviceable condition is the result of other than fair wear and tear, the AMO shall prepare a documented report meeting the content and reporting time-limits defined by the DAR and forward it to the DAR. e. The AMO shall ensure that aircraft and subject to reporting of an unserviceable condition 5.3.1.d are quarantined from other serviceable aeronautical product, and appropriately identified reporting action. 5.3.2. Reporting of Unairworthy Conditions a. Unless otherwise specified by the DAR, the AMO shall report to the DGTA within 24 hours any conditions that have the following characteristics: (1) the condition or failure of an aircraft or aeronautical product could cause the loss of an aircraft, (2) any failure of an emergency system or life support system, or (3) the condition or failure of an aircraft or aeronautical product could adversely affect wider fleet operations. 5.3.3. AMO Investigation of Reported Unserviceable and Unairworthy Conditions a. Unless otherwise specified by the DAR, all unserviceable and unairworthy conditions reported in accordance with Regulation 5.3.1.d and 5.3.2 shall be investigated by the AMO, and a report forwarded to the DAR within 15 working days. b. The AMO shall report to the DAR and DGTA within 24 hours when, during the investigation of a condition the AMO becomes aware of the following: (1) the condition or failure of an aircraft or aeronautical product could cause the loss of an aircraft, or (2) the condition or failure of an aircraft or aeronautical product could adversely affect wider fleet operations. 5.3.4. Maintenance Incident Reporting a. When an incorrect or inappropriate maintenance activity that adversely impacts technical airworthiness has occurred, the AMO shall ensure an investigation is conducted and a formal report is submitted to the DGTA and the DAR. 5.3.5. Other Reporting Requirements a. Unless covered as part of a report submitted in accordance with Regulation 5.3.1.d or 5.3.2., the AMO shall submit a report to the DAR where: (1) an unapproved aeronautical product has been received, aeronautical product that are in accordance with Regulation and unserviceable aircraft or to show the item is subject to

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(2) an installed aircraft system component has been identified as an unapproved aeronautical product, (3) a system or component is believed to make the aircraft or aeronautical product substandard for the required system performance, or (4) the packaging of an aircraft or aeronautical product compromises technical integrity. b. The AMO shall comply with any other failure or unairworthy condition reporting requirements defined by the DAR for the aircraft or aeronautical product. 5.3.6. Technical Reporting Systems a. Unless otherwise stated by the TAR or responsible DAR, the SMM shall ensure that the AMO complies with all technical reporting requirements as defined in the applicable SAO publications and instructions. 5.4. DEVIATIONS 5.4.1. Deviations a. AMOs shall maintain a system documented, either directly or by reference, in the MMP, to formally request the grant of Deviations. b. AMOs shall submit a Request for Deviation to the DAR when the AMO requires approval to: (1) temporarily depart from the DAR-approved weapon system type design, (2) incorporate a non-standard repair to: (i) (ii) an aircrafts primary and/or secondary structure; or a safety-critical system.

c. AMOs shall submit a Request for Deviation to DAR when the AMO requires approval to temporarily depart from a maintenance publication or instruction sponsored by DAR. d. AMOs shall maintain a permanent record of the details relating to all deviations. e. AMOs shall advise the relevant authority when the status of an incorporated deviation is changed. 5.5. TOOLS, EQUIPMENT AND AERONAUTICAL PRODUCT 5.5.1. Tools and Support Equipment a. The AMO shall document, either directly or by reference, in the MMP a general description of the test and support equipment and tools used in the support of State aircraft and/or aeronautical product. b. The AMO shall maintain and follow a tool management system, documented, either directly or by reference, in the MMP, for the control and accounting of all tools, equipment and test equipment used on, or in the vicinity of, State aircraft and aeronautical product. www.dgta.gov.my 2.5 - 10 of 13 TERHAD

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c. The AMO shall ensure that Ground Support Equipment used for the maintenance of aircraft and aeronautical product is approved for use by the AEO responsible for the aircraft or aeronautical product being maintained. d. AMOs shall ensure that all tools and support equipment, including test equipment and ground support equipment, used in the maintenance and servicing of aircraft and aeronautical product are: (1) serviceable; (2) appropriate and authorised for the maintenance tasks for which they are employed; (3) calibrated (where applicable); (4) individually identified and traceable to the job and person using the tool; and (5) accounted for during maintenance or servicing and prior to final certification of the maintenance or servicing. e. Where a tool or item used in maintenance can not be located and accounted for, all aircraft, aeronautical product or equipment in the vicinity in which the tool may have been used or stored shall not be released from maintenance until the tool or item is found, or the SMM, or nominated delegate, is satisfied that the tool or item has not been left in any of the aircraft or aeronautical product in question. f. The use of test equipment in-flight shall be authorised by the SMM only when: (1) the aircraft does not need to be modified and no flight-critical system is affected, or (2) the DAR grants approval.

5.5.2. Local Manufacture or Modification of Tooling a. The SMM may authorise the local manufacture, modification and use of standard tooling where an urgent operationally based maintenance requirement exists. b. Where a tool is to be locally manufactured or modified, and this is not listed in the maintenance documentation approved by the ASR, the SMM shall ensure that: (1) and the tool manufactured or modified is fit for the intended purpose,

(2) details of the tool and its intended and correct use shall be documented in the AMOs local procedures. 5.5.3. Maintenance Tools and Material During Period of Operation a. The AMO shall have procedures to control and account for maintenance tools and materials to be used during the Period of Operation. b. Procedures to control maintenance tools and material during the Period of Operation shall be approved by the SMM and recorded in local documentation. c. Tools used during the Period of Operation shall be approved by the SMM and recorded in local documentation.

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5.5.4. Aeronautical Product a. The AMO shall document, either directly or by reference, in the MMP, procedures for management (relating to maintenance and logistics aspects) of aeronautical product. b. Prior to the installation of aeronautical product to higher assemblies (for example aircraft or other aeronautical product), maintenance personnel shall ensure that all reasonable steps are taken to qualify that product. c. AMOs shall ensure that: (1) all aeronautical product is or has been identified from the relevant AEO-approved parts list; (2) all aeronautical product is or has been sourced from the relevant AEO-approved manufacturer, nominated agent or accredited vendor; (3) initial receipt inspection requirements defined by the procurement / ordering authority to the AMO are conducted; (4) an identification and tracking system, records and tracks each aeronautical product that is received, stored, issued and used within the organisation; (5) only aeronautical product that is correctly identified and approved for fitment is installed or used on aircraft or aeronautical product; (6) except when fitted to aircraft or other aeronautical product, all aeronautical product is to be labelled, to provide the following information: (i) (ii) (iii) (iv) (v) and item name; manufacturers part number(s); stock number (where applicable); serial number or batch / lot number (where applicable); status and the date of status change (where applicable);

(vi) name(s) and signature(s) of person(s) certifying the equipment as serviceable or unserviceable (where applicable). (7) methods of handling aeronautical product prevents damage or deterioration; (8) designated storage areas or stock rooms prevent damage or deterioration of aeronautical product, pending use or delivery; (9) all aeronautical product is packaged and labelled to the extent necessary to ensure conformance to all required standards stipulated by the relevant AEO; (10) all Certificates of Conformity (C of C) or AEO-approved equivalent documents are retained; (11) aeronautical product that is suspected as being unacceptable for use is subjected to investigation; (12) any aeronautical product which is subject to investigation is segregated and quarantined from other aeronautical product, reported to the relevant authority and labelled with investigation and full identification details; (13) unserviceable aeronautical product shall be separated from serviceable product; www.dgta.gov.my 2.5 - 12 of 13 TERHAD

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(14) aeronautical product that is to be transported is packaged, labelled and transported with all applicable documentation in accordance with AEO requirements; and (15) aeronautical product is segregated and disposed of following authorisation, and in a manner determined by, the relevant AEO. 5.5.5. Transfer of Aeronautical Product (Cannibalisation/Robbery) a. Where an AMO elects to transfer an aeronautical product from an aircraft or higher assembly, the AMO shall validate the serviceability of the cannibalised aeronautical product prior to, or on installation of the product. 5.5.6. Local Manufacture of Aeronautical Product a. Where local manufacture is required, AMOs shall manufacture and qualify aeronautical product against AEO certified design specifications that form part of the Type Design. b. AMOs shall permanently and legibly mark locally manufactured aeronautical product with: (1) (2) a part number or an equivalent, and a serial number or an equivalent.

5.6. AIRCRAFT ACCIDENTS 5.6.1. Initial Requirements a. The AMO shall comply with all accident reporting requirements defined by the DGTA and the relevant AEO. b. Following the report of an aircraft accident, the SMM shall ensure that, for the affected aircraft, all actions are taken to preserve evidence both at the accident site and within the AMO. 5.6.2. Recovery of Aircraft a. Where an Approved Maintenance Organisation (AMO) is responsible for the recovery of accident damaged aircraft, the SMM shall ensure that: (1) procedures for those actions are defined and documented in a controlled document; (2) the AMO has, or has timely access to, any required recovery equipment; and (3) personnel are competent and authorised to carry out the recovery procedures. 5.6.3. Salvage a. Aircraft and aeronautical product that have been the subject of an aircraft accident shall only be reused following authorisation by the relevant AEO. b. The SMM may approve the use of salvaged aeronautical product without AEO approval when Contingency Maintenance has been invoked.

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