1. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
AJD21603 ROTORCRAFT SERVICING,
MAINTENANCE AND ROLE EQUIPMENT
WEEK 5:
ROUTINE OF HELICOPTER MAINTENANCE ACTIVITIES

2. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
LESSON OBJECTIVES & OUTCOMES
OBJECTIVES:
1. GAIN KNOWLEDGE ON VARIOUS TYPES OF HELICOPTER
MAINTENANCE ACTIVITIES.
2. GAIN KNOWLEDGE ON SAFETY PRECAUTIONS WHILE
PERFORMING THOSE INSPECTIONS.
OUTCOMES:
1. EXPLAIN THE VARIOUS TYPES OF HELICOPTER
MAINTENANCE PRACTICES AND DIFFERENCES BETWEEN
THEM.
2. EXPLAIN THE SAFETY PRECAUTION ASSOCIATED WITH
HELICOPTER MAINTENANCE PRACTICES.

3. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
INTRODUCTION
IN THE PREVIOUS LESSON, WE HAVE LEARNED ON THE
IMPORTANT CONCEPT OF HELICOPTER MAINTENANCE.
WHEN THE MANUFACTURER DESIGNED THE AIRCRAFT, PART OF
THEN DESIGN STAGE IS TO COME OUT WITH THE MAINTENANCE
PROGRAM APPLICABLE TO THAT AIRCRAFT.
THE PROCESS IS LENGTHY AND IS NORMALLY DONE IN
CONSULTATION WITH THE POTENTIAL OPERATORS OF THE
AIRCRAFT.
Maintenance – FAA – This includes inspection, overhaul, repair,
preservation, and the replacement of parts, but excludes preventive
maintenance.
Maintenance – EASA - Maintenance means any one or combination of
overhaul, repair, inspection, replacement, modification or defect rectification
of an aircraft or component, with the exception of pre-flight inspection

4. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
IMPORTANT TERMINOLOGIES
SCHEDULED INSPECTION - INSPECTION OR GROUP OF
INSPECTION THAT IS BEING PERFORMED AT SPECIFIC
INTERVALS.
UNSCHEDULED INSPECTION – INSPECTION THAT IS
PERFORMED AS A RESULT OF ANY INCIDENT SUCH AS HARD
LANDING OR TAIL ROTOR STRIKES.
PRE-FLIGHT INSPECTION – INSPECTION PERFORMED PRIOR TO
THE FIRST FLIGHT OF THE DAY.
POST-FLIGHT INSPECTION – INSPECTION PERFORMED AFTER
THE LAST FLIGHT OF THE DAY.
TURN-AROUND INSPECTION – INSPECTION PERFORMED IN
BETWEEN FLIGHT SORTIES.
FLIGHT HOURS SCHEDULED INSPECTION – INSPECTION BASED
ON NUMBER OF HOURS AIRCRAFT HAS BEEN FLYING.

5. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
CALENDER MONTH SCHEDULED INSPECTION – INSPECTION
BASED ON CALENDER.
HOURS/CALENDER SCHEDULED INSPECTION – INSPECTION
BASED ON EITHER HOURS/CALENDER WHICHEVER COME
FIRST.
FLIGHT CYCLE INSPECTION – INSPECTION BASED ON EITHER
THE FLIGHT CYCLE OR ENGINE CYCLE
MINOR INSPECTION – INSPECTION REQUIRE MINIMUM
DOWNTIME PERIOD.
MAJOR INSPECTION – INSPECTION REQUIRE LONGER
DOWNTIME PERIOD.
DOWNTIME – TERMINOLOGY OFTEN USED IN AVIATION TO
INDICATE THE UNAVAILABILITY OF THE AIRCRAFT DUE TO
MAINTENANCE PROGRAM.
MAINTENANCE SCHEDULED – DOCUMENT APPROVED BY DCA
STATING THE REQUIRED MAINTENANCE REQUIREMENT ON
AIRCRAFT.

6. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
MANUFACTURER MAINTENANCE PROGRAM
MPD - MAINTENANCE PLANNING
DATA DOCUMENTS THE DATA
DEVELOPED BY THE
MANUFACTURER OF A PARTICULAR
AIRPLANE THAT CONTAINS THE
INFORMATION EACH OPERATOR OF
THAT AIRPLANE NEEDS TO DEVELOP
A CUSTOMIZED, SCHEDULED
MAINTENANCE AND INSPECTION
PROGRAM
IT IS USUALLY DIVIDED INTO 2 MAIN
CATEGORIES;
1. SCHEDULED INSPECTION
2. UNSCHEDULED INSPECTION.
SCHEDULED
INSPECTION CAN BE
FURTHER DIVIDED
INTO INSPECTION
THAT ORIGINATED AS
A RESULT OF;
1. HARDTIME
2. ON CONDITION

7. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
MANUFACTURER MAINTENANCE PROGRAM
INSPECTION THAT IS BASED
ON HARD TIME/ON
CONDITION CAN BE
FURTHER DIVIDED INTO
THE FOLLOWING
CATEGORIES;
1. FLIGHT HOURS
2. CALENDER
3. FLIGHT
HOURS/CALENDER
4. CYCLE
COMMON MAINTENANCE
ACTIVITIES FALL UNDER
‘ON CONDITION’ ARE;
1. PRE-LIGHT INSPECTION
2. TURN –AROUND
INSPECTION
3. POST FLIGHT
INSPECTION
4. MINOR INSPECTION
5. MAJOR INSPECTION

8. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
MANUFACTURER MAINTENANCE PROGRAM
COMMON MAINTENANCE
ACTIVITIES FALL UNDER
‘HARD TIME’ ARE;
1. OVERHAUL
2. ULTIMATE LIFE
DIFFERENCES BETWEEN
OVERHAUL IS THAT UNDER
OVERHAUL, COMPONENTS
ARE DISMANTLED ARE
SPECIFIC INTERVALS,
CHECKED/REPLACED AND
REASSEMBLED. THE
COMPONENTS WILL BE
GIVEN ‘0’ HOURS
FOR COMPONENTS FALL
UNDER ULTIMATE LIFE,
THEY ARE SCRAPPED
AFTER REACHING SPECFIC
PERIOD
THE FOLLOWING 3
ELEMENTS ARE THE MAJOR
SOURCE OF UNSCHEDULED
INPECTION ON AIRCRAFT;
1. INCIDENTS – HARD
LANDING, TAIL ROTOR
STRIKE & HELICOPTER
LANDED ON WATER.
2. SERVICE BULLETINS
INSPECTION
REQUIREMENT – SUCH
AS MANDATORY
SERVICE BULLETIN
3. FOREIGH OR LOCAL
AUTHORITY
REQUIREMENTS IN THE
FORM OF
AIRWORTHINESS
FIRECTIVES.

9. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
LINE MAINTENANCE VS HEAVY MAINTENANCE
Line Maintenance – Line
Maintenance is generally minor
or scheduled maintenance carried
out on aircraft:
1. that is in service; and that is:
2. preparing for its first flight in
service after a period of being
out of service; or
3. en route and stopped before its
next flight; or
4. preparing for any other flight
during a period of service; and
5. to ensure that the aircraft is fit
for the flight.
Heavy Maintenance – Heavy
Maintenance is any maintenance,
inspection, repair, or alteration a
manufacturer has designated that
requires specialized training,
equipment, or facilities.

10. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
PRE-FLIGHT INSPECTION
INSPECTION PERFORMED BEFORE THE FIRST FLIGHT OF THE
DAY.
DETAILS OF INSPECTION TO BE PERFORMED ARE STATED IN
THE MAINTENANCE SCHEDULE IN ADDITION TO THE CHAPTER
5 OF THE MAINTENANCE MANUAL.
MOST OF INSPECTION UNDER THIS CATEGORY INVOLVES
VISUAL INSPECTION OF THE SPECIFIC PARTS AND AREA ABD
TOPPING UP THE OIL LEVELS AS NECESSARY.
THE WAY THE INSPECTION IS ARRANGED IS SUCH THAT ALL
AREAS ARE COVERED THAT INCLUDES INTERNAL &
EXTERNAL OF AEROPLANE.
THE MAINTENANCE MANUAL MAY DIVIDED THE HELICOPTER
INTO FEW STATIONS TO ENSURE THAT THE
TECHNICIANS/ENGINEERS PERFORMING THE INSPECTION WILL
NOT MISSED THE VITAL PARTS OF THE AIRCRAFT.
THIS INSPECTION IS VERY IMPORTANT AS IT SERVE AS A LAST
INSPECTION BEFORE THE AIRCRAFT COMMENCE ITS DUTY
FOR THAT PARTICULAR DAY

11. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
TURN AROUND INSPECTION
TURN AROUND INSPECTION IS LESS STRINGENT THAN THE
PRE-FLIGHT OR THE DAILY INSPECTION AS IT INVOLVE
MAINLY FEW PARTS THAT ARE VITAL FOR THE SUBSEQUENT
FLIGHT. MAINTENANCE PERSONNEL SHOULD CHECK FOR ANY
FLUID LEAKS THAT ORIGINATED FROM THE PREVIUOS FLIGHT.
THIS INSPECTION IS SOMETIME PERFORMED BY PILOT IF THE
AIRCRAFT IS OUTSTATION.

12. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
PRE-FLIGHT INSPECTION ON AS355

13. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
PRE-FLIGHT INSPECTION ON AS355
THE FIGURE BELOW SHOWS THE APPROACH THAT SHOULD BE
FOLLOWED WHEN PERFORMING THE PRE-FLIGHT INSPECTION

14. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
POST FLIGHT INSPECTION
INSPECTION PERFORMED AFTER THE LAST FLIGHT OF THE
DAY.
IT IS MORE DETAILED THAN PRE-FLIGHT & TURN AROUND
INSPECTION.
INVOLVES TOPPING UP THE FLUID LEVELS AS NECESSARY.
MOST OF THE TIME ADDITIONAL CHECK & WORK IN THE FORM
OF DEFECT RECTIFICATION WILL BE DONE DURING THIS
INSPECTION.

15. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
MINOR VS MAJOR INSPECTION
MINOR INSPECTION IS
INSPECTION THAT CAN BE
PERFORMED WITHIN THE
SHORT PERIOD.
IT IS USUALLY CARRIED OUT IN
CONJUNCTION WITH THE POST-
FLIGHT INSPECTION.
IT COMPRISES MOSTLY VISUAL
INSPECTION & IF ANY
REMOVAL OF COMPONENTS
ARE REQUIRED, IT IS USUALLY
CARRIED OUT ON VITAL
COMPONENTS SUCH AS
FILTERS & CHIP DETECTORS
EXAMPLE 25/50 HOURS
INSPECTION OR 3/6 MONTH
INSPECTION.
NO GROUNDING OF AIRCARFT
IS NECESSARY
MAJOR INSPECTION IS
INSPECTION THAT TAKES
CONSDERABLE TIME AND
USUALLY REQUIRE
GROUNDING OF AIRCRAFT.
INVOLVES DETAILED
INSPECTION ON MAJOR
COMPONENTS & AS SUCH
REQUIRE REMOVAL OF SUCH
COMPONENTS FROM AIRCRAFT.
THE DOWNTIME PERIOD IS
VARY FROM 1 DAY TO FEW
MONTHS DEPENDING ON THE
TYPE OF INSPECTION OR
AVAILABILITY OF MANPOWER.
EXAMPLE OF SUCH INSPECTION
INCLUDES 100/200/300/500/1000
HOURS INSPECTION OR 5/12
YEARS INSPECTION

16. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
EXAMPLES OF HEAVY MAINTENANCE ACTIVITIES

17. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
UNSCHEDULED INSPECTION
UNSCHEDULED INSPECTION WILL BE TOUCHED IN DETAILS
UNDER DIFFERENT TOPIC

18. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
SOMETHING TO
THINK ABOUT!
IAW A.N 3, 10 & MCAR PART 5, BEFORE
AN ENGINEER ISSUE A CRS AFTER
COMPLETION OF ANY WORK, HE MUST
ENSURE THAT HE HAS SATISFY THE
FOLLOWING REQUIREMENT;
1. UP-TO-DATE INSTRUCTION & APPROVED
AIRWORTHINESS DATA (Including manuals,
drawings, specifications, DCA mandatory
modifications or inspections and where
applicable company procedures)
2. RECOMMENDED TOOLING AND TEST
EQUIPMENT WHICH IS CURRENTLY
CALIBRATED WHERE APPLICABLE.
3. WORKING ENVIRONMENT APPROPRIATE
TO THE WORK BEING CARRIED OUT.

19. FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
SAFETY PRECAUTION & WORD OF ADVICE
PERSONNEL INVOLVES IN MAINTAINING OF AIRCRAFT PLAY A
VERY IMPORTANT ROLE AS IT RELATED TO THE LIFE OF THE
PASSENGERS OF THE AEROPLANE/HELICOPTER.
UNDER NO CIRCUMTANCES SHOULD AN ENGINEER
RELEASING THE AIRCRAFT IF IN HIS/HER OPINION THAT THE
AIRCRAFT IS NOT FIT FOR THE FLIGHT.
AS MENTIONED IN THE PREVIOUS SLIDE, WHEN PERFORMING
MAINTENANCE ACTIVITIES ON AIRCRAFT, THE ENGINEER
CONCERNED SHOULD ALWAYS ENSURE THAT ALL THE 3
REQUIREMENTS ARE MET.
FAILURE TO DO SO CAN RESULT IN THE CRS BEING ISSUED
BECOMES INVALID AND HENCE THE C OF A BECOMES
INVALID AS WELL.
MCAR STIPULATED THAT LICENCED PERSONNEL CAN BE
PROSECUTED IN THE COURT OF LAW IF HE IS FOUND GUILTY
OF BREACHING THE SAFETY ASPECT OF THE AIRCRAFT.