maintenance manual - dv-1 skylark

sheets riveted and sealed together. Each fuel tank is equipped with filling intake, outlet valve, sludge valve, air-bleeding valve and fuel-meter. Fuel system itself is equipped with three-ways fuel valve, fuel filters and electrical fuel pump. Interior: Aircraft is equipped with two upholstered seats placed side-by-side. Position of each seat is adjustable with position lock. Further equipment are four-point safety belts, baggage compartment placed behind the seats and safety net for fixing luggage. Canopy: Canopy is made from one single part of organic glass. This glass is riveted and glued to welded frame from duralumin tubes. Canopy opens with forward sliding movement. Canopy frame is attached to fuselage through metal pull-out system. The canopy latch is placed in the top of the canopy and it is lock-able. Ventilate system: Ventilation is provided through rounded valve in front of the canopy. As an option, there are side sliding windows. Electrical installation: Electrical system is single phase 12V system with negative pole grounded. As a source, there is a duty-free battery and engine alternator. Each electrical circuit is protected with fuse or circuit breaker placed on instrument panel. Labels: Ready-to-fly aircraft delivered from manufacture is equipped with given labels. In case of kit the labels are delivered, but the owner had to placed them into correct positions. Warning: owner of the aircraft is responsible for readability of the label during the aircraft lifetime. Instruments: Minimal instruments equipment: - in-flight instruments: air speed indicator, altimeter, vertical speed indicator, slide-ball indicator, compass, fuel gauges - engine instruments: tachometer, oil temperature indicator, engine head temperature indicator, oil pressure indicator Radio: ICOM 200 Servo: for elevator trim surface Ray Allen T10A Options: fuel pressure indicator, manifold pressure indicator, GPS AvMap EKP IV, transponder Garmin , artificial horizon, landing light 100W. Signal lights: position lights placed in winglets and strobe lights (2pcs in winglets ad 2pcs on fuselage) Additional equipment: There is a preparation for installation of ballistic rescue systems already provided. Previews DV–1 SKYLARK 6 1.2. BASIC DIMENSIONS AND AIRCRAFT PREVIEW 2288 /90,08/ 2863 /112,72/ 5° 1092 /42,99/ 1486 /58,49/ 776 /30,56/ 8136 /320,32/ 1756 /69,12/ 6624,3 /260,80/ ø1 090 /42,92/ ø1 620 /63,78/ 1367 /53,81/ 4315 /161,89/ Fuselage: Length 6,62 m Width 1,09 m Height 2,28 m Wings: Wingspan 8,14 m2 Wing surface 9,44 m Empennage: 2 Horizontal tail surface 1,47 m 2 Vertical tail surface 1,02 m Undercarriage: Track 1,70 m Wheelbase 1,36 m Empty weight ..................kg ± 2 % Maximum Take-Off weight 450 kg Useful load 170 kg Fuel capacity 90 liters Maximum baggage weight 20 kg Maximum loads +4,4 / -2 Stall speed without flaps 79 km/h Stall speed with flaps 64 km/h Never exceeded speed 280 km/h Maximum horizontal speed 240 km/h Cruise speed 210 km/h Climb speed 8 m/s Ceiling 3 650 m Range (45 min. reserve) 1 200 km Term of engine overhaul is given as 2000 flight hours or 10 years for ROTAX 912 UL/S (first reached is valuable). See Rotax Bulletins – operational condition of engine manufacturer Had to be changed every 5 years: • air supplying hose for carburetors (AIRBOX) • all rubber hoses of cooling circuit 1.2. BASIC DIMENSIONS 1.3. WEIGHTS AND PERFORMANCES 1.4. ENGINE LIFETIME 1.5. ENGINE PARTS WITH RESTRICTED LAIFETIME 8 • all rubber hoses of oil circuit • carburetors flange • rubber hoses connecting carburetors • belt attaching alternator • fuel pump including fuel hoses Had to be changed every 2 years: • cooling liquid of engine – structural: lifetime for changing parts of structural joint will be estimated by manufacturer, alternatively authorized service center during estimated inspections. In case that you will find any sign of rising wear of parts, higher friction or backlashes during your pre/after flight check, call authorized service center. – flight, navigate and engine instruments: DV-1 SKYLARK is equipped with 1.6. LIST OF PARTS WITH RESTRICTED LIFETIME Item Basic equipment Air Speed indicator Altimeter Vertical speed indicator Side slip ball Compass Fuel gauges Tachometer Oil temperature indicator Head temperature indicator Oil pressure indicator Nb. Overhaul (flight. Hours/years) Date of installation (Fl. hours/years) Item Options Fuel pressure indicator Manifold pressure indicator Artificial horizon Transponder Garmin Ballistic Rescue System Nb. Overhaul (flight. Hours/years) Date of installation (Fl. hours/years) 10 1.7. TECHNICAL DESCRIPTION OF AIRCRAFT ASSEMBLIES WITH DRAWINGS - ATTACHMENT Nb.1 Wings (version flap 1:1 aileron) 1-11-00-00 - left wing equipped 1-11-10-00 – wing L 1-11-20-00 – aileron L Fuselage 1-21-00-00 - front fuselage 1-21-10-00 – firewall 1-21-20-00 – main beam 1-21-30-00 – U/C beam 1-22-00-00 - rear fuselage 1-23-10-00 – canopy frame 1-24-00-00 - controls 1-24-10-00 – steering rod 1-24-20-00 – elevator control 1-24-30-00 – rudder/front wheel control 1-24-40-00 – flap control Empennage 1-30-00-00 - empennage 1-31-00-00 – horizontal tail surfaces 1-31-10-00 – stabilizer 1-31-20-00 – elevator 1-32-00-00 – vertical tail surfaces 1-32-00-00 - fin 1-32-20-00 – rudder Undercarriage 1-41-00-00 - main undercarriage 1-42-00-00 - front undercarriage Fuel tanks 1-51-00-00 - fuel tank equipped 1-51-10-00 – fuel tank Power plant 1-60-00-00 - Power plant equipped 1-61-20-00 – engine frame for ROTAX 1-61-30-00 – cowlings for ROTAX 1.8. CONTROLS IN COCKPIT 1 2 3 4 5 6 13 9 14 10 11 18 19 28 15 26 27 23 21 25 24 22 20 29 15 12 7 Description: 1. Airspeed indicator 2. Altimeter 3. Vertical speed indicator 4. Compass 5. Side slip ball 6. Elevator trim control 7. Elevator trim position indicator 9. Fuel pressure indicator 10. Oil pressure indicator 11. Head temperature indicator 12. Oil temperature indicator 13. Tachometer 14. Engine operation hours indicator 15. Fuel gauges 2x 16. Diode for indicating failure of battery loading 18. Radio 19. Transponder 20. Fuel valve 21. Master switch 22. Switches 23. Fuses 24. Starter button 25. Magnetos 26. Choke 27. Throttle control 28. Heating control 29. Propeller pitch control 12 CHAPTER 2 Basic handling 2.1 (DIS) ASSEMBLING OF WINGS 2.2 (DIS) ASSEMBLING OF TAIL SURFACES Warning: (Dis) Assemble aircraft always on place with enough space to safely manipulate with the parts or with whole aircraft. In case of disassembling aircraft, be sure that you have enough right pads (soft, clean, height enough) to protect the wing from damage during storage (on ground for ex.). During handling (hold/push/pull) aircrafts parts always touch in place of structural reinforcement like ribs, wall and beams (shortly in positions of rivets lines). There’s needed to be at least two men to (dis) assemble wing safely. Always keep all disassembled parts, joining materials and others aircrafts items. Used self-locking nuts replaced with new ones! Disassembling of wings − remove the covers inside the pilots cabin (flap control handle, under pilot, around the steering) − disconnect aileron control rod from the steering joystick − disconnect and blind fuel hoses from the wing-fuselage connection − disconnect the pitot-static hoses in left wing connection – first mark the hoses with static pressure and then disconnect to prevent wrong re-connection . Blind disconnected hoses to prevent getting dirty inside − after each re-assembling check proper pitot-static hoses connection and verify function − disconnect electro-installation connectors from wing to fuselage − remove self-locking nuts with washers from wing hinges on main and rear beam. (6+6 peaces on main, 2+2 peaces on rear one) − remove bolts from rear hinges, remove bolts from main hinges except 1+1 in upper hinges and except 1+1 in lower hinges − one man holds the end of the wing and second one remove upper and lower bolts (little up and down movement of wings end is required to release the bolts) − one man holds the end and second one holds the wing root attachment. Move the wing slowly out of the fuselage. During moving out, watch carefully the rod ball-ends, hoses, connectors to avoid their damaging from edges. During moving wing out, automatic disconnection of flap control happened, so it is better to hold the flap position during that act. − Put the wing carefully on suitable pad ( watch out for the pitot-static tube under the wing – had to be lifted) − Same procedure for opposite wing Assembling of wings − Assembling means reverse procedure of disassembling − During assembling it is required to connect the flap controls properly. For that it is needed to set 0 positions on control flap handle and 0 positions on flap itself (that means trailing edge in straight line). With that the flap control will re-connect automatically. Disassembling horizontal tail surfaces - remove fiberglass covers from stabilizer - disconnect connectors for trim control and strobe lights in front cavity - disconnect elevator control in rear cavity - remove self-locking nuts, washers and 4 bolts connecting stabilizer together with fin. - Remove horizontal tail surfaces and put it on suitable pad Assembling of horizontal tail surfaces - assembling means reverse operation mentioned above 2.3. ESTIMATING AIRCRAFT WEIGHT AND CENTER OF GRAVITY 2.4. OPERATIONAL VALUES 1000 1190 T 119 M2/M3 M1 Y Csat Formula for counting center of gravity (c.g.) position: T = ( X * ( M2+M3)/(M1+M2+M3) – Y – 119 ) / 11,9 (% Csat = % Cmac) Allowable range of c.g. movement is from 23 to 36% Csat. Operational values for engine: Information bellow is not complete. Complete information can be found in Original ROTAX 912 engines manual. Oil pressure max. 7 bar, min. 0,8 bar optimum 2-5bar Oil temperature min. 50°C, max. 130°C optimum 90-110°C Cylinders head temperature max. 135°C Exhaust gas temperature max. 880°C – start max. 850°C – in flight optimum 800°C Fuel pressure max. 0,4 bar optimum 0,15-0,4 bar Operational filling for ROTAX 912S: Fuel Natural 95 (Pb free) Engine Oil Castrol GTX 5 10W-40 Oil volume 2,5 l Cooling liquid ARAL Antifreeze with distilled water with mix ratio 1:1 Cooling liquid volume 2,7 l 14 Operational tire pressure: - front wheel tire 160kPa - main wheels tires 180kPa Fuses and battery: Fuses used: 30A, 20A, 16A, 2x10A, 4x5A,1A Duty-free Battery : 12V, 18Ahod Control surfaces deflections: - Ailerons: up 15° ± 1° down 10° ± 1° - Flaps: position -1 -10° ± 2° position 0 0 position 1 +10° ± 2° position 2 +40° ± 2° - Elevator: up 30° ± 2° down 20° ± 2° - Rudder: right 30° ± 2° left 30° ± 2° 2.5 (DIS) ASSEMBLING OF ENGINES COWLING - Disassembling of upper engine cowling requires just releasing cam-locks fasteners and removing two screws in front of the cowlings – close to the propeller nose. Removing of this cowling for the pre/after flight check of the engines compartment is required. Removing creates easy access to check level of engines liquids like oil and cooling liquid. - Disassembling of lower part of the cowlings requires disconnecting vent hoses from Naca’s inlets and removing of bolts connecting cowling with firewall. It is required to start removing bolts from lower one and then move up to next ones. Removing will create easy access to exhausts pipe system, coolers, temperatures and oil sensors. - Assembling means reverse procedure. CHAPTER 3 Maintenance 3.1. GENERAL 3.2. MAINTENANCE LIST WITH TERMS 3.3. MAINTENANCE Flight and operational eligibility directly depends on complying scheduled maintenance intervals and degree. For proper maintenance service even the weather, quality of hangar, surface of airfield and other factors had to be considered. This manual presents information for maintenance and operation in average standard conditions known for this category. Caution: The intervals of engine inspections and the list of works are shown in Maintenance Manual (Line Maintenance) for installed engine. The intervals of propeller inspections and the list of works are shown in Technical description and operation instructions for the installed propeller. If the periodical inspection is performed before reaching the specified time interval, then the following inspection must be performed at the latest within the specified time interval from this inspection (e.g. if the first 100-hour inspection is performed after 87 flight hours then the following 100-hour inspection must be performed at the latest after 187 flight hours) Maintenance system is composed of periodic inspections which must be performed at least in the following intervals: a) Pre-flight inspection is performed within the scope given in Flight Manual b) Propeller inspection after first 5, 20 and 50 flight hours (see Technical description of the propeller) Note: To be performed with a newly installed propeller or with the propeller that was dismantled and reinstalled on the airplane. c) Inspection after the first 25 flight hours - engine inspection. Inspection after the first 25 flight hours to be performed with the new engine or Caution: with the engine after overhaul. d) Periodical inspection after 50 flight hours - inspection of engine and propeller e) Periodical inspection after 100+5 flight hours - airframe and propeller inspections, engine inspection according to maintenance system which is described in Maintenance Manual (Line Maintenance) for installed engine. Maintenance is provided in periodically estimated terms. Pay attention to revising parts according to their function, wear and parts importance. Purpose of periodical maintenance is to avoid or find right in time any damage/wear of aircraft construction, which can cause failure of aircrafts parts. maintenance provides according to maintenance manual for installed engine - Engines (for example ROTAX 912UL/S engines). maintenance provides according to propellers manufactures manual (for - Propeller example Kaspar’s propeller manual). , flap, rudder, elevator, trim surfaces hinges – pay attention to free - Aileron noiseless movement without backlashes. Re-grease once per each 100 flight hours or once per year. In case of operation in dusty conditions, clean and grease with shorter period. 16 – pay attention to sliding surface of the leg and level of its wear. Verify zero - Front leg movement movement in X and Y-axis of leg inside lower and upper “pertinax” guides. Clean them from dust and re-grease them once per each 50 flight hours or once per year. In case of dusty, humid or other extreme operation conditions make the mentioned period shorter., , choke, ventilation valve re-grease once per year. In case of dusty, - Bowden cable for throttle humid or other extreme operation condition grease earlier. of controls rod grease once per year. In case of dusty, humid or other extreme - Swing-bearings operational condition grease earlier. - Provide consistent check of for seal condition, proper function, hoses Pitot-Static system connections and secure connections with instruments. Verify free and clean intake of Pitot- tube. In case of present of condensate water in the system – remove it and dry the system. - Check the tightening of bolts: Engine’s frame - check the bolts between engines bed and firewall, between engine’s frame and engine’s ring, between engine and engine’s ring Front undercarriage – check the bolts on lower and upper guide, bolt of shock absorber, bolt of front wheel and bolts attaching fork to leg Main undercarriage – check bolts attaching legs to U/C beam, check the M12 bolt with plastic washer on the leg, check the main wheels nuts Elevator control system – check the bolts connections of the control rods with steering, angle lever and elevator. At same places check the secure nuts of swingbearing of the rods Front leg control system – check the bolts connections of the control rods with front leg steering arm and pedals. At same places check the secure nuts of swing-bearing of the rods Ailerons control system – check the bolts connections of the control rods with steering levers, angle levers in wings and ailerons. At same places check the secure nuts of swing-bearing of the rods Flap control system – check bolt attaching flap control handle to U/C beam, bolts connecting pushing rod to handle and to torsion tube, check the secure nuts of swingbearing of pushing rod. Rudder control system – check the bolts attaching ropes to rudder and to pedals, check the secure-wiring on turnbuckles - Special equipment inspections – given by suppliers manuals (for example ballistic rescue system) Inspection performed and information found out had to be written down to this manual. 3.4.PERIODICAL INSPECTION AFTER FIRST 25 FLIGHT HOURS Clean aircraft before inspection. Periodical inspection after first 25 flight hours. S/N: ………………… Flight hours: ………… Registration mark: ………………… Number of starts: ………… Chap. Prescribed inspections Engine and propeller Engine frame Intake system Electrical installation Battery Fuel installation According to engine’s manual According to propeller’s manual Remove and check engine’s cowlings for any signs of thermal damage, bubbles or cracks Inspection, tightening, securing (if necessary) of engine’s ring and frame bolts. Inspection of welded frames for any signs of cracks, inspection of rubber shock absorbers between engine’s ring and frame Inspection of air-filters, their attachment to carburetors Inspection of intake pipes Visual inspection of seal installation Inspection of carburetors – attachment, control, cleanness Inspection of wires and cables for undamaged condition, their connection and securing Check the battery voltage (should not be less then 12,4V unplugged) and wires connections Check and replace, if need to be, fuel filter. Inspection of undamaged fuel hoses, their connections, attachment and securing Damaged hoses need to be replaced Made by Checked by 18 Chap. Prescribed inspections Cooling system Check the density of cooling liquid to prevent freezing in winter condition. Fill in non-frost liquid if needed Oil system Exhaust system Check the silencer attachment and its faultless condition Check the self-locking nuts used on exhaust system Front undercarriage Inspection of undamaged hoses, their connections, attachment and securing Check the volume of cooling liquid in system Inspection, tightening, securing (if necessary) of engine’s ring and frame bolts. Damaged hoses need to be replaced Check the oil level in oil tank according to engine’s manual Provide inspection of cooler for cleanness, seal and undamaged condition. Check the cooler attachment for cracks. Inspect and tight if necessary all unmovable joints with bolts, all moveable joints secure Inspection of exhaust system for any signs of crack or damage on welds or tubes Inspect condition and attachment of front leg, check and refill if necessary pressure of front tire Made by Checked by Chap. Prescribed inspections Main undercarriage Aileron Flap Wings anchor Visual inspection, cleaning, conservation Tightening of joint verifying Inspection of canopy latch Inspection of free noiseless rudder movement Inspection of rudder hinges Check securing of hinges and bolts joint Visual inspection, check free noiseless movement Inspection of hinges and controls Fuselage Cockpit canopy Horizontal tail surfaces Inspect condition of composite leg for cracks, cranny or holes, even for paint damage. In case of finding mentioned fault, contact the manufacturer Inspect tightening of bolts Check hydraulic brake system for leak Wing Visual inspection for loose rivets, skin deformation, cracks or other damages Visual inspection of fuel tank for leak Visual inspection Check free noiseless movement Inspection of hinges Inspection of controls Visual check for loose rivets, skin deformations, crack or other damage Visual check for loose rivets, skin deformations, crack or other damage Made by Checked by 20 Chap. Prescribed inspections Cockpit Pedal steering Pitot’s tube Inspection for clean waterless undamaged condition Flap control Inspect free noiseless movement Inspect proper function of vent control Inspect proper function of choke control Inspect proper function of throttle control Inspect proper function of propeller control Steering joystick Inspect free noiseless movement Inspect backlashes in the system Inspect securing of bolts Inspect strength of system Inspect securing of bolts Inspection for hydraulic brake system leak Inspection of rudder ropes condition and attachment Made by Checked by 3.5.PERIODICAL INSPECTION AFTER FIRST 50 FLIGHT HOURS Annual periodical inspection after 50 flight hours S/N: ………………… Flight hours: ………… Registration mark: ………………… Number of starts: ………… Chap. Prescribed inspections Construction Inspection of spur for faultless condition Inspection of canopy attachment Inspection of rivet lines of undercarriage beams Fuselage Visual inspection for loose rivets, deformations, cracks and other damages of construction including fiberglass parts. Inspection of fiberglass fairing between fin and fuselage for faultless condition Inspection of fiberglass fairing between wing and fuselage for faultless condition Inspection of ventilation system for proper function and condition Inspection of side windows of fuselage for faultless condition Inspection of proper function and condition of canopy latch Inspection of condition and completeness of safety equipment, if it is installed Inspection of tires condition, inspection of rubber sealing of canopy. Inspection of condition and attachment of accessories like antenna, strobe… Made by Checked by 22 Chap. Prescribed inspections Wing Inspection of condition and attachment of winglets Inspect free noiseless movement Inspection of condition of position lights Inspect the hinge Inspection of condition of strobe lights Inspect controls rods Inspection of condition of landing light Ailerons Inspection of free noiseless movement Inspection of hinge Flaps Visual inspection for loose rivets, deformations, cracks and other damages of construction including fiberglass parts. Inspection of wing hinges backlashes in fuselage attachment Visual inspection for loose rivets, deformations, cracks and other damages of construction Visual inspection for loose rivets, deformations, cracks and other damages of construction Made by Checked by Annual periodical inspection after 50 flight hours Chap. Prescribed inspections Empennage Horizontal tail surfaces Inspect free noiseless movement of the elevator Inspect free noiseless rudder movement Inspect free noiseless movement Inspect securing of bolts Inspect condition and rudder control ropes securing Check backlashes Inspect steering limits condition Visual inspection of trim surface Inspection of rudder condition and attachment Vertical tail surfaces Controls Steering joystick Inspection of attaching and securing of horizontal tail surfaces Visual inspection for loose rivets, deformations, cracks and other damages of construction Inspection of fiberglass ends of stabilizer and its attachment Visual inspection for loose rivets, deformations, cracks and other damages of construction including fiberglass parts. Visual inspection of trim surface’s and elevator’s control and their securing Inspection of lower rudder bushing and securing of lower hinge Inspection of upper rudder bushing and securing of upper hinge Made by Checked by Annual periodical inspection after 50 flight hours 24 Chap. Prescribed inspections Steering pedals Inspect free noiseless movement Inspect hydraulic brake system for leak Inspect securing of bolts Inspect flap control handle and its position lock function Inspect Instrument panel condition and electrical connectors securing Inspect backlashes in system Inspect securing of bolts Check the system limits conditions Serve-control inspection Inspect trim surface position indicator Inspect system backlashes Inspect free noiseless movement Elevator’s trim surface control Flap control Equipment Inspect instruments connections and functionality Inspect securing of trim surface hinge pin Verify its completeness and its validity of documentation Verify neutral position of trim surface Inspect condition, pre-stress and securing of controlling ropes Made by Checked by Annual periodical inspection after 50 flight hours Chap. Prescribed inspections Check condition and function of switches and fuses Inspect free noiseless movement Check the readability and completeness of labels Inspect conditions of safety and rescue equipments Inspect cleanness and conditions of upholstery Inspect seats condition Undercarriage Inspect brake system hoses for undamaged condition and its attachment Inspect brake’s pad’s level of wear and of the brake disc Inspect hydraulic brake system for leak from valves, connectors, cylinders. Exchange of brake liquid can be done. Main legs condition and attachment inspection Inspect wheel’s condition and its attachment Main undercarriage Inspection of undercarriage bolts tightening Inspect the wheel’s free and noiseless rotation Inspect wheel’s covers conditions and its attachment Verify brake system function Check tires wear, conditions and pressure Inspect wheel’s disc for any signs of cracks or damage Inspect condition and function of throttle, choke controls, fuel valve, heating and ventilation controls Inspect safety belts attachments and belt’s faultless condition Inspect level of lubrication and securing of moveable parts of the wheels. Made by Checked by Annual periodical inspection after 50 flight hours 26 Chap. Prescribed inspections Front undercarriage Inspection of leg and its attachment point Inspect the bolts securing Inspect free noiseless rotation of the wheel Inspect according to Engine’s and Propeller’s manufacturer Check the tore pressure and its faultless condition Fuel system Empty the fuel from wings Inspect fuel system for leak of fuel Fuel hoses connections inspection Propeller and engine Fuel filter exchange Inspect condition of fuel pump (seek for any signs of cracks) and of fuel hoses in engine’s compartment Inspect the shock absorbers condition and level of wear Inspect the front wheel disc for any sign of cracks or damages Inspect the front wheel control system and its free movement Inspect the condition of control pushing rods and its securing Made by Checked by Annual periodical inspection after 50 flight hours Chap. Prescribed inspections Inspect the engine’s frame for any sign of cracks Electrical system Inspection of battery’s condition and its attachment Inspection of battery’s voltage Check the connectors conditions and their securing Inspect the pitot-static system condition Verify zero electrical resistance of connectors Pitot-Static systems Inspection of proper function of pitot-static tube Inspect the seal status of the system Inspect inlets of pitot-static tube for its cleanness and waterless condition Inspect pitot-static system for presence of condensate water – if so, remove it Inspection of pitot-static system connections with instruments and their securing Disassembling of engine’s cowlings and inspec t their condition for sign of thermal damage, cracks, or other defects Inspection of tightening and securing of engine’s frame bolts Inspection of exhaust system for any signs of cracks on tubes or welds Made by Checked by Annual periodical inspection after 50 flight hours 28 Chap. Prescribed inspections Heating and vents Inspection of cleanness of intakes Navigate and communicative instruments Inspection of status Inspection of functionality Re-calibrate compensation of compass declination NOTES: Inspection of thermal exchanger condition and its attachment to exhaust system Check the faultless condition of distribution’s hoses Made by Checked by Date: ………………… Sign: ………………… Annual periodical inspection after 50 flight hours 3.5.PERIODICAL INSPECTION AFTER FIRST 100 FLIGHT HOURS Annual periodical inspection after 100 flight hours S/N: ………………… Flight hours: ………… Registration mark: ………………… Number of starts: ………… Chap. Prescribed inspections Construction Inspection of spur for faultless condition Inspection of canopy attachment Inspection of rivet lines of undercarriage beams Fuselage Visual inspection for loose rivets, deformations, cracks and other damages of construction including fiberglass parts. Inspection of fiberglass fairing between fin and fuselage for faultless condition Inspection of fiberglass fairing between wing and fuselage for faultless condition Inspection of ventilation system for proper function and condition Inspection of side windows of fuselage for faultless condition Inspection of proper function and condition of canopy latch Inspection of condition and completeness of safety equipment, if it is installed Inspection of tires condition, inspection of rubber sealing of canopy. Inspection of condition and attachment of accessories like antenna, strobe… Made by Checked by 30 Chap. Prescribed inspections Wing Inspection of condition and attachment of winglets Inspect free noiseless movement Inspection of condition of position lights Inspect the hinge Inspection of condition of strobe lights Inspect controls rods Inspection of condition of landing light Ailerons Inspection of free noiseless movement Inspection of hinge Flaps Visual inspection for loose rivets, deformations, cracks and other damages of construction including fiberglass parts. Inspection of wing hinges backlashes in fuselage attachment Visual inspection for loose rivets, deformations, cracks and other damages of construction Visual inspection for loose rivets, deformations, cracks and other damages of construction Made by Checked by Annual periodical inspection after 100 flight hours Chap. Prescribed inspections Empennage Horizontal tail surfaces Inspect free noiseless movement of the elevator Inspect free noiseless rudder movement Inspect free noiseless movement Inspect securing of bolts Inspect condition and rudder control ropes securing Check backlashes Inspect steering limits condition Visual inspection of trim surface Inspection of rudder condition and attachment Vertical tail surfaces Controls Steering joystick Inspection of attaching and securing of horizontal tail surfaces Visual inspection for loose rivets, deformations, cracks and other damages of construction Inspection of fiberglass ends of stabilizer and its attachment Visual inspection for loose rivets, deformations, cracks and other damages of construction including fiberglass parts. Visual inspection of trim surface’s and elevator’s control and their securing Inspection of lower rudder bushing and securing of lower hinge Inspection of upper rudder bushing and securing of upper hinge Made by Checked by Annual periodical inspection after 100 flight hours 32 Chap. Prescribed inspections Steering pedals Inspect free noiseless movement Inspect hydraulic brake system for leak Inspect securing of bolts Inspect flap control handle and its position lock function Inspect Instrument panel condition and electrical connectors securing Inspect backlashes in system Inspect securing of bolts Check the system limits conditions Serve-control inspection Inspect trim surface position indicator Inspect system backlashes Inspect free noiseless movement Elevator’s trim surface control Flap control Equipment Inspect instruments connections and functionality Inspect securing of trim surface hinge pin Verify its completeness and its validity of documentation Verify neutral position of trim surface Inspect condition, pre-stress and securing of controlling ropes Made by Checked by Annual periodical inspection after 100 flight hours Chap. Prescribed inspections Check condition and function of switches and fuses Inspect free noiseless movement Check the readability and completeness of labels Inspect conditions of safety and rescue equipments Inspect cleanness and conditions of upholstery Inspect seats condition Undercarriage Inspect brake system hoses for undamaged condition and its attachment Inspect brake’s pad’s level of wear and of the brake disc Inspect hydraulic brake system for leak from valves, connectors, cylinders. Exchange of brake liquid can be done. Main legs condition and attachment inspection Inspect wheel’s condition and its attachment Main undercarriage Inspection of undercarriage bolts tightening Inspect the wheel’s free and noiseless rotation Inspect wheel’s covers conditions and its attachment Verify brake system function Check tires wear, conditions and pressure Inspect wheel’s disc for any signs of cracks or damage Inspect condition and function of throttle, choke controls, fuel valve, heating and ventilation controls Inspect safety belts attachments and belt’s faultless condition Inspect level of lubrication and securing of moveable parts of the wheels. Made by Checked by Annual periodical inspection after 100 flight hours 34 Chap. Prescribed inspections Front undercarriage Inspection of leg and its attachment point Inspect the bolts securing Inspect free noiseless rotation of the wheel Inspect according to Engine’s and Propeller’s manufacturer Check the tore pressure and its faultless condition Fuel system Empty the fuel from wings Inspect fuel system for leak of fuel Fuel hoses connections inspection Propeller and engine Fuel filter exchange Inspect condition of fuel pump (seek for any signs of cracks) and of fuel hoses in engine’s compartment Inspect the shock absorbers condition and level of wear Inspect the front wheel disc for any sign of cracks or damages Inspect the front wheel control system and its free movement Inspect the condition of control pushing rods and its securing Made by Checked by Annual periodical inspection after 100 flight hours Chap. Prescribed inspections Inspect the engine’s frame for any sign of cracks Electrical system Inspection of battery’s condition and its attachment Inspection of battery’s voltage Check the connectors conditions and their securing Inspect the pitot-static system condition Verify zero electrical resistance of connectors Pitot-Static systems Inspection of proper function of pitot-static tube Inspect the seal status of the system Inspect inlets of pitot-static tube for its cleanness and waterless condition Inspect pitot-static system for presence of condensate water – if so, remove it Inspection of pitot-static system connections with instruments and their securing Disassembling of engine’s cowlings and inspec t their condition for sign of thermal damage, cracks, or other defects Inspection of tightening and securing of engine’s frame bolts Inspection of exhaust system for any signs of cracks on tubes or welds Made by Checked by Annual periodical inspection after 100 flight hours 36 Chap. Prescribed inspections Heating and vents Inspection of cleanness of intakes Navigate and communicative instruments Inspection of status Inspection of functionality Re-calibrate compensation of compass declination NOTES: Inspection of thermal exchanger condition and its attachment to exhaust system Check the faultless condition of distribution’s hoses Made by Checked by Date: ………………… Sign: ………………… Annual periodical inspection after 100 flight hours 3.7. LUBRICATION PLAN Unit Lubricant Area of lubrication After first 25 hours Every 100 hours According to propeller’s manual Hinges. Hinges. Two-arm control lever in the wings. Rod end bearing of the elevator control tubes. Cable shackles on the rudder control cables. Elevator hinges. Rudder hinges. Tab hinges. Rod end bearings on actuators. Rod end bearings of the control tubes. Torque tube bearings in center console in fuselage and wings. Landing gear leg in the area of mounting Landing gear leg in the area of mounting All movable links in the cockpit. All movable links in the cockpit. Propeller Engine oil .... Engine oil Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Pro-Long Grease Engine Nose landing gear Main landing gear Manual control Foot control Ailerons Flaps HTU VTU Trim tab Throttle control cable on the inlet into terminal (in the engine compartment). Choke control cable on the inlet into terminal (in the engine compartment). 38 3.8. GROUND HANDLING PRE-FLIGHT INSPECTION - MAINTENANCE During handling (hold/push/pull) aircrafts parts always touch in place of structural reinforcement like ribs, wall and beams (shortly in positions of rivets lines). Do not touch fiberglass parts, neither controls surfaces. The aircraft can be pushed/pulled only through: - Propeller and only in case of holding it as close to its cone as possible - Step-on surface on wings - Eventually though fuselage in place of its walls In case of parking outside the hangar, use wing’s anchors and fuselage strut to fix aircraft movement For easy movement on the ground, the aircraft is equipped by hangers on sides of fork of front undercarriage leg. So you can pull/push aircraft through towing rod. Remove all covers, disconnect anchors (in case of parking aircraft outside of hangar) and block the wheels. On figure above, there are checkpoints marked and each point is described in text bellow. For providing proper inspection, some of the cowlings and covers, had to be removed. Aircraft should be inspecting as follows: 1) Canopy - Master ON, check sufficient volume of fuel - Master, Magnetos and other switches OFF! - Fuel stopped - Visual check of interior, remove all free-moving things - check free-movement of steering and controller 1 2 3 4 5 18 6 7 16 17 8 15 9 10 11 13 14 12 2) Engine space - remove upper canopy, visual check of engine and accessories - check status and fixation of units, tightening and locking of screws, status of tubes (look for cracks), status and fixation of electric-installation. - check volume of oil and cooling liquid - check propeller blades, fixation of propellers cone - put the cover and lock it 3) Landing gear - checking the pressure, status and fixation of each gear 4) Wings - Visual check of leading and trailing edge - Visual check of fuel tanks, check the volume of fuel - check Pitot tube on left wing (status, fixation, direction) 5) Ailerons - Visual check of construction - check easy and free movement - check hinge-line of ailerons 6) Flaps - Visual check of construction - checking of free movement, locking of each flaps position - check hinge-line of flaps 7) Main landing gear - check pressure of tires - check fixation 8) Fuselage - Visual check for any damage of construction - check antenna (status, fixation) 9) Horizontal Tail surfaces - Visual check of construction - check the connection to vertical tail surfaces - check hinge of elevator and trim surfaces - check free movement, easy to control 10) Vertical Tail surfaces - Visual check of construction -check hinge of rudder- check ropes status (strain, secure, free-movement) 11) – 18) are just for another half of a plane Tools needed: - Hexagonal socket keys from 3 to 10 mm - “Flat” keys from 6 to 22 mm and 32mm - screwdrivers with flat and cross head - ROTAX’s key supplied with engine Result of inspection had to be written down into Aircraft’s book. In case of discovering rising backlashes or any other defects – contact the manufacturer. 40