MCR Maintenance Manual

1.3.5.3 Parachute ...................................................................................................................................................... 27 1.3.5.4 Glider towing devices .................................................................................................................................... 27 1.3.5.5 Other equipment .......................................................................................................................................... 27 1.3.6 Non-repeating inspections ................................................................................................................. 28 1.3.6.1 Introduction .................................................................................................................................................. 28 1.3.6.2 25H Inspection .............................................................................................................................................. 28 1.4 UNSCHEDULED MAINTENANCE CHECKS ................................................................................................... 29 1.4.1 Introduction ........................................................................................................................................ 29 1.4.2 Specific maintenance operation ......................................................................................................... 29 1.5 REMARKS ......................................................................................................................................... 32 1.5.1 Repetition of operations..................................................................................................................... 32 1.5.2 Counting of hours ............................................................................................................................... 32 1.5.3 Margins .............................................................................................................................................. 32 1.5.4 Maintenance report sheets ................................................................................................................ 33 1.5.5 Documents ......................................................................................................................................... 33 SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :5/74 2 AIRCRAFT MAINTENANCE MANUAL AMM ............................................................. 35 2.1 INTRODUCTION .................................................................................................................................. 35 2.2 TECHNICAL PROCEDURES ..................................................................................................................... 35 2.3 REMARKS ......................................................................................................................................... 55 2.3.1 Bolt tightening torque values ............................................................................................................. 55 2.3.2 3.2 Units and conversions .................................................................................................................. 55 2.3.3 Paint work .......................................................................................................................................... 55 2.3.4 Fuel ..................................................................................................................................................... 55 2.3.5 Hydraulic fluid (brakes, oil-pneumatic landing gear) ......................................................................... 56 3 APPENDIX APX ....................................................................................................... 57 3.1 50H INSPECTION REPORT .................................................................................................................... 57 3.2 100H OR ANNUAL INSPECTION REPORT ................................................................................................. 61 3.3 1000H INSPECTION REPORT ................................................................................................................. 65 3.4 5 YEARS INSPECTION REPORT ................................................................................................................ 69 3.5 POSTPONED OPERATION LIST ............................................................................................................... 71 3.6 TECHNICAL EVENT FORM...................................................................................................................... 73 3.7 LUBRICATION POINTS .......................................................................................................................... 74 SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :6/74 1 MASTER SERVICING MANUAL MSM 1.1 General 1.1.1 Introduction The maintenance program is available only for the MCR below:  MCR Sportster  MCR Club  MCR M  MCR UL / ULC  MCR 4S  MCR Pick-up  MiniCRuiser and equipped with engines :  ROTAX 912 (all versions)  ROTAX 912 S (all versions)  ROTAX 914 (all versions)  ROTAX 915 (all versions) This document defines the maintenance operations and frequencies necessary to preserve the airworthiness of your MCR. It was established thanks to the experience feedback and the recommendations of the engine and various equipment manufacturers. The present manual, made by SE Aviation, is based on the French CNSK regulation. In France, it is directly applicable for all MCR with a CNSK registration and for ultra-lights (ULM). Concerning CNSK aircraft: The owners have to make a maintenance declaration to the OSAC (form AC159a ), approving an “inspection program”. The present document could be the owner’s inspection program on condition that it is personalized to your aircraft (refer to cover page). French OSAC RP 42-50 §9.6 booklet: Maintenance or inspection program. […] The CNSK owners have to use the program of inspection of the kit manufacturer, by personalizing it with their name or with the registration of the aircraft. For other countries, it is the owner’s responsibility to ensure that this present program is sufficient to cover the requirements of the local regulations. If applicable, this program must be completed by the owner to fulfil local requirements. However, this program is a minimum base to be followed : No ‘lightening’ or ‘shortening’ concerning the aircraft maintenance is allowed by SE Aviation. Although it is statutorily possible to postpone some maintenance operations if necessary, we strongly advise strict adherence to this handbook. In case of doubt (of either an administrative or technical nature), it is strongly recommended to contact SE Aviation as soon as possible for advice and instructions. If any anomaly is discovered during the maintenance of your MCR, fill in a technical event form appropriate to the model, provided in appendix 3 and contact SE Aviation for advice and instructions. Only the French version of this manual is reliable SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :7/74 1.1.2 Terminology (Routine) Inspection Consists of a simple visual insitu examination, or an operational test, of a sub-group or component of the aircraft, provided that no disassembly is required. Detailed Inspection Consists of a close examination of an aircraft component, with the necessary dismantling operations, in order to detect defects and to predict those which would have catastrophic consequences. The simple inspections are performed for the 50h and 100h/1y maintenance inspections and the detailed inspections only for the 1000h and 2000h/5y maintenance inspections. Visual Check This is one of the features of the routine inspection defined above. The aim of this examination is to verify satisfactory condition of a system, visually, “in situ”. Example : Corrosion investigation. Thorough examination This is one of features of the detailed inspection defined above. It consists of a thorough examination of a component, either visually, after disassembling, or with the help of a magnifying lens or by using other means of investigation (dye penetrant inspection, magnetoscopy, Foucault currents, …). Verification This can be part both of the routine and detailed inspections. This operation ensures the conformity or correct state of a component, either by measuring or by use of a control instrument. Example : checking the tension of control surface operating cables. (Functional) Test This can be also part of a routine or detailed inspection. This operation aims to check that a component or equipment is functioning correctly, possibly with a performance check, with or without control instruments. 1.1.2.1.1 Example : altimeter bench test Flight test For French operated aircraft, flight tests must be made according to annex 4 of the “Arrêté du 24 juillet 1991 relatif aux conditions générales des aéronefs civils en aviation générale”. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :8/74 Use the last issue of SE Aviation’s flight test program (document ref xEXNO04) and the inspection procedure before first flight (document xEXNO05). Removal/Refitting Removal / refitting means that one sub part of the aircraft must be disassembled to perform a detailed inspection on it, and then reinstalled on the aircraft. Example : Removal/refitting of the landing gear leg. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :9/74 1.1.3 Abbreviations List of abbreviations and acronyms used in this handbook. Items written in Italic letters refer to useful French terms, that might help English speaking operators of French registered airplanes to deal with the French authorities. AC Advisory Circular (reference procedures published by the FAA) AD AirworthinessDirective : Terme générique employé pour désigner une directive de navigabilité émise par une autorité étrangère ou par l'EASA (The CN are french AD). Generic name used to indicate a directive of seaworthiness(airworthiness) emitted(uttered) by a foreign authority or by an EASA IND (air) INDuction (system) AMM Aircraft Maintenance Manual APX APpendiX APRS Approbation Pour Remise en Service =Certificate of Release to Service, to be logged (in French language for French registered aircraft) in the aircraft documents after a maintenance operation, before next flight. SB Service Bulletin DGAC Direction Générale de l’Aviation Civile CoA Certificate of Airworthiness CoG Centre of Gravity CMD CoMmanD CN Consigne de Navigabilité (emitted by the French DGAC and published by the French OSAC), see also AD. A CN is a French AD. CNSK Certificat de Navigabilité Spécia ld’aéronef en Kit (Special Kit Certificate of Airworthiness) MIR Maintenance Inspection Report EASA EuropeanAviationSafety Agency EFIS Electronic Flight Instrument System FAA Federal Aviation Administration ( Authority of regulation and supervision of the civil aviation of United states of America) GSAC Groupement pour la Sécurité de l’Aviation Civile – French civil aviation authority of monitoring. OSAC Organisme pour la Sécurité de l’Aviation Civile – French civil aviation authority of monitoring. (supersedes GSAC) h hour of operation IRB = ARNI Installation Radioélectrique de Bord = Airborne Radio-Navigation Installations LSA = ASL Licence de Station d’Aeronef = Aircraft Station License OTL Operating Time Limit : MSM = PRE Master Servicing Manual = PRogramme d’Entretien SIL Service Information Letter TBO Time BetweenOverhaul IPC = TCI Illustrated Parts Catalogue = (TCI in French) OT Overall Test VFR Visual Flight Rules VHF VHF Transceivers (Very High Frequency) SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :10/74 1.1.4 Bulletins Service (BS) A Service Bulletin (SB) is a document issued by the aircraft TC holder or part manufacturer to notify to operators and recommend modification, part replacement, particular inspection, existing operating time limit reduction or new time limit definition, and also any transformation of an engine type to another type. The “maintenance” service bulletins, issued by the aircraft TC holder, are considered as an evolution of the maintenance manual (MSM + AMM) and therefore, they are applicable as well as the present leaflet. The “Maintenance” SB issued by the aircraft manufacturer, the engine and the propeller manufacturers, after the date of issue of the recommended maintenance program are applicable within the time limits prescribed in the SB. Those SBs may be incorporated into the owner’s personalized maintenance program. The SBs are classified into 3 categories: mandatory, recommended or optional. The complete list of applicable Service Bulletins is available on SE Aviation‘s Website: www.se-aviation.fr (Service Bulletins section) Note: The only service bulletin official publication media is SE Aviation Website → The Service Bulletins of the different equipment manufacturers may be found on their websites: Equipment Manufacturer Address Web site ENGINE ROTAX WelserStraße 32 A-4623 Gunskirchen ÖSTERREICH www.flyrotax.com France Dealer: Avirex Aérodrome F-28500 VERNOUILLET FRANCE www.avirex.fr PROPELLER E-PROPS The E-PROPS PROPELLERS Company ZI aérodrome Sisteron 04200 VAUMEILH - France www.e-props.fr MT PROPELLER Airport Straubing-Wallmuehle D-94348 Atting DEUTSCHLAND www.mt-propeller.com EVRA Avenue de la Forêt d'Halatte F-60100 CREIL FRANCE www.helices-evra.com SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :11/74 PARACHUTE BRS 300 Airport Road S. St. Paul, MN 55075 USA www.brsparachutes.com Moreover, it is strongly recommended to subscribe to the aircraft and equipment manufacturer’s mailing lists, in order to receive directly the last issued service bulletins. Procedure to subscribe to the BS broadcasting list of Rotax : 1. Contact the local Rotax reseller. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :12/74 1.1.5 Directives de navigabilité (AD) / Consignes de navigabilité (CN) The AD (Airworthiness Directives), the generic name used to indicate a directive of airworthiness emitted by an aviation authority (in France these are known as “Consigne de Navigabilité” (CN), published by the OSAC), aimed at indicating a dangerous state, an absence of correspondence with regard to the requirements constituting the base of certification of an aircraft or an element of aircraft, as well as any state likely to compromise the airworthiness of an aircraft. They stipulate mandatory measures to be taken to insure that an aircraft can continue to be used safely, they sometimes forbid any flight before the prescribed corrective measures are taken. The AD’s must be applied in due time, according to the delay of application prescribed on the AD (hours of flight, cycles, landings, and/or calendar limit). The delay given for the execution of an AD must be strictly respected. Extending the delay may jeopardize the safety of the aircraft and its occupants and constitutes a case of inaptitude to fly and is punishable by law. Failing to apply an AD on an aircraft concerned by this AD, leads to the loss of validity of its CNSK, which is therefore in situation “R”. Failing to apply AD’s repeatedly can lead the local monitoring authority (OSAC in France) to apply penalties: reduction of the duration of validity of the CNSK, refusal of renewal of CNSK, etc… The AD is also applied to Ultralight or microlight, although the airworthiness regulations of these types are different in each NAA (National Aviation Authority). AD’s concerning engine, propeller and equipment For French registered aircraft, registered in the Ultralight or CNSK categories, ADs concerning the engines, propellers and equipment are not mandatory. Therefore, the owners are responsible to collect the AD’s concerning their aircraft and to decide to apply them or not. The monitoring authority (the OSAC in France), will not check their application during the renewal procedure of the restricted certificate of airworthiness. However, when the aviation authority (DGAC in France), decides that the level of safety is below the minimum acceptable level for a ULM or a restricted Certificate of Airworthiness, it will issue a specific AD for the type of aircraft concerned (ULM,CNSK,…). This AD will include a mention declaring that the application of the AD is imperative for the preservation of the validity of the restricted certificate of airworthiness of the aircraft, or the airworthiness of the concerned ULM. In France, for CNSK’s, this CN will be sent personally to any French registered aircraft owner. The monitoring authority (the OSAC in France), will check their application during the renewal procedure of the restricted certificate of airworthiness. For the ultralights (ULM), the DGAC will send this CN to any French registered ULM owner personally, providing that they are known by the local DAC (Directions de l’Aviation Civile) (this means that it is strongly recommended to declare yourself to the local DAC), and it will be sent also to the representative organizations of ULM operators (such as the French Ultralight Federation FFPLUM). A list of the non-specific ADs will be made by the owner, showing if they have been applied or not, under his entire responsibility. A list of the specific ADs will be made by the owner, showing when the ADs were applied, this list will be checked during the renewal of the restricted certificate of airworthiness. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :13/74 The applicable airworthiness directives list is available on the French OSAC website : www.osac.aero PROCEDURE : 1. Click on the UK flag (to consult the website in English) 2. click on “consignes de navigabilité” (on the menu on the left, at the top). 3. click on the big blue button “Consignes de Navigabilité triées par date et référence” 4. Click on « recherche » in the top left menu 4. In the field « Type de matériel », write: MCR . 5. In the field « Responsable de Navigabilité », write :DYN . 6. Click on « Rechercher » button… (search). The ADs list relating to the MCR is now displayed. ADs must be registered in the aircraft logbook and/or the engine logbook according to the component concerned by the AD. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :14/74 1.2 Time limits 1.2.1 Introduction This section clarifies the list of elements concerned by time limits, and indicates the corresponding deadlines. 1.2.2 Type of time limits There are two types of time limits :  OTL : Operating Time Limit When the time limit of the component is reached, this component must be removed and replaced by a new one. The OTL is the limit life of the component.  TBO : Time Between Overhaul When the TBO of a component is reached, it must be removed from the aircraft to be overhauled, and replaced by an overhauled or a new component. These limits are not airworthiness limits, therefore, they can be postponed to a later date. In that case, you must make a list of postponed operations according to the template given in the appendix. In France : Booklet OSAC RP 42-50 §9.6.1.1 CNSK When the kit aircraft manufacturer’s (TC holder) maintenance manual defines time limited components, those time limits are applicable and must be taken into account. 1.2.3 Time Limits For the Time Limits having two type of terms (operation hours or calendar), the component shall be revised/replaced once the first one occurs. MCR Designation Reference Type of limit Deadline IPC Sportster Club ULC M 4S Pick -up Mi niCRuiser ATA 25 - EQUIPMENT AND FITTINGS     Parachute canopy (option) BRS TBO (Repacks) 6 years (2) PS  PBN      Parachute rocket (option) OTL 12 years (2) PS  PBN SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :15/74 MCR Designation Reference Type of limit Deadline IPC Sportster Club ULC M 4S Pick -up MiniCRuiser ATA 27 – FLIGHT CONTROLS   Flap drive-belt xFURR4301 OTL 5 years 28     xFURR6701      Flap control lead screw and bronze nut 08-27-0002 + 08- 27-0003 OTL 1000 landings 28  Flap control bronze nut NVLAL2W01 OTL 300 hours 3 years(a) 28  Flap control gimbals OFUAC2302 QFUAC2M01 OTL 50h/1year 28  Artificial force rubber bands (of flight controls) xFUWC2P01 OTL 50h 3 months 10     10, 27  _ (1) Flap Belt Tensioning Bungee xFUEQX801 OTL 2 years 28 ATA 31 – INSTRUMENT PANEL   Instrument panel Silentblocs xFURR5201 And xFURR0901 OTL 1000h 10 years 54     55 ATA 32 – LANDING GEAR  Nose gear bungees xTREQ5601 OTL 1000h 5years 9    Silentbloc of the main landing gear leg xTREQS601 OTL 1000h 5 years 47  Tyres On condition, depending on the type of aircraft and the tyre diameters OTL “On condition” 22, 24 O rings and scraper ring set (oleo-pneumatic gear option) xGENO2100 OTL 1000h 5 years PBP      QGENO0100 64 ATA 61 - PROPELLER  Propeller MT Propeller MTV-6… TBO 6 years (2) H6  MT Propeller MTV-7… H3  H5  MT Propeller MTV-21... H8      ArplastECOprop None / / Arplast PV50 ATA 71 – POWER PLANT  Engine Silent blocks (3) MMORR2901 ET MMORR6900 (ROTAX 912 UL/ULS ) OTL 800 h 5 years M0  MMOEQZ602 (ROTAX 912 UL/ULS : montage façon 914) M60    MMOEQZ603 (ROTAX 914 UL) 600 h 5 years M40      ZMAEQZ600 (ROTAX 915iS) 600 h 5 years M4015 BS 12 F 0043 BS 13 D 0044 BS 19 G 0048 BS 12 F 0043 BS 13 D 0044 SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :16/74 (a) In case of regular use in conditions favoring the contamination of the grease by abrasive elements (sand, dust, etc…) the operator has to decrease the life cycle of these parts accordingly ; and take a particular care in the cleaning, the greasing, and in the periodic control of these part. MCR Designation Reference Type of limit Deadline IPC Sportster Club UL C M 4S Pick -up MiniCRuiser ATA 72 - ENGINE  Engine ROTAX 912 UL/ULS TBO 2000H (2) -  ROTAX 914 UL TBO 2000H (2)      ROTAX 915 iS TBO 1200H (2)  Engine rubber parts (3) MMOKIRG . . (3) OTL 5 years  Gear box - TBO ½ ENGINE TBO (4) ATA 73 - FUEL ENGINE LINE     Cabin fuel filter QCCEM0101 OTL 100h 14 ATA 75 – IND & COOLING SYSTEM  Coolant Recommended : 50-50% water – glycol ZMAWC5S00 OTL 2 years (2) M8, M48 ou M68 (5) ATA 80 – ENGINE START  Spark Plugs For Rotax 912 OTL 200h (2) - For Rotax 912 S / 914 100h (2)     For Rotax 915 100h (2) (1) Only the aircraft equipped with the new flaps control assembly (since march 2004 and IPC board 28 rev. 1). (2) Equipment manufacturer’s data, only for “last generation” engines : These time limits are not mandatory for CNSK and ULM aircraft (except if a specific AD stipulates it, refer to section 1.4). Moreover, these TBO and OTL are not the same for “older” engines, and may be updated, refer to the last issue of the equipment manufacturer’s maintenance manuals. (3) SE Aviation offers a kit for the replacement of the engine rubber parts, reference: - Rotax 912/912S : MMOKIRG10 - Rotax 912 assembly like Rotax914 : MMOKIRG20 - Rotax914 : MMOKIRG30 - Rotax 914 W : MMOKIRG50 - Rotax 915 : MMOKIRG40 (4) If the aircraft is operated mostly on AVGAS 100LL (more than 30% of operation), It is strongly recommended by the engine manufacturer to remove the propeller gear box and to clean entirely the mechanism at half TBO of the engine. This maintenance operation is performed only by ROTAX or its local agents. (5) According to the power plant. MCR LETTER Sportster M SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :17/74 Note : « x » in the beginning of the reference : According to your MCR, replace the « x » by the corresponding letter: MiniCRuiser C Club O ULC P M T 4S Q Pick’ up K SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :18/74 Page intentionally left blank SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :19/74 1.3 Scheduled maintenance 1.3.1 Periodic inspections 1.3.1.1 Introduction This section details every periodic maintenance inspection to carry out on your MCR and indicates the corresponding period and operations. Chapter 3.1.3 of this section details the inspection program of your MCR. 1.3.1.2 Maintenance operation board For inspections with two types of deadline (operating hours or calendar), the inspection must be done at the deadline coming first. Inspection Hours Margin Calendar Margin 50h 50 h +/- 5h - - 100h or Annual 100 h +/- 10 h 1 year 1 month 1000h 1000 h +/- 50 h - - 5 years * - - 5 years 3 months  * When you perform a 5 years inspection, you must also perform :  - either a 100h inspection,  - or a 1000 h inspection Refer to paragraph 5.2 and 5.3 of this manual for more information regarding operating hours and margins. During 50h, 100h and annual maintenance inspections, routine inspections must be performed. During 1000h and 5 years maintenance inspections, detailed inspections must be performed. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :20/74 1.3.1.3 Inspection program The inspection program below itemizes the maintenance operations to be performed during the periodic inspections of 50 h, 100h or annual, 1000h and 5 years. MCR OPERATIONS Inspection Sportster Club ULC M 4S Pick -up MniCRuiser 50h 100h or Annual 1000h 5 years PRELIMINARY INSPECTION     0000 Update documentation         0001 Run-up and engine stop         0002 Vital check         0003 Beginning of inspection procedure     ATA 12 – SERVICING     1201 Lubricating points     ATA 21 – VENTILATION AND HEATING     2101 « Naca » vents check         2102 Cabin heating check     ATA 23 – COMMUNICATION     2301 Radio equipment inspection         2302 Radio equipment detailed inspection         2303 Antenna inspection     ATA 24 - ELECTRICAL POWER     2401 Operational test of electrical circuits         2402 Detailed inspection of the electrical circuits and the engine connections         2403 Battery check         2404 Generator check     ATA 25 - EQUIPMENT AND FITTINGS     2501 Composite seats and floor checks         2502 Harnesses check          2503 Baggage compartment check         2504 Check of the trap door and strap covers of the safety parachute         2505 Check of the safety pin of the parachute handle     Safety parachute maintenance : Refer to the last edition of the parachute maintenance manual ATA 27 – FLIGHT CONTROLS     2701 Rudder pedals check         2702 Flight controls check (rough friction point or excess play)         2703 Flight controls removal/refitting, adjustments and tests           2704 a Cleaning, visual check and greasing of lead screwand brass nut in the flap carriage (in situ)  ²       2704 b Removal / refitting of the flap carriage lead screw and bronze nut See §1.2.3        2705 Cleaning, inspection, control the play of leading screw in bronze nut and lubrication of flap control           2705 b Cleaning, inspection, control the play and the absence of sseizure in the gimbals and lubrication of flap control         2706 Tab control rod detailed inspection         2707 Check of rod ends of flight controls           2708 MEVO Flap control detailed inspection     BS 12 F 0043 BS 13 D 0044 BS 19 G 0048 SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :21/74 MCR OPERATIONS Inspection Sportster Club ULC M 4S Pick -up MniCRuiser 50h 100h or Annual 1000h 5 years            ATA 28 – FUEL LINE     2801 Fuel hoses check         2802 Fuel filters examination          2803 Tank removal/refitting          2804 Wing tank covers removal/refitting         2805 Fuel line check     ATA 31 – INSTRUMENT PANEL     3101 Instrument Panel rubber pads        3102 Instrumentation and warning light installation check     ATA 32 – LANDING GEAR     3201 Wheels removal/refitting         3202 Wheel fairings inspection         3203 Undercarriage mounting bolts torque check (check torque)         3204 Brake lining or brake pad check and replacement if necessary          3205 Removal/refitting of the landing leg          3206 Oleo-pneumatic gear removal/refitting         3207 Nose/Tail wheel support and fork check         3208 Brake circuit check     ATA 33 – LIGHTING     3301 Strobes, Nav-lights and landing lights check     ATA 34 – NAVIGATION     3401 Static and dynamic line check         3402 Static and dynamic line detailed inspection (sealing test)         3403 EFIS calibration         3404 Magnetic compensating compass adjustment     ATA 52 – CANOPY     5201 Canopy removal/refitting         5202 Canopy check     ATA 53 – FUSELAGE     5301 Fuselage skin inspection         5302 Rudder ribs inspection     ATA 55 – FLIGHT CONTROL SURFACES     5501 Control surfaces skin inspection         5502 Tab inspection         5503 Elevator removal/refitting         5504 Rudder removal/refitting         5505 Inspection of elevator fixation lug fixation screws     ATA 57 - WINGS     5701 Wings skin inspection           5702 Flaperons removal/refitting          5703 Ailerons removal/refitting          5704 Flaps removal/refitting         5705 Wing attachements examination         5706 Wing removal/refitting     ATA 61 – PROPELLER     6101 Propeller inspection(blade impact damage inspection)         6102 Spinner inspection     SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :22/74 MCR OPERATIONS Inspection Sportster Club ULC M 4S Pick -up MniCRuiser 50h 100h or Annual 1000h 5 years     6103 Propeller mounting check         6104 Propeller bolt torque (wooden propeller) (Apply also at each season change)     Propeller maintenance: Refer to the last edition of the propeller maintenance manual. MCR OPERATIONS VISITES Sportster Club ULC M 4S Pickup Minicruiser 50h 100h 1an 1000h 5years ATA 71 – POWER PLANT 7101 Cylinders and baffles check     7102 Engine mount and silentblocs check     7103 Control of engine mount bolts (tightening)     7104 Engine cowls check     7105 Cowl flap check     ATA 72 – ENGINE Engine maintenance : Refer to the last edition of the engine maintenance manual. ATA 73 – ENGINE FUEL LINE 7301 Carburettor check : Refer to the engine maintenance manual See Engine Maint. Man. ATA 74 – IGNITION 7401 Ignition check (spark plug)     ATA 75 – IND / COOLING SYSTEM 7501 Air induction circuit check     7502 Cooling system check     ATA 76 – ENGINE CONTROLS 7601 Engine control check     7602 Throttle check     ATA 78 – EXHAUST 7801 Exhaust system examination     7802 Silencer removal/refitting     ATA 79 – OIL LINE 7901 Oil change Consult engine manual Note : Depends on the type of operating fuel 7902 Magnetic plug check     7903 Oil hoses check     7904 Oil tank cleaning     ATA 80 – ENGINE START 8001 Starter examination     FINISHINGS / POST - INSPECTION PROCEDURES 0004 Post - Inspection run-up     0005 Vital check     0006 End of inspection procedure     0007 Check Flight     Note : SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :23/74 SE Aviation can provide complete kits of parts that are required to be exchanged during the 5-year maintenance. These kits include the parts with a 5 year OTL mentioned in the “time limits” section of this manual. These kits have the following references : MCR Sportster : MFUKIGV01 MCR M : TFUKIGV01 MCR Club : OFUKIGV01 MCR 4S : QFUKIGV01 MCR ULC et MiniCRuiser : PFUKIGV01 MCR Pick’Up : KFUKIGV01 MCR ULC Train Oléo. : PFUKIGV02 SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :24/74 Page intentionally left blank SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :25/74 1.3.2 Overall test of the airborne radio-navigation installation (OT ARNI) SE Aviation do not ask any particular maintenance of the airborne radio navigation installation (ARNI), only the national requirements apply. These ARNI maintenance requirement depend on : - The specific statutory requirements from the country where the aircraft is registered - In France, on the classification of the aircraft (CNSK or Ultralight) - In France, on the date of certification of the equipment installed (“old” or “new” generation of equipment) It is the aircraft maintenance manager’s responsibility to check the ARNI statutory requirements and their evolutions. Therefore, the following information are only indicative, and is subject to the evolution of these statutory requirements, and are only valid for French registered aircraft. - Any aircraft registered in France must have a valid Licence de Station d’Aéronef (LSA) - Roughly summarized; the renewal conditions of the LSA are the following 1.3.2.1 For CNSK registered aircraft The rules have changed in 2011. For CNSK aircraft used in general aviation, VFR, equipped with “new generation” (the most common MCR in service ) : - No ground test bench check required - No global test required - If a transponder is installed, ground test of the global ATC installation is due every 5 year and .fly test between the 2nd and the 3rd year. For more information : For CNSK registered aircraft : The French rules related to aircraft radio navigation installation maintenance are given in the document OSAC/NO P-41-15. At the date of issue of this manual , the latest update is edition 2, rev. 4, March 2019 www.regles-osac.com/OSAC/fascicules.nsf 1.3.2.2 For ultralight (ULM) registered aircraft In the most common case where the aircraft is equipped with one or several “new” generation equipment, the LSA expires 6 years after the date of issue of the compliance certificate (ex: EASA Form one of the equipment). - If the aircraft is equipped with only one VHF transceiver : the new certificate of conformity of the installation can be written by the owner - If the aircraft is equipped with several equipment (ex : VHF + ATC) the ground test control and the corresponding certificate of conformity must be done by a licensed maintenance workshop. For more information, or if your aircraft doesn’t correspond to these cases : For ULM’s : Refer the DGAC document referenced : NOTE TECHNIQUE N°02/ULM « Note relative aux conditions de délivrance et de renouvellement de la licence de station d’aéronef pour les ULM » At the date of issue of this manual , the latest update is edition 4 dated 27/06/2019 www.ecologique-solidaire.gouv.fr/ulm-demarches-particuliers SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :26/74 1.3.3 Weighing A new weight and balance must be performed as soon as a modification may affect significantly the weight and/or CoG position of the aircraft.  Important modification  Major repair  Significant cockpit refurbishing  Painting on a significant surface of the aircraft  Any modification of the aircraft which cannot be evaluated precisely enough to be able to update the weight and balance data sheet by a simple calculation. Contact SE Aviation to get the latest update of weighing procedure xEXNOPP corresponding to your aircraft After weighing, it is mandatory to fill in a weight and balance data sheet, with inventory sheet, according to Dyn’Aéro’s procedure, and forward the results to SE Aviation. 1.3.4 Magnetic compass swinging To swing the magnetic compass is required:  At the 1000h inspection.  At the 5years inspection.  As soon as a new radio or electrical device is installed or removed.  When a sizeable metallic equipment is removed or added to the aircraft. Procedure for magnetic compass swinging: Refer to AMM operation n°3404. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :27/74 1.3.5 Maintenance of Equipment 1.3.5.1 Engine Periodic inspections: Non-periodic inspection: Time limits: Refer to the Rotax latest Maintenance Manuals updates, and service bulletins, to find the periodic inspection program, the details of the operations to be done during these inspections, and the time limits. Note : On removal of the engine (for overhaul, preparing to send it for overhaul). It is recommended to clean the oil tank (operation 7904) and the water and oil coolers with fuel and to dry them correctly. Check and straighten out (if necessary) the air baffles (operation 7101). 1.3.5.2 Propeller Time limits : Refer to the section ‘Time limits’ of this manual. Refer to the last edition of the propeller maintenance manual for the detail of the maintenance operation to perform. Note : A thorough examination of the propeller mounting bolts must be carried out each time you exchange or send the propeller for overhaul. 1.3.5.3 Parachute Time limits : Refer to the section ‘Time limits’ of this manual. Refer to the last edition of the BRS parachute maintenance manual for the detail of the maintenance operation to perform. 1.3.5.4 Glider towing devices Refer to the last edition of the equipment manufacturer maintenance instructions, SB/TN (Tost) : - Tow cable retractor winch with guillotine - Tow releases (hooks) 1.3.5.5 Other equipment Refer to the last edition of the equipment maintenance manual for the detail of the maintenance operation to perform. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :28/74 1.3.6 Non-repeating inspections 1.3.6.1 Introduction These are maintenance operations or group of operations , planned, but without given intervals. 1.3.6.2 25H Inspection This inspection must be performed after 25h of operation:  of a new plane or new engine.  or of an overhauled engine.  or after a 1000h inspection. Operations to perform during this inspection: MCR OPERATIONS Sportster Club ULC M 4S Pick -up ATA 73 – ENGINE FUEL LINE 7304 Replacement of the fuel filters after new or after any operation on the tank. ATA 76 - ENGINE Reminder : First engine inspection : Refer to chapter 3.5.1 of this manual SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :29/74 1.4 Unscheduled maintenance checks 1.4.1 Introduction This section details the specific maintenance operations to perform after a particular use or mis- use of the aircraft. 1.4.2 Specific maintenance operation  Period of storage  Wood propeller : Position the propeller horizontally. Monthly :  Start the engine and run it for few minutes (let the oil temperature increase to 80°C in order to eliminate internal condensation). Every 3 months :  Re-inflate tires.  Lubricate if necessary. Remark : Before a long period of storage (greater than 1 year), it is necessary to :  Protect or remove and store in an suitable room equipment which can become damaged, in particular with moisture (instruments, …).  Disconnect the battery.  Fill the fuel tank.  Refer to engine manual, for possible additional operations (engine preservation).  Remove and store 2 blade wooden propellers flat in a dry place and protect the propeller hub against corrosion.  After a period of storage (greater or equal to 3 months) :  Check equipment (specifically static and dynamic pressure ports).  Check the battery (recharge it, replace it if necessary).  Lubricate if necessary.  Perform a fuel line test : Put the fuel circuit under pressure then check for leaks.  In case of long duration storage :  Change oil.  Drain the fuel tank completely, rinse and fill with new fuel. (Do NOT use old fuel in your aircraft !).  Perform an engine run-up.  Check correct operation of all instrumentation. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :30/74  After an important change of climatic conditions (season changing) :  Wooden propeller : Torque the propeller bolts (refer to AMM procedure n°6104)  After a hard landing :  Landing gear detailed inspection, perform a close examination of the mounts wheels and tires.  Check for play in the wheel axle mounting.  Check for damage to the propeller. Look for impact marks near the tip and carry out a more detailed inspection of the entire propeller if any are found.  Engine suspension examination. (engine mount, diagonal brace, silentblocs…)  Anchor nut security check.  Check the fuselage frames for delaminating, (especially the main frames holding the landing gear, the wings and the control surfaces).  Check the Keel. If it is damaged: perform a detailed examination of the rudder and of the tail structure.  Wing and tail mounting check (operation n°5705) .  After a flight in turbulent air or after exceeding the limit load factors :  Verification of the bonding of ribs and frames (using a tapping method, refer to operation n°5707) Ribs and hoop frames bonding check, by performing a tapping operation (refer to operation n°5707).  Verification of the structure condition (no cracks on the fuselage).  Wing and Tail mounting check (operation n°5705) .  Engine suspension examination.  Salty (Saline) and tropical atmosphere :  Every 6 months: Perform a detailed inspection of every metallic component in order to detect corrosion. If you find corrosion, carry out an anti-corrosive treatment immediately.  Refer to chapter 6 of the AC 43-13-B.  Use in dusty conditions (dry grass or ground airstrip, sand, desert...) :  Single case: as soon as possible, clean and re-grease every assembly subject to abrasion, particularly the bronze nuts and lead screws in the flap control system.  Regular use in these conditions :  Remove and inspect the bronze nuts and lead screws, at least every 100h/annual inspection (see operation 2704b for the Sportster and 2705 for the other MCRs), and replace them as soon as required.  Clean the plane regularly (outside / inside)  Clean / replace the engine air filter more often  Avoid dust accumulation on the sliding parts of the landing gear  After propeller strike :  Refer to the propeller and engine manufacturer’s documentations  After a flight in hail (or aircraft exposed to hail on the ground) :  Contact SE Aviation immediately.  After a lightning strike :  Contact SE Aviation immediately. In all these situations, please complete a technical event sheet according to the template supplied in the appendix. And contact SE Aviation for recommendations and instructions SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :31/74 Page intentionally left blank SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :32/74 1.5 Remarks 1.5.1 Repetition of operations When an operation repeats on several types of inspection, we shall consider that the operation is to be made, in every visit, in an identical way. If a similar but more comprehensive inspection is required it will be written and identified differently. 1.5.2 Counting of hours Times are counted since new, or since the last 1000h visit. Flight hours used to calculate component service lives and time intervals must be counted “block-block” (between the moment when the aircraft taxies by itself to fly, to the final stop). 1.5.3 Margins The margins cannot be cumulated: The 50h inspection must be done between 45 and 55 h after a 100h/1year inspection. The 100h or annual inspection must be done at the deadline coming first :  Either 100h, 200h, 300h, etc. …(+ /- margin) since the last 1000h inspection.  or 1 year (+ /-margin) since new or last 100h or annual inspection The 1000h inspection must be done between 950 and 1050h since new or the last 1000h inspection. The 5 years inspection must be done (+ /- margin) since new or last 5 years inspection. It is necessarily accompanied by a visit of 100h or a visit of 1000h (according to the operating hours of the aircraft). One could try to match the maintenance inspections related to the operating hours with the maintenance inspections related to a calendar deadline, in order to avoid two distinct groundings. Therefore, it is possible to postpone, within reasonable limits, one of two deadlines:  Either 50 hours with the deadline related to the operating hours (1 000 h),  or 3 months with the calendar deadline (5 years), but in no case, both simultaneously SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :33/74 1.5.4 Maintenance report sheets In order to facilitate the maintenance of your MCR, we have produced some maintenance report sheets for the 50h, 100h/1year, 1000h and 5years inspections. These reports contain check lists which allow easy verification that each item has been performed. 1.5.5 Documents Documents to be used in addition to this handbook:  Essential documents : SE Aviation documents :  Mounting instructions ref. xEXNO02.  IPC ref. MGENO13 (MCR Sportster) or xGENO09 (other MCRs).  Flight test program ref. xEXNO04.  Control inspection procedure before the first flight ref. xEXNO05.  SE Aviation weighing procedure, ref. xEXNOPP.  Flight Manual ref. xEXNO01.  SE Aviation Service Bulletins. Equipment manufacturer documents :  Operating and maintenance manuals of the engine, of the propeller and of the safety parachute (if fitted to your A/C).  Operating and maintenance manual(s) specific to particular equipment and/or specific modification(s).  Equipment manufacturers’ Service Bulletins. Regulation and control authorities’ documents :  CN/AD published by the DGAC/EASA. (for French registered aircraft)  Additional documents : SE Aviation documents :  Eligibility sheet (CNSK).  Identification sheet (ULM).  SE Aviation SIL. Equipment manufacturers’ documents :  SIL of the equipment manufacturers. Regulation and control authorities’ documents :  OSAC Fascicules:  RP-41-15  RP-42-50  French “Arrêté du 24 Juillet 1991” related to general conditions of general aviation civil aircraft.  Further information: Advisory Circular AC 43.13-1B of the FAA. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :35/74 2 AIRCRAFT MAINTENANCE MANUAL AMM 2.1 Introduction The aircraft maintenance manual clarifies the procedures to be followed for the realisation of the maintenance operations called for in the Master Servicing Manual. For some of these operations, the procedure refers to the IPC and the building instructions to clarify and illustrate them. The procedures to be employed for the execution of these operations are the ones described in the building manuals or, if not available, the "rules of the art" of the AC 43-13-1B. 2.2 Technical procedures OPERATIONS PROCEDURES PRELIMINARY INSPECTION 0000 Update documentation Procedure : Obtain the latest update Maintenance Manual (contact@se-aviation.fr) 0001 Run-up Procedure : 1. Perform an engine run as described in the flight manual. 2. Check correct operation of the engine instrumentation. 3. Check the idle and full RPM. 0002 Vital check Procedure : 1. Refer to the flight manual of your aircraft. 0003 Before Inspection Procedure : 1. Consult the documents on board : 1.1. Check the flight manual presence. 1.2. Check the A.S.L. (Aircraft Station License). 1.3. Check the possible remarks mentioned in the aircraft logbook, airframe and engine logbook and the propeller sheet. 2. Consult the CN/AD and SB of the aircraft and of the equipment (engine, propeller, optional equipment)  Section 1.3 et 1.4 of the maintenance program (PRE). 3. Consult the time limits Section 2 of the maintenance program (PRE). 4. Consult the PRE sections from 3.2 to 3.5. 5. Consult the postponed operation list. 6. Check that the aircraft does not have unapproved modifications. 7. Clean the aircraft entirely (outside and cabin). 8. Check the presence of the mandatory marking plate. 9. Carry out an after-flight check  Flight manual. 10. If the maintenance inspection is not done just after a flight, perform a run-up  OPERATION 0001. 11. Removal the engine cowlings (unscrew). 11.Start inspection Tooling : 1. Airframe : Sponge, soapy water (car body cleaner) and rinse with clear water. 2. Canopy : Soft cloth and specific cleaning product such as ALTUNET. Micro-scratches can be removed or reduced with special polish type ALTUPOL 1 and 2. 3. 8mm flat blade screwdriver SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :36/74 OPERATIONS PROCEDURES ATA 07 - LIFTING 0701 Lifting Procedure : 1. Lift the MCR by the tail with a hoist, use wide straps and foam. Avoid putting trestles under the wings. 2. MCR Sportster, M, Club and ULC : Put trestles (covered with foam) under the fuselage at the wing root. MCR 4S and Pick-up : Put the trestles (and foam) under the skids under the fuselage on the level of the slice plates. Avoid lifting an airplane with a full fuel tank. ATA 12 - SERVICING 1201 Lubrication plan Procedure : 1. Remove the keel  OPERATION 5303. 2. Lubricate all the parts mentioned in the lubrication plan which you can find in the appendix 4 of this manual. CAUTION : DO NOT LUBRICATE CONTROL CABLES ATA 21 – VENTILATION AND HEATING 2101 « Naca » vents check Procedure : 1. Check that the « naca » vents are not blocked by referring to :  The IPC, section 53 and P5 (two-seater) or 61 (4S and Pick- up).  The mounting instruction MMONO08 and MFUNO19 (two- seater). 2. Perform an operational test of the cabin ventilation system. 2102 Cabin heating check Procedure : 1. Perform a test of the cabin heater operation. ATA 23 – COMMUNICATION 2301 Radio equipment inspection Procedure : 1. Check that the radio installation is correctly fixed to the instrument panel. 2. Perform a functional test. 2302 Radio equipment detailed inspection Procedure : 1. Radio removal. 2. Inspection of the coaxial wires. 3. Checking the security of the mounting racks. 4. Check there are no cracks in the rack. 5. Radio refitting. 6. Perform a test. Tooling : 1. Phillips screwdriver 2303 Antenna inspection Procedure : 1. Inspect the antenna condition (VHF, VOR, Transponder, GPS,…) and verify the absence of corrosion 1. Check the mounting security of antennas on the fuselage. ATA 24 – ELECTRICAL POWER 2401 Operational test of electrical circuits Procedure : 1. Switch on the main power switch. 2. Perform a functional test of the electrical circuit by switching one of the electric components (test them one after each other). 3. Start up the engine in order to test the starter and to check the electrical generating circuit (test voltage with a multi-meter in the cigar lighter plug). 2402 Detailed inspection of the electrical circuits and the engine connexions Procedure : 1. Switch off the electrical circuit. 2. Check the electrical circuits and engine connections condition by referring to :  The electrical diagrams provided by SE Aviation.  The IPC, board M11 (Rotax 912), M51 (Rotax 914), M5115 (Rotax 915) or M71 (Rotax 912, assembly like 914).  The mounting instruction MMONO01. 3. Check the conductivity of the circuits if required (in case of doubt). Tooling : 1. Electrical multimeter. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :37/74 OPERATIONS PROCEDURES ATA 24 – ELECTRICAL POWER (Continued) 2403 Battery check Procedure : 1. Switch off the electric circuit. 2. Recharge the battery. 3. Measure the voltage on the battery terminals. A fully charged battery has a voltage between 12,8 and 13 Volts. If the battery voltage is lower than 11,5 Volts, the battery is at the end of its life : Therefore, replace it. Tooling : 1. Voltmeter. 2404 Generator check Procedure : Tooling : 1. Run the engine at 4000 rpm minimum (for at least 10 minutes). 2. Measure the voltage (cigar-lighter plug). 3. Verify that the voltage is between 13,5and 14 Volts. 1. Voltmeter. ATA 25 - EQUIPMENT AND FITTINGS 2501 Composite seats and floor check Procedure : 1. Check the seat mountings referring to section 31 of the IPC and to the mounting instruction xFUNO14. 2. Check the molded seats (check the locking, height setting system). 3. Check the floor condition referring to section 5 of the IPC (check the absence of delaminating in particular). 2502 Harness check Procedure : 1. Verify the harnesses mounts are in good condition. 2. Check the condition of the frame close to the harness fixings and, in particular, the absence of cracks. 3. Check seat belt fasteners (test the locking and release mechanism). 2503 Baggage compartment check Procedure : 1. Check the baggage compartment, and in particular the absence of delaminating. 2504 Check of the trap door and strap covers of the safety parachute Procedure : 1. Check visually that the adhesive holding the trap door of the safety parachute and the strap covers are correctly stuck and in good condition (no traces of moisture, separation or tears). 2. Check the state of the parachute trap door, absence of shock, etc. 2505 Check of the safety pin of the parachute handle Procedure : 1. Check that the safety pin of the safety parachute handle is in place. ATA 27 – FLIGHT CONTROLS 2701 Rudder pedals check Procedure : 1. Check the state and functioning of the rudder pedals referring to :  The IPC, section 30 (and sections P2, PW, PAD or PAS according to the fitted option).  The mounting instruction xGENO05. Check the absence of sticking and axial play during the pedal floor motion. If necessary, clean the slide bar and apply grease on it: Operate the rudder pedals several times. 2. If the A/C is equipped with it, test the rudder board adjustment knob and its position adjustment bracket. 3. Check the cable mounting on the firewall. 4. Replace the artificial strength rubber bands, if necessary. 5. Check the rudder cables are in good condition, in particular at the level of the "S" of pedals. A 25 % wear on the outside strands is tolerated (do not grease cables). SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :38/74 OPERATIONS PROCEDURES ATA 27 - FLIGHT CONTROLS (continued) 2702 Flight controls check (hard spot and clearance) Procedure : 1. Check the absence of hard friction points by operating slowly the different flight controls (pitch, roll and yaw). 2. Check play, looseness and deflections and perform adjustments if necessary  Refer to the FLIGHT MANUAL of your MCR for the maximum tolerated play and deflections. For the flaps, switch on the battery and operate the flap control in all possible positions and check that the operation is correct (by listening, verify normal operation).  Flaperon control : (MCR SPORTSTER) : Refer to the IPC, section 28 and to the mounting instructions MGENO16.  Aileron control: Refer to the IPC, section 48 and to the mounting instructions xAINO02 .  Flap control : Refer to the IPC I, section 28 and to the mounting instructions xVLNO02.  Elevator control : Refer to the IPC, board 26 and to the mounting instructions xGENO06.  Rudder control : Refer to IPC, section 10 (or section PX for Swiss-registered MCR) and to the mounting instructions xGENO05. 2703 Flight controls removal/refitting, adjustments and tests Procedure : 1. Remove the flight controls. 2. Inspect the bell-cranks and the rods of the different flight controls in order to detect possible abnormalities : 2.1. Check clearances and hinges. 2.2. Control rods, bolts and rod end bearings, check the fittings are riveted as well as bonded to the rods. 3. Lubricate hinges, and bearings of the flight control systems. Refer to the Lubrication plan in appendix 4 of this handbook. 4. Refit the flight controls. 5. Check the cinematic functioning of the hinges is correct. 6. Adjust. 7. Perform a test of the cinematic linkage of the different flight controls. Referring, IPC and mounting instructions : Refer to Operation 2702. 2704a Cleaning, visual check , greasing of the flap control bronze nuts and lead screws Procedure : On the aircraft, without disassembly : - Check the correct condition of the grease (clean, no dust or sand..) - Clean very thoroughly the grease (fuel, WD40) while actuating the system to remove any residues inside the nut - Visual check of the part condition and absence of axial play. In case of doubt, perform following operation (2704b) - Grease with Aeroshell Grease 33. SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :39/74 OPERATIONS PROCEDURES 2704b Removal/refitting of flap control lead screws and bronze nuts Procedure : (see detailed procedure in service Bulletin BS 12 F 0043) - Remove the flap carriages - Clean the parts carefully - Inspect with a magnifying lens the lead screw and nut threads to detect any trace of damage (wear scratches, foreign matter inclusion...) - On a bench, assemble the parts without grease and check o the axial play (it must be lower than 0.1 mm) o and the “angular” play than must be lower than 1.2 mm (radial movement of the screw tip, cf method in BS 20 F 0010 R1) - Refit the parts - Grease with Aeroshell Grease 33 NEVER SWITCH LEFT AND RIGHT PARTS If required, always replace BOTH SCREWS AND BOTH NUTS together IN ALL CASES THE OPERATING TIME LIMIT IS 1000 LANDINGS 2705 Cleaning, inspection, control the play of leading screw in bronze nut and lubrication of flap control Procedure : On the plane, after remove of fairings or bucket seat, - Check the condition of the grease (cleanliness, contamination by dust, sand…) - Clean carefully grease (gasoline, WD-40) by operating the system to remove residues inside the nut. - Check leading screws and nuts with a magnifying lensto look for trace of damage (corrosion, scratches, blows, strains, particle inclusions…). In case of damage or deformation of the screw, it must be replaced. Always replace 2 BOLTS AND 2 SCREWS AT THE SAME TIME. - Check the axial nut/screw, by measuring the different distance between the nut and the mechanical stop of the screw, when one exerts a force on flap up or down. The play must not exceed0.2 mm. If the clearance is greater than this value, then replace the bronze nut (and screw – on condition). - Check the general condition of the control system. - Lubricate the screw and bronze nut with Aeroshell Grease 33. IN ALL CASESTHE OPERATING TIME LIMIT OF NUTIS LIMITED TO300 HOURSOR 3 YEARS 2705 b Procedure : On the plane, after remove of fairings or bucket seat, - - Check the condition of the grease (cleanliness, contamination by dust, sand…) - Clean carefully grease (gasoline, WD-40) by operating the system to remove residues inside the gimbals - Check the gimballs to look for trace of damage (corrosion, scratches, blows, strains, particle inclusions…). In case of damage or deformation of the gimbals, it must be replaced. - Check the axial play, by measuring the different distance between the gimbals and the frame, when one exerts a force on flap up or down. The play must not exceed 0.3 mm. If the clearance is greater than this value, then replace the gimbals. - Check the radial play by using the 17mm locking nuts (ref NFUEQ6K01) to turn the leading screw. If the play is greater than 2°, then replace the gimbals - lubricate the gimbals with Aeroshell Grease 33 2706 Tab control rod detailed inspection Procedure : 1. Carry out a detailed inspection of the tab control rod with reference to the mounting instructions xGENO06. 2707 Check of rod ends of flight controls Procedure : 1. Check the condition of the rod ends (hinges) of flight controls (riveting, corrosion, general state, …) 2708 MEVO Flap control detailed inspection Procedure : - Check the flaps control screws (IPC 2802) - Grease the ball joints, the hinges and the bearings - Check for the absence of hit and crack - Check corrosion points in aluminum parts SE Aviation Aircraft Aérodrome de Pontarlier, Route de Salins 25300 PONTARLIER 03 81 89 70 84 26/11/19 M EX NO 03 07E MCR MAINTENANCE MANUAL [ED 25/09/19] Page :40/74 OPERATIONS PROCEDURES ATA 28 – FUEL LINE 2801 Fuel hose check Procedure : 1. Inspect fuel lines, hoses and fittings of the fuel system by referring to the IPC, section 14, 41 and :  for ROTAX 912 : section M6  for ROTAX 914 : section M46  for ROTAX 912 (assembly like ROTAX 914) : section M66  for ROTAX 915 : section M4615 And also mounting instructions MMONO01, QCCNO01 (for 4S and Pick-up) and MCCNO05. 2802 Fuel filters examination Procedure : 1. ROTAX 912/912S : Clean the fuel filter inside the electrical pump by referring to the mounting instructions MMONO01 (Firewall installation section). 2803 Tank removal/refitting Procedure : 1. Drain the tank entirely. 2. Remove the tank by removing the casing (refer to section 8 of the IPC). CAUTION : Hold the instrument panel vertically. 3. Clean and rinse with fuel 4. Check there are no leaks. 5. Perform a detailed inspection of the fuel tank. 6. Refit the tank. Note : After cleaning the tank, check or replace filters very frequently for about 50h (check for small particles). 2804 Wing tank access covers removal/refitting Procedure : 1. Remove the access covers by referring to section 8 of the IPC. 2. Clean and rinse with fuel the inside of the tank. 3. Inspect the inside of the wings with a mirror. Be careful of fuel fumes and suitability of light source ! 4. Clean traces of silicone compound from the covers and cover recesses on the wings. 5. Check the condition of the threads of the captive nuts. 6. Check the absence of peeling, delamination and rips in the fuel sealing layer. 7. Replace the O rings ref. : QCCEQBY01 (6 per cover) and QCCEQBZ01 (one per cover). 8. Refit the traps with a bead of silicone sealant type ORAPI 145 ref QCCWC7P01. Tooling : 1. White vinegar or acetone (for cleaning of the silicone joint) 2805 Fuel line check  Procedure : 1. Put the fuel circuit under pressure (switch on the fuel pump) and ensure there are no leaks. Refer to the IPC and the mounting instructions : Refer to Operation 2801. ATA 31 – INSTRUMENT PANEL 3101 Instrument Panel Rubber mount check Procedure : 1. Check the condition of the anti-vibration mounts of the instrument panel by referring to section 54 of the IPC and the mounting instruction xGENO13. 2. It they are in poor condition, replace them. 3102 Instrumentation and warning light check Procedure : 1. Ensure all of the instruments and warning lights are securely mounted to the instrument panel. ATA 32 – LANDING GEAR