SV4 : 100h Maintenance Schedule / Annual Inspection

EA 767/3 - inspection (CAA AD 1767 PRE 80) 50h Lyc Lubricate starter drive O Lyc Inspect tension of Alternator drive belt O OIL Drain and flush oil sump/ tank, check oil tank general condition for leaks, cracks, damage and attachment, flush oil pipes. O Remove all oil filters and all screen oil filters, clean, check and reinstall with proper “clean” gasket O Clean oil suction strainer, oil pressure screens at oil change (check strainer for foreign particles). O Lyc Change full flow (cartridge type AEIO-360-A1E type engine) oil filter element (check element for foreign particles). O Lyc Clean and inspect oil radiator attachment Eng OH Inspect flexible oil lines, oil return lines and fittings for leaks, security of anchorage and for wear due to rubbing or vibration O Check for chaffing, dents, and cracks. Check fire sleeves. O Lyc Replace external full flow oil filter element. Check used element for metal particles, drain and renew with lubricating Oil. O Lyc Inspect Christen or Lycoming Inverted Oil System for general condition, secure mounting and tight connections. O Inspect gearbox for cracks and oil leaks O Rocker box cover and system Remove and inspect valve rocker box covers for evidence of oil leaks. If found, replace gasket in case of oil leak. Torque cover screws in accordance with MFG instructions O Check valve clearance and reset if necessary according MFG instructions O GM CS Check valve gear and springs for wear and breakages, measure with special tool. Must be all equal in accordance with MFG instructions. O GM Ren CS Check " bracket bolts" on tightness and check rocker clearance when engine is cold for correct measuring (valve clearance, see data plate or MFG instructions) O Inspect rubbers at top and bottom of push rod covers for deterioration O GM Ren CS Clean rocker covers, refill with engine oil up to level of oil vent pipes O Lubricate all hinges, bearings, connections, rod- ends, engine commands and check proper function O Service engine with recommended lubrication oil in according with manufacture instructions (RENAULT=6L/ GIPSY MAJOR=9L/ LYCOMING 8qts/7,55L) and prime lubrication system with Aero 100, W100 or 15W50 O Clean engine and check for oil and fuel trace/ leaks (clean with fuel or cleaner) O Exhaust and induction system Inspect exhaust and induction manifold, stacks, connections, nuts attachment, studs and gaskets (replace gaskets as required). O Check attaching flanges at exhaust ports on cylinder for evidence of leakage. If they are loose, they must be removed and machined flat before reassembling and tightening O SV4 : 100h Maintenance Schedule / Annual Inspection Page 3 08/10/2016 SV4-100h/annual.doc-01 Inspect exhaust system attachment and slip joints for general condition O Inspect intake seals and O-rings for leaks and clamps for tightness O GM Inspect induction manifold & drain O GM Perform pressure test on inlet pre-heat box and check for corrosion (UK CAA 1776 PRE 80) (F-CdN 1974-78) O Ignition System Be aware all L.T. and H.T. connection of ignition system are secure and safe O Lyc Remove & adjust spark plugs (Lycoming SI 1042) If fouling of spark plugs has been apparent, rotate bottom plugs to upper and vice versa O Remove, inspect, clean, test all spark plugs and re- gap as required by the MFG, pressure setting refer to the MFG instructions (100lbs./sq.in). Inspect leads, cable and ceramics for corrosion deposits. Clean the cable ends, spark plug walls and ceramics with a dry, clean cloth or a moisture cloth with methyl-ethyl-ketone. O Inspect ignition harness for security of mounting clamps, chaffing and be sure connections are tight at spark plug and magneto terminals, check insulators for high tension leakage and free from cracks O Check breaker points for pitting and minimum gap. Inspect for excessive oil in the breaker compartment, if found, wipe dry with a clean lint less cloth. The felt located at the breaker points should be lubricated in accordance with the magneto MFG instruction. O Inspect magneto contact breaker points, springs for deterioration & confirm with MFG specifications O GM Clean the contact breaker points, and adjust the gaps to .012 inch to .015 inch (except KA1 & KH1 .015 to .018 inch) if necessary O CS Clean the contact breaker points, and adjust the gaps to .012 inch if necessary Check an adjust magneto to engine timing, refer to the MFG procedure and Overhaul manual O Clean the distributor and contact breaker covers and examine for cracks. Lubricate the contact breaker rocker arm bush O Lyc Inspect wiring conditions, vent holes and P-lead attachment, refer to magneto Maintenance and Overhaul manual. O Fuel GM Clean and check fuel filter (1 x head filter, 2 x pump filter) if foreseen also drain sump each fuel pump – Drain fuel system O GM CS Every 1y or 100h, clean fuel filter complete, replace gasket on condition. O Check and clean fuel filter and gascolator screen, fuel bowl of each pump. Lubricate by filling lubrication oil reservoir, check oil level fuel pump case. O Ren Lyc Check practical fuel pumps pressure ((210 kg/cm² range), inspect for leaks O CS Internal examination fuel pump Amal type 136 by SI G10 (CAA AD 1765 PRE 80) 12m 150h CS The normal pressure of the pump is between 0.75 to 2 lb. per square inch, each pump can be tested by operating the priming lever provided O Ren Inspect fuel pressure membrane for leaks O Check fuel shut-off/ fuel cock for operation, proper pointer indication, leaks and security (F-CdN 1972-28) O Inspect fuel lines, fuel system, accessories, fittings, fuel for leaks, security, chaffing, dents and cracks. O Inspect primer lines for leaks and security of the clamps. Remove and clean the fuel inlet strainer. O Check condition fire sleeves O Lyc Inspect fuel injector fuel lines and fittings (Lyc SB 342) FAA AD 2015-19-07 O GM CS Remove and check carburetor jets and flush chamber and drain carburetor chamber O Lyc Check fuel injector nozzles for looseness, tighten to MFG torque instructions. Check fuel lines for fuel stains, fuel leak indicating and security. Repair or replacement must be accomplished before the aircraft resumes operation O CS Inspect drain from induction manifold is clear Check throttle, mixture, + inverted system for proper operating travel, freedom of the movement, security of the clamps and lubricate all controls per lubrication chart 14 O GM CS Check proper function of the flame-trap, at full- throttle => full open O GM CS Ren Pull fuel handle open and check for leaks. Check specially inverted flight system, serve fuel pumps without pulling on the float of carburetor. carburetor may not overflow O GM CS Inspect the serviceability of the Simms rubber “Vernier-coupling”. No oil trace allowed O GM CS Lubricate the impulse starter with mix of ½ oil SAE50 and petrol O Ren GM CS Perform leak Soap test on cold engine on the connection between Cylinder and cylinder head. O Controls and ball ends should be given a little grease, and checked for wear Clean engine O If the engine is to be stored, follow MFG instructions AIRFRAME Remove all access/ inspection panels, fairings and seats Wings Inspect general condition wing covering, painting, rigging, position (in case of repair/ revision foreseen extra inspection panels O Inspect wings leading edge for dents and damage, check spars, ribs for cracks, check for loose ribs and lacing cords O Inspect wing spar main bolts for looseness and security, safety wires and safety screws O Check wings and ailerons drain and ventilation holes for obstruction O Inspect LH and/or RH wing walk area for dents, cracks, deformation, damage O SV4 : 100h Maintenance Schedule / Annual Inspection Page 4 08/10/2016 SV4-100h/annual.doc-01 Inspect controls surfaces for security of attachment, dents, delamination’s and cracks O Inspect ailerons hinges, bolts, hinge bearings, self- locking nuts for condition, cracks and security, check aileron for proper operation O Check wires between lower and upper aileron for damage, looseness, corrosion O Check free play in control system, torque tube, control surface, control sticks, rod-end bearing, deflector limiter O Inspect fly wires on deformation, damage, tightness, corrosion, self-lock nuts, safety pins O Inspect wing arrows and attachment for cracks, damage remove if necessary O Inspect fly wires and attachment (F-CdN 1975-90) O Inspect wing struts and attachment for corrosion or damage, bolts for tightness, certainly below trailing edge, if necessary replace bolts & use bushing 10/12, L= 78 mm O Check if all nuts are on place and well locked O Inspect aileron cables and pulley for wear and function, lubricate all hinges (NOT on pulley or cables) O Inspect wing internal, inter rib bracing tape for broken ribs, lacing cords O Clean wing attachment below and inspect O Central Wing Remove central fuel cover (if installed) O Inspect fuel tank fittings O Inspect fuel tank, sump, fuel gauge and lines for fuel leaks, security, chaffing, dents, cracks O Inspect wing attachment and area O Inspect inverted pick-up tube O Inspect fuel evaporation hole for freedom, check fuel filler cap for security function O Inspect central wing area covering and check underside for fuel leaks O Check fuel placard for fuel type and quantity are proper installed or marked O Stabilizer and Elevator, SV4C complete Ceconite, SV4B tip stabilo triplex Inspect stabilizer and elevator for general condition, covering, spars, painting, rigging, position for dents, cracks, stone nicks and delamination’s O Inspect stabilizer and elevator spar main bolts for looseness and security O Inspect elevator central part where tumbler is attached for cracks, press gently up and down at Left and Right side O Inspect stabilizer rear attachment on fuselage, if washer is pressed to deep into the wood structure, replace by a square washer of 3mm thickness O Inspect all hinges, hinge bolts, hinge bearings, self- locking nuts for condition, attachment, looseness, corrosion O Check trim system, trim cable sleeve for proper operation, attachment, rigging and play Check pulleys and cable retracting springs O Check stabilo & elevator drain holes O Check if reinforcement Aèrospatiale SB N°2 is performed for Aerobatic Category O Lubricate all hinges and rod-end bearings O Check elevator control cables and steering system for condition, attachment, chaffing O Fin and Rudder Inspect fin and rudder for general condition, covering, spars, painting, rigging, position O Inspect fin forward attachment on fuselage for looseness, cracks, inspect inside O Inspect etambot, vertical lower part of the fin for cracks and oil trace, or oil trickle through O Check rudder hinges, rod-end bearings, turnbuckles for proper condition, function, play and corrosion O Inspect fly wires for proper condition, attachment, corrosion, damage, looseness, especially the fly wire tension system O Check drain holes of fin & rudder O Inspect Front & Rear pedal pivot bolts, rudder control cables and steering system for condition, attachment and wear, re-torque pedal pivot bolts O Inspect rudder trim plate for condition, attachment, setting, cracks, corrosion O Lubricate all hinges and rod-end bearings O Fuselage SV4C adjustable Seat, SV4B fixed seat Wash fuselage in & outside with NON aggressive, cleaner (example White Spirit). Clean and dry, remove all oil traces and dirt’s O Inspect main fuselage fabric and painting, bottom fabric, tail fairing and spars for condition, check for cracks, delamination’s, loose screws and rigging position (in case of revision foreseen extra access panels on fuselage covering O Check installed parts for general condition and security of attachment (antenna’s, exterior lights) O Inspect fuselage for foreign matters O Inspect fuselage wood construction for general condition, cracks, (aerobatic above all-in areas of load stress) O Inspect main and auxiliary wing spar attachment for general condition O Inspect wood spar and ribs for damage O Check tail section for trace of oil, liquid, dirt O Inspect all engine mount attachment bolts, brackets and fire wall for cracks, corrosion O Inspect attachment rear central wing struts on fuselage, check bolts for corrosion and tightness (F-CdN 1988-55) O Check free travel of flight control system, steering, ailerons, elevator, trim, rudder, torque tube, bell cranks, bearings, sprockets, pulleys, turnbuckles, control surfaces, control sticks, deflector limiter, check for proper operation, abnormal noise, chaffing, cable tension O SV4 : 100h Maintenance Schedule / Annual Inspection Page 5 08/10/2016 SV4-100h/annual.doc-01 Check throttle, mixture, + inverted system for proper operating travel, freedom of movement, security of the clamps and lubricate all controls per lubrication chart 14 O Remove battery and inspect battery box for proper condition, acid trace, corrosion and check all electrical wiring and equipment for condition, connection, isolation, chaffing O B Clean and lubricate canopy hinge and latching mechanism, inspect emergency canopy drop system for function and condition (SV4B) O A/C/E Check lock system cockpit doors panels O A/C/E Check wind screens for security, loose screws, and damage. (SV4 open cockpit) O Remove both stick covers and check stick base, welding for cracks and attachment, safety pins, nuts for proper installation O Inspect elastic seat system behind pilot seat (if installed) O Check tension of bracing wires behind pilot seat and fuselage O Inspect Air driven alternator, attachment, wiring, cleanness, supply to the battery, obstructions (check function during flight) O Check rudder pedals, brake system and parking brake for free travel, play and lubricate O Check fire extinguisher weight, pressure, expiry date, attachment O Check baggage compartment and equipment for correctly stowed (fire extinguisher, first Aid kit) O Instruments Inspect cockpit general condition, instruments, accessories, wiring, loose parts, damage O Inspect front and rear instrument panel mounting for security and safety. Check shock mounts for general condition O Check operation, mounting and wiring of switches, relays, electrical equipment, fuses, voltage regulator, … for condition and safety O Check circuit breakers mounting, wiring for condition and safety O Check the mechanical function of the Magneto switches. BATTERY DISONNECTED !!!! O Check compass and compass deviation card for proper indication and compensation O Inspect pitot tube, static dynamic air pressure system, lines for condition and leaks (perform Static pressure test every 4y) O Check for oil leak at RPM gear box cable exit (plugs) and RPM cable trough the firewall into front cockpit board O Main Landing Gear Inspect landing gear for general condition, , cracks, damage, corrosion, abnormal landing stress O Stand in front of A/C and check MLG symmetry Inspect landing gear shock absorber rubber for dimension and deterioration if less than 125mm, replace rubber blocks (9pc) (38 mm/block) O Set aircraft on SV4 jacks check play of all hinges, use correct bushing to rectify play O Check bearings for abnormal noise, clean and lubricate landing gear system, nipples, bearings: lubrication chart 14, drill out in case of stoppage O Check nuts of the MLG strut and airframe bracket fittings for tolerance and play O Check play on MLG internal legs. If necessary remove thickness plate and tightened bolts. O Inspect wheels for cracks or other damage, wheel nuts for tightness, play on bearing. O Inspect tires for cuts, flat spots, and tread or side wall damage. If changing of tires is necessary follow the SV4 instructions Check tire pressure 1,5 kg/cm² maximum O Inspect for slackness of the wheels on the axles and check for side play O Inspect brake system for general condition, function, corrosion, cracks or other visible damage. Remove wheels and check brake shoes/blocs for use and clean. If brake cable ends, replace brake shoes by new or oversize or place a smaller spacer on the bell crank O Tail wheel Inspect tail wheel for general condition, fitting, dents cracks and delamination’s Check play on piston/axe and lubricate. O Inspect tail wheel rubber tire for condition free rotation and steering function O Inspect wheel fork and shock absorbing strut for damage, attachment, cracks, and corrosion O Inspect the axle bolt & nut for fretting, wear fitting, damage and lubricate wheel strut & bearing. O Renault – VIET startsysteem Inspect pressurized bottle, hoses, lines, tubes, connections, attachment, junctions, check for leaks and damage O Compressor Visual check, start 1h pressure test (must remain 1h on pressure setting) O Drain pressure bottle O Smoke system Check for leaks, Aircraft cleanness, fitting, function O Recurrent inspections Lyc Clean and flush the Inverted Oil System with suitable petroleum solvent, such as varsol according to Lycoming Operator’s Manual 60297-21 & SI 1397, Christel system Inverted Oil System Manual 300h Lyc Remove box cover and check for freedom of valve rockers, when valves are closed. Look for evidence of abnormal wear or broken parts in the area of the valve tips, valve keeper, springs and spring seats. If any indications are found, the cylinder and all of its components should be removed (including the piston and connecting rod assembly) and inspected for further damage. Replace any parts that do not confirm with limits shown in the latest revision of Special Service publications No. SSP1776. 400h Check fuel flow to fuel pumps Remove fuel hose and flow 1L into reservoir, min debit of 50L/u or 1L/72 sec. If less check flexible with lead head in the fuel tank for deformation or obstruction 2y SV4 : 100h Maintenance Schedule / Annual Inspection Page 6 08/10/2016 SV4-100h/annual.doc-01 A/C/E Drain fuel tank, remove and inspect for leaks, fittings, cracks and reinstall 2y Closing Aircraft Check placards and marking properly present and readable Check all tools, rags, cleaning cloth, and loose parts are removed O Ensure all Airworthiness Directives are complied with O Ensure that all defects reported by owner/operator have been rectified O Make an appropriate CRS and entry in the log books O Ensure that all filler caps, fuel and oil are properly filled and secured O Reinstall al cowlings, fairings, access panels and removed accessories, check for security O Perform a POST RUN-UP and check for oil & fuel leaks O Check of all documents are on board Owner/ Operator:  Flight Handbook  Weight &Balance report  Insurance  Radio License  CofA or Permit to Fly  Certificate of Registration  Pilot Logbook  First Aid Kit  Fire extinguisher  If in use: Parachute in safe and operational condition Perform after each maintenance task, during the first flight an operational check if everything function properly and if installed check proper function of the G-meter Airworthiness Limitations & Airworthiness Directives Aerospatiale SB N°2 Tie Rods Stampe N° 44 880 500h DGAC-CdN 1988-55 remove & inspect rear attachment central wing struts screws on fuselage for corrosion and tightness (4y inspection corrosion cover with blue Loctite) 4y BCAA TN 89-01Replace Engine flexible oil & fuel line OH 10y BCAA TN 92-01 R2 Technical Note 500h magneto Inspection 500h/ 120m GM CAA UK AD 1772 PRE 80 Remove hub and inspect crankshaft front shaft with magnifying-glass 2y CS CAA AD 1762 PRE 80: Crankshaft inspection front end (FPI SI F1/G13/J36) 200h CS CAA AD 1763 PRE 80: Piston oil pump GC1601 by SI G2 300h CS CAA AD 1765 PRE 80: Inspect Fuel pump Amal type 136 by SI G10 12m 150h GM CAA AD 1776 PRE80: Manifold press test 12m CS CAA AD 1767 PRE 80: Engine control ball and socket joints type EA 767/3 50h DGAC-CdN 1974-78 Manifold pressure check 12m BCAA Communication 5 : Weight & Balance 10y BCAA Communication 23 : Oil Change 6m BCAA Circ/Equip-04 : Altimeter & Encoder test 4y BCAA Circ/Equip-04 : Transponder test VFR 4y BCAA Circ/Equip-02 : Pressurized bottle hydrostatic test (min 30 bar test pressure) 5y  Propeller bolts tightness should be done more frequently if propeller is new or if machine is operating in hot and or wet climate.  Attention is called to the necessity for periodical lubrication of all engine control moving parts. Cases of seizure have occurred owing to neglect in carrying out this simple operation. Some thin type of oil, or failing this, ordinary engine oil can be used, and owing to the inaccessibility of some of the control parts, it will be found that the oil can best be applied by means of a small brush. The moving parts that require attention include: - Control Shaft Main Bearings, Ball Ends, Bell Crank Bearings and Cams and Plates for Magneto Control.  Annex: Lubrication Chart N°14 in Annex Mark Model SN° TT TSOH Aircraft Engine Propeller Name Signature Stamp Date Mechanic Independent Inspection