Top 10 Tips for Maintainers

Engine failure or malfunction events continue to be one of the most common occurrence types reported to RAAus. As an RAAus maintainer, it is essential that maintenance is carried out regularly and as per the manufacturer’s aircraft maintenance manual. Here are some top tips to ensure your maintenance is up to standard in order to prevent avoidable failures from occurring to you!

1. Scheduled maintenance

Scheduled maintenance is essential in taking preventative measures to maintain safe operation of an aircraft and is performed at regular intervals including 25 hourly, 50 hourly, 100 hourly and annual inspections. It is essential that scheduled maintenance is carried out in accordance with the aircraft maintenance manual not extending the required intervals.

Remember, an annual inspection must be completed no later than 12 months from your last annual or 100 hourly inspection, even if the aircraft has completed less than 100 hours.

2. Service bulletins

Aircraft and engine manufacturers regularly issue service bulletins based on data collected from occurrences or identified safety concerns. Service bulletins are vital in ensuring the continued safe operation of your aircraft and should be checked when conducting scheduled maintenance. Make sure you are listed with your local aircraft distributer to stay up to date on notices relevant to your aircraft.

3. Unscheduled maintenance

From time to time, pilots or maintainers will identify a component that has failed or is identified as being close to failure. Pilots and maintainers must regularly inspect aircraft for any unscheduled maintenance that may be required over and above that included within the routine maintenance schedule. Maintainers may take the opportunity to conduct maintenance over and above that required within the maintenance manual in order to prevent component failure. This is even more important for aircraft that are flying regularly or used for the conduct of flight training.

4. Landing gear inspections

Due to the weight limitations of LSA and RAAus aircraft, components are built in order to minimise weight wherever possible. One of the most common failures reported to RAAus is undercarriage failure which may result in significant damage to an aircraft. Maintainers should pay particularly close attention to inspecting the undercarriage of their aircraft in an attempt to identify signs of potential failure. Aircraft owners should consider routine replacement of undercarriage parts, even if this is not required within the maintenance manual, particularly on aging aircraft with a high number of landings and/or hours or aircraft used within a flight training school.

5. Oil filter inspection

Routinely inspecting aircraft oil filters at time of replacement is a way of identifying potential engine concerns prior to an engine failure occurring. During this process, the oil filter is cut open to inspect the oil filter for metal fragments which may indicate excessive engine wear.

Oil filter cutters may be purchase by local aircraft supply companies and is a quick way of identifying engine concerns before they become a problem.

6. Compression testing

Engine compression testing is a way of regularly monitoring engine health by determining that the engine is maintaining compression and may identify piston or cylinder damage prior to a serious failure occurring. Compression testing is conducted through the use of a pressure gauge installed into the spark plug socket and compressed air is applied to test the level of compression the engine will maintain. Maintainers should ensure they own the appropriate equipment to regularly conduct compression testing on their aircraft to identify potential concerns prior to a serious failure occurring.

7. Calibrated equipment

A number of occurrences are reported to RAAus that may be avoided through the use of correct, calibrated tools and equipment. This is essential, particularly in relation to torque settings on bolts, including propeller settings. Incorrect torque settings or failure to use appropriate calibrated equipment may result in significant mechanical failure which may be easily avoidable.

8. Maintenance Logbook

Aircraft logbooks are a mandatory document which must be completed for all maintenance actions taken on an aircraft. In addition to showing maintenance history, a full and detailed maintenance logbook increases the future sale value of your aircraft as a potential buyer can review maintenance conducted and ensure compliance. If maintenance is not included within your maintenance logbook then it may be assumed that this has not been completed which may be an expensive exercise if the maintenance logbook is audited, or during transfer to a new owner.

9. Use of Approved Parts

We’ve all heard the term “Bunnings Aerospace”, however, whilst basic aircraft parts may appear the same as those from your local trade store, they are often made from high grade materials with much higher quality assurance procedures. Failure to use approved parts may result in significant safety concerns or expensive non-compliance upon review of your aircraft.

Maintainers should always ensure they use the approved parts during maintenance activities.

10. The Human Factor

Every year, a number of avoidable maintenance related occurrences are reported to RAAus which occur due to human factors. This may be as simple as failing to correctly tighten hoses and may result in serious consequences. Maintainers must take care in order to ensure they conduct maintenance thoroughly, using a checklist where possible, and that all attempts to avoid distractions are made to avoid disruption to work flow. Maintainers should also ensure duplicate inspections are conducted where required and that all work is checked, and checked again, to ensure correct conduct of maintenance for a safe return to flight.

IMPROVE YOUR SKILLS There are a number of maintenance training providers around Australia who can help you review and increase your maintenance skills in order to improve safety, including the RAAus L1 practical maintenance training. Keep an eye out for a course near you, or reach out to the team at RAAus to enquire about maintenance training opportunities available to you!

Maintenance of an aircraft is a task which must be taken very seriously due to the unforgiving nature of the environment in which we operate. All maintainers have an obligation to ensure they are competent to carry out a task prior to performing it. If you are unsure, always reach out to someone in your local area with more advanced knowledge of maintenance practices to assist.

Another outcome of incomplete or poor maintenance practices RAAus has become aware of is that insurance companies may not pay out in the event of an accident if you cannot prove that your maintenance has been conducted thoroughly and in accordance with the aircraft maintenance manual. Avoid the possibility of being tens of thousands of dollars out of pocket by ensuring maintenance standards are completed and recorded to a high standard.