CAO 104.0 Manual: ANNEX A TO CAAP 104-01 (1.1) Sample
CAO 104.0 Manual: ANNEX A TO CAAP 104-01 (1.1) Sample
CAO 104.0 Manual: ANNEX A TO CAAP 104-01 (1.1) Sample
1)
SAMPLE
Disclaimer
This manual template has been prepared to guide and assist Certificate of Approval (COA)
holders who propose to train and authorise maintenance certification staff under the provisions
of Civil Aviation Order (CAO) 104.0. The procedures and training plans that are set out in this
manual represent the minimum acceptable standards that are required in order to satisfy the
requirements set out in CAO 104.0.
It is not a prerequisite that this manual must be used in order to obtain an approval to authorise
certification staff; however, the training outcomes specified in each section of this manual must
be met or exceeded for each particular aircraft or system for which training is to be given.
An applicant for approval under CAO 104.0 may use any form of manual that suits the particular
COA holder provided that these minimum requirements are incorporated into that manual.
Training
Section 6 describes the procedures for training and authorising warbirds, historic and
replica aircraft (WHR) employees
Section 7 describes procedures for training and authorising certain excluded type
employees
Sections 8 and 9 describe the procedures for training and authorising excluded
system employees in wood aircraft structures and/or fabric coverings.
If you do not wish to use the full scope of the training manual, you may delete one or
more of sections 6, 7, 8 and 9. However, if you propose to use this manual in part or in
its entirety, then you should read the manual carefully and ensure that you are able to
incorporate the chosen sections into your organisational procedures. Once approved,
you will be required by regulation 11.077 of the Civil Aviation Safety Regulations 1998
(CASR ) to comply with the manual. Therefore, you should ensure that it is specific to
your operations, not just a generic manual with your name on the cover page.
Important note: When assessing an application for a delegation under subregulation 42ZC (6)
of Civil Aviation Regulation 1988 (CAR) Civil Aviation Safety Authority (CASA) will refuse the
application if the manual does not meet these minimum requirements.
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Wherever a blank space appears, you will be required to ensure that you insert the appropriate
information. Depending on context, the required information may be any of the following:
If a phrase, position name or title is shown with multiple options (e.g. Training/Quality Manager)
you should remove all but the correct option for your organisation. If the position is held under a
different title in your organisation - use that title.
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This manual has been generated to meet CASA Civil Aviation Order (CAO) 104.0 requirements
for the purpose of providing maintenance training and issuing certification authorisations.
This manual sets out the procedures and assessment guidelines for the issue of certification
authorisations that will be followed by . working under the COA
number..
This manual forms part of the .. Quality and Procedures Manual, as accepted by
CASA. Amendments to this manual will only be made by the Training/Quality Manager, in
accordance with the procedures set out in this manual.
Authorised by (signature):
Date
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Revision: 1.0
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Distribution List
Copy number
Manual holder
1
2
3
4
5
6
7
8
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Contents
1
Distribution List
2.1
2.2
Amendment Record
Introduction
4.1
Qualifications
4.2
4.3
Training procedures
5.1
6.2
6.3
Background
7.2
7.3
Training procedure
7.4
Assessment
7.5
Authorisation issue
7.6
Notification to CASA
Objectives
9.2
Reference material
9.3
Theoretical knowledge
9.4
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Appendix B
Appendix C
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1.1
Issue date
Cover page
Page 1
Page 2
Page 3
Page 4
Page 5
Page 6
Page 7
Page 8
Page 9
Page 10
Page 11
Page 12
Page 13
Page 14
Page 15
Page 16
Page 17
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1.2
Amendment Record
Amendment issue number
Date
Initial Issue
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Introduction
This document sets out the procedures, processes and documentation that will be followed for
the purpose of training maintenance personnel in the maintenance of excluded aircraft systems,
excluded aircraft types or WHR Part 1 aircraft as described under Section 5, 6, 8 or 10 of CAO
104.0.
Following these procedures, maintenance training staff will be able to:
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This program will be managed by a person appointed to act as the Training/Quality Manager.
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1.3
Qualifications
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1.4
assessment of training providers using the guidelines set out in Sections 5 and 7 of this
manual
if external training providers are to be engaged, assessment of the external provider to
ensure that the provider is able to deliver the required training outcomes as set out in
this manual
ensuring that each training plan is configured to:
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1.5
In order to meet the requirements specified in CAO 104.0 the following course entry
requirements will be applied:
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the trainee must possess a valid CASA Part 66 licence in the applicable subcategory for
the aircraft for which training is to be provided.
If training is for an excluded type or a Part 1 WHR certification authorisation, the
trainees licence must not be affected by an exclusion which would disallow
maintenance of the particular aircraft (i.e. E9-fabric surfaces, E10 -wooden structures,
E12-propellers).
If training is for an excluded system the trainee must have the appropriate licence
category and sub-category for the system as set out in the CASA Part 66 Manual of
Standards.
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Training procedures
Guidance note: The following training program will ensure that an individual is able to
demonstrate the required competencies for the issue of a certification authorisation. The
training program needs to include the following:
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1.6
Instruction will be provided by personnel experienced and qualified in the type of maintenance
training being given to an individual under this training plan.
Training will be given in an on-the-job format or a combination of on-the-job and theoretical
training. The makeup of the training will be decided by the training manager, based on an
assessment of the needs of the individual trainee and the complexity of the particular aircraft.
Training can be given by approved licence holders or task specialists with recognised skills and
experience in the relevant discipline. In the case of ex-military aircraft, training may also be
provided by non-licenced individuals who have provided or supervised maintenance for a
particular Part 1 aircraft in the military environment or provided maintenance training for the
particular aircraft in the military environment.
Approved training personnel will be listed in a register of trainers contained in each relevant
section of this manual and be revised as instructors are added or removed.
The register will detail the names of approved trainers and their qualifications for the role.
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Part 1 WHR training will be given in accordance with the training plan in this section, which will
be varied as required to reflect the individuals training needs and specific requirements of the
aircraft for which training is to be given.
A record of training and assessment will be retained in the personnel file of the individual and
maintained by the Training/Quality/Aircraft Maintenance Manager.
Training records will be made available to CASA for review, as required by CASA.
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1.7
Upon successful completion of training, a trainee will be assessed in accordance with the
assessment guidelines set out in Section 10 of this manual. Assessment will be made by the
approved training provider conducting the training. The results will be reviewed by the
Training/Quality Manager.
If the Training/Quality Manager is satisfied that the trainee has achieved an acceptable level of
competency in all knowledge topics listed in Table 1 and the maintenance tasks listed in Table 2,
the trainee will be issued with a certification authorisation for the Part 1 aircraft in which the
training and assessment was given. The certification authorisation will be valid for not more than
2 years from the date of issue.
Personnel holding current Part 66 licences in the category and ratings that cover a particular
Part 1 aircraft will be deemed to have met the training requirements as specified in Section 8 of
CAO 104.0 and may be issued with a Part 1 certification authorisation.
Personnel who hold a CASA issued maintenance authorisation issued under regulation 33B or
paragraph 42ZC (6) of CAR will be deemed to have met the training requirements as specified in
section 8 of CAO 104.0; and may be issued a Part 1 certification authorisation.
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1.8
At the end of a 2 year period since issue or reissue of a certification authorisation, the
Training/Quality Manager must assess the trained WHR employee to re-issue the certification
authorisation for a further 2 years.
If, in the view of the Training/Quality Manager, no additional or refresher training is required, the
certification authorisation may be reissued accordingly.
If, in the view of the Training/Quality Manager, further training is required, a training plan will be
drawn up based on the assessed training needs.
Training for re-issue may be given by an authorised trainer or an employee who holds an
equivalent valid certification authorisation.
Certification authorisations held by employees on the basis of a CASA issued authorisation or
type rating, may be reissued without further assessment at the Training/Quality Managers
discretion.
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1.9
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. Pty Ltd
Aircraft Type
COA Number
Model..
Engine..
Trainee..
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1.9.1
The Training/Quality Manager will ensure that a person is properly trained in the knowledge
elements (Table 1 below) and maintenance procedures (Table 2) that are specific to the type of
aircraft.
On completion of the training, the trainee will have demonstrated the competencies required to
maintain the type of aircraft to an acceptable standard of airworthiness in accordance with the
relevant instructions for continuing airworthiness.
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1.9.2
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Reference material
CAO 104.0
Part 4 and 4A of CAR
Applicable aircraft or system maintenance data.
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1.9.3
Processes
This training plan is based on the use of on-the-job training that will be provided using the
aircraft and maintenance facilities of ..
Training and assessment will be provided by an employee or contractor of .................................,
who has the knowledge, qualifications and licence/authorisation required to perform and certify
for completion of the maintenance for which the training is provided. Training in knowledge
topics must verify that the trainee meets the appropriate knowledge level. If deemed appropriate,
external training providers may be engaged to provide supplementary theory instruction or skills
training in particular special processes or techniques.
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1.9.4
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1.9.4.1 Level 1
A familiarity with the principal elements of the topic such that the following trainee objectives are
met:
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1.9.4.2 Level 2
A general knowledge of the theoretical and practical aspects of the topic and an ability to apply
that knowledge, such that the following trainee objectives are met:
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1.9.4.3 Level 3
A detailed knowledge of the theoretical and practical aspects of the topic, and a capacity to
combine and apply the separate elements of knowledge in a logical and comprehensive manner,
such that the following trainee objectives are met:
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Topic
Lev
el
Achieved
Y/N
Date and
Signature
Ground handling
Competent
Y/N
Date and
Signature
mooring
earth points
towing and turning limits
ground power starting
Competent
Y/N
Date and
Signature
daily Inspection
25 hour inspection and service
50 hour inspection and service
Annual inspection
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Airframe
Competent
Y/N
Date and
Signature
ground safety-disarming
safety requirements before entering cockpit
flight arming
removing and installing ejection seats
(For each aircraft, delete if not required or insert additional training headings as
required)
Engine
Competent
Y/N
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Date and
Signature
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compressor/engine wash
compressor/engine inspection
oil sampling
fuel system component changes and rigging
fuel control unit installation and rigging
At the successful completion of the training and assessment in each task, the quality manager
will be notified that the trainee is eligible for issue of a certification authorisation.
Table 3 Training providers for Part 1 WHR Maintenance
Name
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Qualifications
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1.10 Background
This section describes the procedures that will be followed by when training and
assessing an employee for the purpose of issuing a certification authorisation for one or more
excluded aircraft types.
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1.13 Assessment
A trainee will be assessed during the course of the training and a final assessment will be at
completion, using the guidelines set out in Annex A of this manual.
Assessment will be made by the training provider and the results will be reviewed by the
Training/Quality Manager.
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At the completion of 6 months, the Training/Quality Manager will advise CASA that the Licensed
Aircraft Maintenance Engineer (LAME) has successfully completed the excluded type training
and has satisfactorily exercised the privileges of the certification authorisation for 6 months.
Table 4 Instruction plan- Piston Engines
ATA
Chapt
er
70
Elements
70B
Standard practicesengines
Constructional
arrangement and
operation (carburettors,
fuel injection systems,
induction, exhaust and
cooling systems,
supercharging/
turbocharging, lubricating
systems
Engine performance
71
Powerplant
73
73A
FADEC
74
Ignition
76
Engine control
77
79
Oil
80
Starting
70A
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Require
d? Y/N
Theory
Assessme
nt
Person/Sig
n/ Date
Practical
Assessme
nt
Person/Sig
n/ Date
Quality
Assurance
Person/Sign/Dat
e
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81
Turbines
82
Water injection
83
Accessory gearboxes
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ATA Chap
49
70
70A
70B
71
72
73
73A
74
75
76
77
78
79
80
82
83
84
Elements
Required
? Y/N
Theory
Assessmen
t
Person/Sig
n/ Date
Practical
Assessmen
t
Person/Sig
n/ Date
Quality
Assurance
Person/Sign/D
ate
Auxiliary power
(APUs)
Standard
practicesengines
Constructional
arrangement and
operation
(installation,
inlet,
compressors,
combustion
section, turbine
section, bearings
and seals,
lubrication
systems)
Engine
performance
Powerplant
Engine turbine
and turboprop
and ducted fan
and unducted
fan
Engine fuel and
control
FADEC
Ignition
Air
Engine controls
Engine indicating
systems
Exhaust
Oil
Starting
Water injections
Accessory
gearboxes
Propulsion
augmentation
Table 6 The employee will be trained and assessed in the following maintenance procedures
Activity
Competent
Y/N
Date and
Signature
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Daily Inspection
25 hour inspection and service
50 hour inspection and service
Annual/100hourly inspection
At the successful completion of the training and assessment in each task, the Quality Manager
will be notified that the employee is eligible for issue of a certification authorisation.
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Name
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Authorised to provide
training in/on:
Qualifications
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Prerequisites:
Training personnel, for the purpose of excluded type or excluded system training, must have
held a maintenance licence (CAR 30/Part 66/both) in the appropriate subcategory for a minimum
of 5 years. The trainer must have held a rating in the particular aircraft or engine for which
training is to be given for at least 18 months.
A person who holds, or has held, a CASA maintenance authorisation for the particular aircraft or
engine for at least 5 years will be deemed to have met the requirements.
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1.16.1 Objectives
On completion of this training, a trainee will be able to apply hand skills, knowledge of fabric
surfaces and maintenance publications to inspect, test and repair aircraft fabric surfaces and the
application of hand skills, knowledge of fabric surfaces and maintenance publications to re-cover
fabric surfaces of aircraft and aircraft components that are covered with fabric.
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Topic
Level
Achieved
Y/N
1
1
1
2
2
2
2
2
3
3
3
2
3
3
3
If a trainee has passed the CASA Basic examination FE Fabric and Doping, the COA holder may
deem the employee as having met the relevant required knowledge standards for this section.
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At the successful completion of the training and assessment in each task, the Quality Manager
will be notified that the employee is eligible for issue of a certification authorisation.
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1.17 Objectives
On completion of this training, a B1 Part 66 licence holder will be proficient in the application of
woodworking hand skills and knowledge and the use of maintenance publications to inspect and
repair aircraft wooden structures and wooden components to an acceptable standard for the
purpose of applying to CASA for removal of an E10 exclusion.
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Topic
leve
l
caseins
resorcinols
urethanes
epoxies
Achieved
Y/N
Name/Signature/Date
strengths
limitations
storage requirements
mixing precautions
spreading requirements
assembly times
clamping requirements
environmental protection
requirements
compatibilities
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compression cracks
splits
rot
fungal attack
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fabricate
saws
planes
chisels
clamps
drills
At the successful completion of the training and assessment in each task, the Quality Manager
will be notified that the employee is eligible for issue of a certification authorisation.
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10
To be used when assessing an employee in accordance with sections 2, 4 and 5 of this manual
Trainee
AIRCRAFT type/registration...
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1.21 Activity
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ATTEMPTS
1st
2nd 3rd
RESULT
U S
ATTEMPTS
1st
2nd 3rd
RESULT
U S
ATTEMPTS
1st
2nd 3rd
RESULT
U S
ATTEMPTS
1st
2nd 3rd
RESULT
U S
ATTEMPTS
1st
2nd 3rd
RESULT
U S
ATTEMPTS
1st
2nd 3rd
RESULT
U S
Assessors Name
1st attempt
2nd attempt
3rd attempt
Succeeded
TRAINEE NAME:
TRAINEE SIGNATURE:
ASSESSOR NAME:
DATE:
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Remedial
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ASSESSOR SIGNATURE:
DATE:
Unsatisfactory
Observed performance not adequate/ had
safety implications
Satisfactory
Observed performance was adequate
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Appendix A
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Appendix B
Issued by
Appendix C
Position: Quality Manger/Chief Engineer/Training Manager. (delete all which do not apply)
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Amendment Number
Manual Number.
Date..
Manual Holder.
I have actioned the amendment and have read and understand the change(s)
Signed
Date.
Each manual holder, on receipt of a manual amendment must action the amendment as
required (pen amendment or page insertion/replacement) and having done so, return
this signed acknowledgement to ..................................
The acknowledgement may be returned to .. via post, courier or emailed as a
PDF document.
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