Lampiran Keputusan Direktur Jenderal Perhubcrngan Udara

Nomor : Sii3P/l @,dv1/1993

Tanqqal : 23 JUG 1 4 3 1

Advisory Circular

Repair Approval and Return to

Service after Embodiment of a
Repa,iron a Product

P,evision
Date : 1 M a y 1998

REPUELIC OF INDONESIA - DEPARTMENT OF COMMUNICATIONS

DIRECTOFATE GENERAL OF AIR COMMUNICATIONS
JP,KARTA - INDONESIA
 FORWORD

1. Purpose : This Advisory Circular (AC) provides guidance to

aircraft operators, maintenance organization and
DAC personnel regarding approval of repair
embodied on a product operated in Indonesia.

2. References : This Advisory Circular is advisory only and should be

used in accordance with the applicable regulations.

3. Revisions : Revisions of this Advisory Circular will be approved

by the Director General of Air Communications.

Director General of Air Communications

SOENARYO Y.
KIP. 120038217

Sa!inan ir?i sesuai dengan aslinya

f
Pit. i(ep$l Bagian Hukum
b Hubud
~ e i tjen
\

ru iJ5
i?.: 2'
sH
66739
 FORVVORD

1. Purpose : This Advisory Circular (AC) provides guidance to

aircraft operators, maintenance organization and
DAC personnel regarding appioval of repair
embodied on a product operated in Indonesia.

2. References : This Advisory Circular is advisory only and should be

used in accordance with the applicable regula1:ions.

3. Revisions : Revisions of this Advisory Circular will be approved

by the Director General of Air Comm~,~nications.

Director General of Air Communications

ttd

SOENARYO Y.
NIP. 120038217

Salinan ini sesuai dengan aslinya

Bagian Hukurn

NIP.: y e 7 3 9
 Table o f Contents

FOREWORD...................................................................................... ii
...
Table Of Contents ............................................................................. 1 1 1
1. Purpose .............................................................................. 1
2. Related CASR sections ....................................................... 1
3. Requirements....................................................................... 1
4. Background .......................................................................... I
5. Definitions ............................................................................. 1
6. Abbreviation ......................................................................... 2
7. Responsibilities .................................................................... 3
8 Repairs.................................................................................. 3
8.1 . Classification of repairs .................................................. 3
8.2. ~ e p a i substantiated
r by design data previously
approved byDGAC ....................................................... 4
8.3. Repair not substantiated by approved design data ....... 4
8.4. Return to service of a product altered by the
installation of a repair .................................................... 5

Appendix 1 Examples of major repairs ............................................ 7

Appendix 2 Examples of minor repairs ............................................ 9
Appendix 3 DAC Form 21 -9 ............................................................ 12
Appendix 4 DAC Form 43-337 ......................................................... 13
1. Purpose

This Advisory Circular provides information and guidance to aircraft, operators,

aircraft maintenance organizations and DAC personnel concerning the
requirements and procedure for approval of repaired product operated under
lndonesian registration.

2. Related CASR s e c t i o n s

CASR Part A21 - Subpart D and E

CASR Part 121 - Subpart H and other CASR Parts addressing operating rules
when published
CASR Part 145
CASR Part 43

3. Requirements

CASR Part 43 paragraphs 43.5 and 43.7 provides requirements for return to
service of modified or repaired product.

4. Background

Before the implementation of regulation quoted in paragraph 2 above various

methods have been used by DAC to process approval of repair embodied on a
product operated in lndonesian while insufficient guidance was available to the
industry and DAC personnel to discharge properly their respective
responsibilities.

The lack of guidance material has so far created confusion within the industry
and DAC on what were their respective responsibilities.

5. Definitions

1) Civil Aviation Authority (CAA) where used in this document. is an

airworthiness authority that is recognized by the DGAC . a s having a
competent airworthiness system that provides confidence that prodcrct
designed under their control have a level of safety comparable to those
designed under the control of DGAC. The list of these airworthiness
authorities is given in DAC Policy Letter No. 7.

2) Product is an aircraft, aircraft engine or propeller.

3) Aircraft means a device that is used or intended to be used for flight in the
air.
4) Foreign product means a product not designed in Indonesia.

5) Repair is an action to restore a product or appliance to a condition for safe

operation after damage or deterioration.

6) Major Repair means a repair that

(1) if improperly done might appreciably affect weight, balance, structural

strength, performance, flight characteristics, power plant operation or
other qualities affecting airworthiness; or
(2) is not done according to accepted practices or cannot be done by
elementary operations.

NOTE : Typical operations classified as major repairs are listed in Appendix 3

to this AC and in CASR Part 43 -Appendix A item b.

7) Minor Repair is any repair on a product other than a major repair.

NOTE : Typical operations classified as minor repairs are listed in Appendix 4

to this AC

8) Return to service, means to certify any product fit for service by issuing a
maintenance release, certificate of maintenance, serviceable tag as the case
may require.

6. Abbreviation

AC Advisory Circular
AFM Airplane Flight Manual
AM0 Approved Maintenance Organization
CAA Civil Aviation Authority
CASR Civil Aviation Safety Regulation
C ofA Certificate of Airworthiness
DAC Directorate of Airworthiness Certification
DGAC Directorate General of Air Communication
SDAP Sub Directorate of Aeronautical Product
SDE Sub Directorate of Engineering
SDFO Sub Directorate of Flight Operation
SDMC Sub Directorate of Maintenance Control
STC Supplemental Type Certificate
TC Type Certificate
7. Responsibilities

The approval process of a repair embodied on a product must involve :

The person applying for the approval of the engineering data substantiating
compliance of the repaired product with the applicable DGAC airworthiness
codes (CASR part 21, 23, 25, 27, 29, 35, 35)
The person installing the repair on a product whom in accordance with CASR
Part 43 has to demonstrate that this installation has been done using
methods 1 techniques and practices acceptable to the DGAC.
The person apisroving the return to service of a repaired product whom in
accordance with CASR Part 43 has the responsibility to demonstrate that the
repair complies with applicable DGAC airworthiness requirements.
The DAC who has the responsibility to verify that compliance with its
applicable requirements has been demonstrated. Within DAC the
responsibility are split between SDE and SDMC as follows :

- SDE has the responsibility to verify that engineering data submitted by the
applicant for the repair approval are complying with the applicable
airworthiness codes (CASR Part 21, 23, 25, 27, 29, 33, 34, 35 or 36).

- SDMC has the responsibility :

1) to verify that the e m b o d i m e n t of the repair has been d o n e in

accordance with approved data and using methods/techniques and
practices acceptable to the DGAC.
2) when this verification has been completed satisfactorily. to approve
the repaired product for return to service.

Yote : These DAC responsibilities may be delegated in accordance

with existing CASRs (Part 43, Part 121, Part 145, Part 183. . . )

8. Repairs

A repair is an action restoring a damaged product to its original design (parts

replacement) or to a design achieving the same level of safety as the original
design. In this latter case the repair must be considered as a modification and
must be substantiated by technicallengineering data approved by the DGAC.
No p r o d u c t shall be repaired except in accordance with technicallengineering
data a p p r o v e d b y the DGAC.

8.1. Classification o f repairs

Repairs are classified in two categories : "minor repairs" and "major repairs"
defined in paragraph 5 of this AC.
 Note : CASR Part 43 - AppendixA item b gives a list of major repairs
while appendix 1 and 2 to this AC provides examples of niajor and
mincr repairs.

Because most of the repairs applied on engine and propeller belong to the
category of parts replacement, the guidance provided hereafter in paragraph
8.2 and 8.3 f o c u s o n structura! repair en aircraft airframe !ha! are likely to
be developed to address structural damages that occur during the normal
operation of an aircraft.

8.2 Repair substantiated b y d e s i g n data p r e v i o u s l y a p p r o v e d b y DGAC :

Minor or major repair substantiated by already approved design data such as

those contained in Structural Repair Manual does not need further
engineering evaluation nor formal approval from DAC Engineering. In such
case the u s e o f DAC Form 21 -9 i s n o t required.

8.3 Repair n o t substantiated b y a p p r o v e d d e s i g n data :

- The applicant for the repair approval must fill an application Form 21-9
and submit that form to DAC, Sub Directorate of Engineering, together with:

a detailed description of the damage.

a detailed description of the repair.
engineering data substantiating the airworthiness of the repair

- Upon receipt of the file (Form 21-9?the description of the damage and the
repair and the substantiating engir~eeringdata) SDE of DAC will evaluate
the engineering data to verify that the design of the repair is of an
equivalent level of safety to the original certified product.

These engineering data substantiating the structural restoration of the

product are generally limited to static and fatigueldarnage tolerance
analysis and sometimes supported by tests.
However a structural repair may have an impact on the system of the
aircraft or on its performance. In such case this must be evaluatad and
substantiated by the applicant.

If necessary, limitations may be defined to declare the repair airworthy

- Because repairs are always developed to restart operation of a damaged

product in the shortest period of time, the applicant may be unable at the
time of the approval to provide a complete fatigue and damage tolerance
substantiation. In such a case a preliminary analysis may be acc2ptable
 provided a limitation is imposed to the repair (cycles or flight hours).
However the foliowing principles must always be strictly followed :

a) No repair may be submitted to DAC for approval unless a complete

static justification is available.

b) No repair affecting a Foreign product may be approved by the DGAC

unless :

. there is a Non Technical Objection from the product certificate holder

approved by the Authority of the country of design, o r

the applicant for the repair approval can demonstrate that he has all the
information from the product certificate holder to develop and
substantiate the airworthiness of the repair.

c) Any limitation applied to the repair (cycles, flight hours. etc ...) must be
approved by the DGAC and clearly indicated on DAC Form 21-9. Any
extension or cancellation of the limitation must be also approved by the
DGAC.

8.4 Return t o service o f a p r o d u c t altered b y the i n s t a l l a t i o n o f a repair.

Return to service of a product altered by the installation of a repair is ruled by

CASR Part 43 parqgraph 43.5.

Approval of design data substantiating the airworthiness of a repair is n o t a

sufficient c o n d i t i o n to allow return to service of a product altered by the
installation of a modification.

No product altered by the installation of a repair can be r e t u r n e d t o service

unless :

the design data substantiating the airworthiness of the repair have been
approved by DAC.
the installation of the repair has been performed in compliance with
accepted industry practices and applicable CASRs by a scritably
approved person.

DAC Form 43-337 (refer to appendix 4) is the appropriate form available to

the operators, approved maintenance organizations (AMO) or aircraft owners
to record embodiment of repair indicating details and approval.
When all the steps of DAC Form 43-337 are completed satisfactorily then the
aircraft can return to service. DAC Sub-Directorate of Maintenance Control
has the responsibility to control the proper use of DAC Form 43-337.

Note : guidance to use DAC Form 43-337 is given in DAC AC 43-9

"Instruction for completion of DAC Form 43-337".
 APPENDIX 1
EXAMPLES OF MAJOR REPAIRS

Changes such as the following to an airframe, powerpiant, propeiier or appliance

are considered major repairs.

1. AIRFRAME MAJOR REPAIRS

(a)All repairs involving the strengthening, reinforcing, splicing and

manufacturing of primary structural members or their replacement, when this
is by fabrication such as riveting or welding. The following are examples of
such members :

- Box beams
- Monocoque or semi-monocoque wings or control surfaces
- Wing stringers or chord members
- Repairs involving the substitution of materials
- Spars
- Spar flanges
- Mernbers of truss-type beams
- Thin sheet webs of beams
- Keel members of boat hulls or floats
- Corrugated sheet compression members which act as flange material of
wings or tail surfaces.
- Wing main ribs and compression members
- Wing or tail surface brace struts
- Engine mounts
- Fuselage longerons
- Members of the side truss, horizontal truss or bulkheads
- Main seat support braces and brackets
- Landing Gear brace struts
- Axles
- Wheels
- Skis, and ski pedestals
- Parts of the control system such as control columns, pedals, shafts,
brackets, or horns.

(b) The repair of damaged areas in metal or plywood stressed covering

exceeding 6 inches in any direction; the repair of portions of skin sheets by
making additional seams; splicing of skin sheets.
(c) Repair of the three or more adjacent wing or control surface ribs. or leadin9
edge of wings and control surfaces between S L I C ~ adjacent ribs.
(d) Repair of fabric covering involving a greater area than required to rapair two
adjacent ribs, replacement of fabric on fabric covered parts such as wings,
fuselages, stabilizers and controls surfaces.
(e) Rebuilding, including rebottoming, of removable or integral fuel tanks, and oil
tanks.

2. POWERPLANT MAJOR REPP,IRS

(a) Any maintenance operation requiring the separation or disassembly of a

crankcase of crankshaft of an engine equipped with an integral supercharger
andlor propeller reduction gearing; (ii) disassembly of a nonfloat type
carburetor or fuel injection unit used with such engine; or (iii) top overhaul of
such engines.
(b) Special repairs to structural engine parts by welding, plating, metalizing or
other methods.

3. PROPELLER MAJOR REPAIRS.

(a) Any repair to or straightening of steel blades.

- Repairing or machining of steel hubs.
- Shortening of blades.
- Retipping of wood propellers
- Replacement of outer laminations on fixed pitch wood propellers.
- Repairing elongated bolt holes in the hub of fixed pitch wood propellers
- Inlay work on wood blades.
- All repairs to composition blades
- Replacement of tip fabric.
- Replacement of plastic covering
- Repair of balance propellers of rotorcraft
- Overhaul of controllable pitch propellers
- Repairs to deep dents cuts, scars, nicks etc. and straightening of aluminum
blades
- The repair or replacement of internal elements of blades.
 APPENDIX 2
EXAMPLES O F MINOR REPAIRS

Changes such as the following to an airframe, powerplant, propeller or appliance

are considered to be minor repairs.

1. AIRFRAME MINOR REPAIRS

(a) Nonstructural members. Repairs to nonstructural members ivhich may affect

the airworthiness of an aircraft, such as :
- Cowling
- Wing and control surface fairings
- Electrical installations
- Windshields
(b) Tanks. Patching and repairing of leaks in non-integral fuel, oil, hydraulic, and
de-icer fluid tanks.

(c) Ribs, leading and trailing edges, tip strips. The repair of :
- not more than two adjacent wiqg or control surface ribs of a conventional
type (wood or metal) :
- the leading edge of wing and control surfaces between two adjacent wing or
control surface ribs:
- the trailing edge of wing control surfaces, and flaps;
- Wing and control surface tip strips.
(d) Fabric covering. Patching of fabric involving replacement of fabric covering
of a surface when such replacement is of an area not greater than that
required to repair two adjacent ribs.

(e) Metal or plywood stressed covering. The parching of holes in metal or

plywood stressed covering not to exceed 6 inches in any direction when ribs,
stringer, bulkheads, and reinforcements are not directly affected.

(f) Replacement of components or complete units such as listed below with parts
supplied by the original manufacturer or manufactured in accordance with
approved drawings :
- Wing
- Replaceable wing tips
- Control surfaces (fixed and movable) and control cables
- Wing or control surface bracing (struts or wires)
- Floats
 - Landing Gear
- Tail wheel assemblies
- Engine mounts (prefabricated and bolted on, not to be welded on).
- Fuel and oil system accessories
- Hydraulic system accessories
- Fuel and oil tanks
- Powerplant controls
- Propeller controls
Appliances such as instruments, hydraulic or electrical actuating units of
components, cabin heaters, radio units, auto- pilots.

2. POWERPLANT MINOR REPAIRS

(a) Engine top overhauls. Top overhaul of engines which have neither an
integral supercharger nor integral propeller reduction gearing consisting of
the following.
- Removal of cylinders
- Griding valves and removing carbon
- Fitting new ring
- Adjusments of valve gear or replacement of parts in value mechanism
outside of the crankcase.

(b) Engine complete overhauls. Complete overhauls of engine which have

neither an integral supercharger nor integral propeller reduction gearing.

(c) Replacement of components. The replacement of component not a part of the

basic structure of the engine, such as carburetors, magnetos, ignition
harnesses, on engines of any horsepower.

(d) Replacement of accessories. The replacements of components such as

generators, starter, fuel pumps, vacuum pumps, hydraulic pumps. and oil
coolers on engines of any horsepower.

3. PROPELLER MINOR REPAIRS

(a) Repairs to dents, cuts, scars, scratches, nicks, leading edge pitting of
aluminum blades, provided removal of treatment does not materially affect
the strength, weight, balanse, or performance of the propeller.
(b) Repairing dents, cuts, scars, scratches. nick and small cracks parallel to the
grain of wood blades.
(c) Removal and installation of propellers
(d) The assembly and disassembly of propellers to the extent necessary to
permit :
 (i) Assembly of propellers partially disassembled for shipment and not
requiring the use of balancing equipment;
(ii) The accomplishment of routine servicing and inspection;
(iii) Replacement of parts other than those which normally require the use of
skilled techniques, special tools and test equipment.

(e) Balancing of fixed pitch and ground adjustable propellers.

(f) Refinishing of wood propellers.
 Appendix 3

DAC FORM 21 -9

(See fn form ku-21-09/msexel)

1
~<EPUBLIC OF INDONESIA-DEPARTMENT OF COMMUNICATIONS Page of
1
%RECTORATE GENERAL OF AIR COMMUNICATIONS
I
-
.<PPLICATION

<ME
.--
I
FOR APPROVAL OF REPAIR AND MINOR MODIFICATION

2. ADDSESS OF APPLICANT
I
2 IDENTIFICATION OF PRODUCT
JAIRCRAFTTYPE
I
1
I
/REG MARK ~ S E ~ ~NO
I A L
.- I
i
-
$?LICXIJT'S MOGIREP.lJ0 4. TITLE [DESIGN RESPCPISIBILITY (ORGANIZATION)

i
~?IEF
9ESCRIPTIOI.I OF MODIFICATIONIREPAIR (USE ATTACHED PAGES IF NECESSARY)

r
I
I I ! I I I
DOCUMEKTLTION CHECK LlST FOR N O T USE ONLY
REQUIRED (FILL IN BY DC-AC)

I YES N0 YES '\10 DPTE

:rJ?.l?LIC?ICE PROGRAM
!:STER DRAVJIPIG OR MPSTER DRAWING LlST
!A~NTEI~!At.ICE
htPPIU;L SUP?LEMENT
I
i?:cJINEE?II.IG REPDRT
.--
.r.3GN 3FIdWINGS 1 1 1

I L I I I I
9 1 CERTIFY THAT TfiE STATEbIEbiT MACE OX
I
-
=3REIGhl AUT%O?!:,!;:+'t l==RGV!,i THIS APPLIC4TION 4SE TURE.
------
----
.-. -x.;=i\ICE (IF F I * i Y ;
I
PLACE AND DATA

I i I I I I
-. ---- I
I
POSITION I . 1 I

.
,

-,
I I
,
--:a~r',-~TlC>i PHONE NUM3ER 1 I I
PPROVAL I
I I I !
I
I
_ _1 -.G,,E
- * - r

-----... ICE P;1Tn

I
A P P i 3 V E 3 AND $ A Y BE E I ~ I ~ O ~ I E D ,
MQCI~~C;:~~-IS SUBJELT TO COM?LAUCES ih;
I I
+!
-vI?Y-I Ci'JIL A :,ATICN SAFETY REGULATIONS PART 31
On behalf of THE DIRECTOS G E N t i A i OF AIR coMMurIIc;TIsJli
---- . 1
-. --, - ,-.. P~jC
--+ ,,

. . I for THE DIRECTOR OF AIRWORTHlr~lESSCERTIFICATIOI.I I

- , x I ! I I I I I I

- 1
I I I I -I
\
I
i
/DEPUTY DIRECTOR FOR ENGINEERIbJG
I
I 1 1
-.. -" --,^
d -m, I ?, <L, 2 ;;
-73
I
;
I 1 1I I
I
I

I
 Appendix 4

DAC FORM 43-337

 REPUBLIC OF INDONESIA - DEPARTMENT OF COMMUNICATIONS I 3 7 I
i
I
I
DIRECTORATE GENERAL OF AIR COMMUNICATIONS
RETURN TO SERVICE AFTER EMBODIEMENT OF A MODlClATlON OR REPAIR
7
INSTRUCTIONS: Print or type all entries. See CASR 43.9, CASR 43 Appendix B, and AC 43.91 (or subsequent
revision there of) for instructions and disposition of this form. This report is required by law. Failure to report can
result in a civil sanction under KM 11 for each such violation of Aviaticjn Act No. 15 of 1992.
1. Aircraft Make Model
I

1
I

Serial No. Nationality and Registration Mark

2. Owner Name (as shown on registration Address (as s h o r n on registration certificate)

certificate)
No person may operate this airframe, propeller, or appliance as altered hare in, unless the modification or
repair had been embodied in accordance vvith Indonesian CASR

4. Unit Identification 5. Type

Unit Make Model Serial No. Repair Alteration
AIRFRAME (As described in item I above)
I

POWERPLANT 1
PROPELLER i
APPLIANCE Type
L
Manufacturer
6. Conformity Statement
A. Applicant's Name and 8.Kind of Agency C. Certificate No.
I Address
j
- --

7Indonesian Lane 1 1
I ( Foreign Certificated I
I I
Certificated A M 0
(
Manufacturer
D. 1 certify that the modification or repair made to the unit(s) identified in item 4 above and described on the
1
I

reverse or attachments hereto have been made in accordance 14th the requirements of CASR Part 43 and
that the information furnished herein is true and correct to the best of my knowiedge.
I
)
I
Date ( Signature of Authorized Individual 1
7. Approval for Return To Service
I/ Pursuant to the authority given persons specified below, the unit identified in item 4 was inspected in the manner 1
prescribed by the Director of DAC.
I
1 1
--- U APPROVED U REJECTED 1

By 1 1 DGAC Inspector 1 Other (Spec~fy)

.- I I I

I
I
j Manufacturer / AM0 I
-- I 1 -
i Da!e of Approval or Reject~on I Certlflcate or S~gnatureof Authonzed Indfvldual ,