Maintenance Manual

Oil Capacity: max. 3.0 litres – min 2.0 litres COOLING Cooling system: Mixed air and liquid pressurized closed circuit system Coolant: Coolant type and specifications are re- ported into the “Rotax Operator’s Manual” and in its related documents. 2st Edition, April 22th, 2008 P2002 Sierra M A I N T E N A N C E M A N U A L SECTION A GENERAL pag. A-6 MAXIMUM WEIGHTS Maximum Takeoff weight 450 kg Maximum Landing weight 450 kg STANDARD WEIGHT Standard empty weight 289 kg SPECIFIC LOADINGS Wing loading 39 kg/m2 Power loading 4.6 kg/hp P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-1 2st Edition, April 22th, 2008 INSPECTION & SERVICING SECTION B INSPECTION & SERVICING TABLE OF CONTENTS 1 GROUND HANDLING--------------------------------------------------------------------------------------- 2 2 PARKING AND TIE-DOWN -------------------------------------------------------------------------------- 2 3 JACKING ------------------------------------------------------------------------------------------------------- 2 4 LEVELLING --------------------------------------------------------------------------------------------------- 4 4.1 LONGITUDINAL LEVELLING ----------------------------------------------------------------------------------- 4 4.2 TRANSVERSAL LEVELLING------------------------------------------------------------------------------------- 4 5 MOVING SURFACES CONTROL SETTINGS ---------------------------------------------------------- 5 5.1 STABILATOR SETTING ------------------------------------------------------------------------------------------ 5 5.2 TRIM-TAB ADJUSTMENT --------------------------------------------------------------------------------------- 5 6 AIRCRAFT ALIGNMENTS --------------------------------------------------------------------------------- 6 6.1 DATUM --------------------------------------------------------------------------------------------------------- 7 6.2 NOMINAL DISTANCES ------------------------------------------------------------------------------------------ 7 7 WEIGHING AND DETERMINATION OF VERTICAL CG ------------------------------------------ 8 8 CORROSION PREVENTION ------------------------------------------------------------------------------ 10 9 SERVICE BULLETINS ------------------------------------------------------------------------------------- 11 10 SERVICING. ------------------------------------------------------------------------------------------------ 12 11 LUBRICATION--------------------------------------------------------------------------------------------- 14 11.1 INTRODUCTION ----------------------------------------------------------------------------------------- 14 11.2 LUBRICATION POINTS (SEE FIG. B-6 & B-7) -------------------------------------------------------- 14 12 INSPECTION ----------------------------------------------------------------------------------------------- 17 13 INSPECTION ----------------------------------------------------------------------------------------------- 18 13.1 INTRODUCTION ----------------------------------------------------------------------------------------- 18 13.2 PERIODIC INSPECTIONS ------------------------------------------------------------------------------ 19 13.3 SERVICING REQUIREMENTS ------------------------------------------------------------------------- 19 14 SUMMARY OF REFERENCE VALUES -------ERRORE. IL SEGNALIBRO NON È DEFINITO. P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-2 2st Edition, April 22th, 2008 INSPECTION & SERVICING 1 GROUND HANDLING Move the aircraft on ground by pulling on the propeller blades close to hub. A tow bar can be attached to fittings. Aircraft can be steered using the rudder or, for sharp turns, by lowering the tail to raise nosewheel off the ground. In this case, owing to the favorable CG location, a gentle push on the tailcone just ahead of empennage surfaces is all that is needed. Avoid dragging nosewheel sideways and do not attempt to counter any movement of the aircraft by handling it by its wing tips. 2 PARKING AND TIE-DOWN As a general precaution for outdoor parking, it is wise to position aircraft into the wind and to set the parking brakes or chock the wheels if chocks are available. In severe weather and high wind conditions, aircraft tie-down is recom- mended. Tie ropes should be secured to the wing tie-down fittings located under each wing. Secure opposite end of ropes to ground anchors. Nose gear fork may be used as fixing for forward tie-down. Aircraft control stick should be locked using safety belts to prevent possi- ble weathervaning damage to control surfaces. 3 JACKING For the jacking of the main landing gear, two lifting points are provided under the two outer keelsons (see Figure B-1). The lifting point consists of a small aluminium cylinder fastened to the outer keelsons. Below of it could be placed either a hydraulic jack or a lifting rod. The lifting point is realized with a φ11mm hole which could be used to fit a lifting rod safety pivot. Given the light empty weight of the aircraft, lifting one of the main wheels can be easily accomplished even without the use of hydraulic jacks. P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-3 2st Edition, April 22th, 2008 INSPECTION & SERVICING FIGURE B-1 REAR LIFTING POINT In case of it would be necessary to lift the nose gear, we suggest you to remove the engine’s cowling and then, acting on the engine’s mount, lift the aeroplane. As general rule, apply force to aircraft structure only on main struc- tural elements such as frames, ribs or spars. WARNING P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-4 2st Edition, April 22th, 2008 INSPECTION & SERVICING 4 LEVELLING Occasional levelling of aircraft may be necessary to insure proper wing in- cidence and/or dihedral or for exact CG location. FIGURE B-2 LONGITUDINAL LEVELLING 4.1 LONGITUDINAL LEVELLING To check the longitudinal levelling act as follows: • Slide off one of the two seat to get the access to the two seat track’s supporting trusses. • Place longitudinally a spirit or water level over the two supporting trusses using, if necessary, a straight piece of wood as indicated into figure B-2. • Adjust the aircraft’s tilt through shims placed under wheels or by regulating tire pressure. 4.2 TRANSVERSAL LEVELLING With one seat removed place a level along the forward seat track’s supporting truss. Level the aeroplane by deflating the main gear tyres. P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-5 2st Edition, April 22th, 2008 INSPECTION & SERVICING 5 MOVING SURFACES CONTROL SETTINGS Adjustment of control surfaces must not exceed travel limits reported in table below. 5.1 STABILATOR SETTING In order to find the stabilator’s “zero” the aeroplane must be previously longitudinally levelled. Place a shim 19mm thick over the stabilator’s rear spar and place the level over the shim and the stabilator’s tubular spar (see figure B-3), then level the stabilator. FIGURE B-3 STABILATOR SETTING 5.2 TRIM-TAB ADJUSTMENT The following procedure lists the operation to be carried out to adjust the trim tab excursion: • Set the stabilator in its “zero” position and lock it in this position. • Turn the Master switch ON. • Trim to maximum pitch-up; • Adjust thread of hinged control rod until tab is deflected down- wards 9° (use a protractor or measure downward displacement of trailing edge - 9° is approximately 16mm); • Tighten lock-nut for adjustment thread and fasten connecting pin of control rod to trim-tab. AILERONS (starting from tip line-up) up 25o dwn 19o ± 1o STABILATOR up 15o dwn 3o ± 1o TRIM ( Stab. at 0o, see picture below) 2o 9o ± 1o RUDDER Lh 30o Rh 30o ± 2o FLAPS ( max. travel ) 0o 40o ± 1o CONTROL CABLE TENSION (for all) 20 daN ± 2 daN P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-6 2st Edition, April 22th, 2008 INSPECTION & SERVICING 6 AIRCRAFT ALIGNMENTS FIGURE B-4 ALIGNMENTS C' A A B C C D' D B A' D' C' C' P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-7 2st Edition, April 22th, 2008 INSPECTION & SERVICING 6.1 DATUM • A & A’ – On the wing upper surface, is the rivet shared between the main spar’s and the composite wing tip rivet lines (of the two tip rivet lines, we are referring to the external one). • B – The reference pointed in Figure B-4 on the top of the propeller reduction gearbox. To get the access it is necessary to remove the engine’s upper cowling. • C & C’ – On the stabilator upper surface, is the rivet shared be- tween the composite tip and the tubular spar rivet lines. • D & D’ – On the fin’s skin is the upper/aft rivet. It shared between the upper rib and the rear spar rivet lines. 6.2 NOMINAL DISTANCES The aim of the alignment control is mainly to compare the measures taken on both sides and to check if the difference between them, if any, is within the tolerances reported below. Datum Nominal distances (mm) A - B 4360 ± 20 A’- B 4360 ± 20 A - C 4685 ± 20 A’- C’ 4685 ± 20 C - D 1810 ± 10 C’- D’ 1810 ± 10 P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-8 2st Edition, April 22th, 2008 INSPECTION & SERVICING 7 WEIGHING AND DETERMINATION OF VERTICAL CG USE GUIDELINES AS FOLLOWS: a. Carry out weighing procedure inside hangar b. Remove any unnecessary objects inadvertently left on board aircraft c. Make sure of the on-board presence of the Flight Manual. d. Align nose wheel e. Drain fuel f. Oil, hydraulic fluids and coolants at operating levels g. Move seats to most forward position h. Flaps retracted (0°) i. Control surfaces in neutral position j. Position scales (min. capacity. 200 kg) under each tire LEVELLING a. Level the aircraft (see par.4 “Levelling”) WEIGHING a. Record weights of individual scales b. Calculate empty weight DETERMINATION OF CG a. Drop a plumb bob tangent to the wing’s leading edge, as indicated into fig- ure B-5. Trace a reference mark on floor. b. Repeat operation on other wing. c. Connect the two reference marks with a taut line d. Measure distances between reference line and landing gear wheel axles e. Recorded data allows determination of C.G. location and aircraft’s moment (see following table) P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-9 2st Edition, April 22th, 2008 INSPECTION & SERVICING 1337 from the propeller's flange (without sapacer) W2=WL+WR CMA 1370 D B W1 A 15 mm inboard from rib n°7 4 2 1 3 6 5 7 W2 * A - W1 * B * 100 D% = D = D 1370 W1 + W2 Reference line WEIGHT AND CG DETERMINATION TABLE Kg metres Fwd wheel weight W1 = Distance from bob to Lh wheel AL = Lh main “ “ WL = “ “ Rh wheel AR = Rh main “ “ WR = Average distance (AL+ AR)/2 A = W2=WL+WR= Distance from bob to nose wheel B = Empty weight
We =W1 + W2 = D W A W B We = ⋅ − ⋅ =2 1 ________meters C.G. position as wing chord % D% = D/1.37 ⋅ 100 = FIGURE B-5 WEIGHT & BALANCE P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-10 2st Edition, April 22th, 2008 INSPECTION & SERVICING 8 CORROSION PREVENTION It is important to keep the aircraft clean and to remove any collection of corrosive agents such as oil, grease, dregs and other foreign matter. To avoid damage to finish, do not use polishing detergents. Original or equivalent corrosion prevention must be re-applied after any alteration or repair. If any trace of corrosion is detected it should be removed as soon as possible and part should be immediately treated to prevent further corro- sion. (a) For steel parts, with the exception of highly stressed components or stainless steel, it is possible to use abrasives, power brushes, steel brushes if operated manually and steel wool. Removing corrosion by products from highly stressed steel components (main gear steel spring) requires particular care. (b) For aluminum parts, treatment consists in mechanically removing as much as possible corrosion by products, applying corrosion inhibitor and replacing original finish. Steel wool, emery or steel brushes (unless stainless steel) along with other highly abrasive material should not be used since steel or emery par- ticles become embedded in the softer material causing corrosion. After cleaning surface corrosion, parts must be treated with an anti- corrosion finish prepared as follows: 4 liter solution containing 10% cromic acid with 20 drops of battery electrolyte. Accurate brushing with a sturdy fiber brush will rid of most of the corrosion and insure that the anti- corrosion agent will penetrate completely in the cracks. Leave the cromic acid solution on the part for at least five minutes and then remove excess with water or a damp cloth. Apply protective finish the same day in which treatment begins. P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-11 2st Edition, April 22th, 2008 INSPECTION & SERVICING 9 SERVICE BULLETINS NO. DESCRIPTION CL(#) N/C VALIDITY # O Optional P Prescribed R Recommended F Voluntary P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-12 2st Edition, April 22th, 2008 INSPECTION & SERVICING 10 SERVICING. 1 - Pitot and static ports – Check for obstructions. (see sect. E, Pitot & static system); 2 - Oil – Check oil level in reservoir located on the firewall (see: Mainte- nance Manual of the ROTAX 912ULS); 3 - Coolant – Check coolant level in the expansion tank located at the top of the engine; 4 - Fuel strainer – Drain off any water and sediment by opening drain valve and collecting an amount of fuel at lest equal to cup’s capacity. 5 - Fuel tank vents – Check vents for obstruction.(see sect. E, Fuel sys- tem) 7 - Battery – Check electrolyte level. 8 - Fuel filter – Remove and clean the fuel filter built in the electric pump. 9 - Engine oil – Replace oil and filter (see ROTAX 912ULS Maintenance Manual) initially after the first 25 hours. 10 – Brake fluid – Check level of brake fluid in the master cylinder lo- cated below the left seat. Add fluid as needed using MIL H5606 type UNIVIS J43. 11 – Carburettor air filter/s – Check filter/s and clean. Repeat operation more often if operating in dusty conditions. 12 - Gyro instrumentation (if installed) – In case of incorrect readings of vacum system, clean or replace central filter and, if needed, adjust vacum valve. D a i l y E v e r y 1 0 0 h o u r s P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-13 2st Edition, April 22th, 2008 INSPECTION & SERVICING 13 - Airspeed system drain – Slide off the left seat, disconnect the hose fit- tings and let drain the system 14 - Tyres – Check condition and maintain proper tyre pressure. FIGURE B-6 INSPECTION POINTS A s n e e d e d P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-14 2st Edition, April 22th, 2008 INSPECTION & SERVICING 11 LUBRICATION 11.1 INTRODUCTION Periodic lubrication of moving parts insures proper operation and ex- tends parts’ life considerably. Lubrication type, points and intervals are indicated below. Avoid excessive lubrication as this may cause external surfaces of hinges and bearing to collect dirt and dust. If part is not lubricated using a grease gun, grease part by hand re- moving excess. To grease main gear wheel bearings, first remove thrust bearings from wheel hubs, then clean surface using solvent, apply grease and re- assemble. NOTE - Use grease type MIL-G-3278 or equivalent (e.g. ESSO BEACON 325). 11.2 LUBRICATION POINTS (SEE FIG. B-7 & B-8) 1-2 Rudder hinges 3-4 Rudder control cable terminals 5 Stabilator control rod terminals 6-7 Stabilator support bearings 8-9 Trim-tab hinges 10 Tab control push-rod terminals 11 Stabilator pass-through rod 12 Stabilator control rod (inside cabin) 13-14 Aileron hinges 15 Differential ailerons hinges 16 Aileron control pushrods 17 Aileron control rods pass-trough 18 Flaps control pushrods 19-20 Flaps torque-tube support 21 Flap actuator terminals 22-23 Rudder pedals support 24-25 Rudder pushrods and cable terminals 26-27 Brake lever support 28-29 Control stick lever and support 30-31 Aileron control pulleys 32 Nose gear fork attachment hinge 33 Shock absorber attachment hinge 34 Nose gear strut attachment hinge 35 Steering pushrod terminals Grease canopy’s ball bearings and adjustable seat rails when necessary. P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-15 2st Edition, April 22th, 2008 INSPECTION & SERVICING FIGURE B-7 LUBRICATION POINTS P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-16 2st Edition, April 22th, 2008 INSPECTION & SERVICING FIGURE B-8 LUBRICATION EVERY 100 HOURS P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-17 2st Edition, April 22th, 2008 INSPECTION & SERVICING 12 INSPECTION Inspection points that are not in plain view may be accessed through spe- cific portholes and/or removal of panels or fairings as detailed below: 1 - Portholes on wing underside - access to aileron differential bellcrank, main spar and torque box; inspection of the wing tank outlet. 2 - Tailcone underside portholes - access to: stabilator control rod pass- through; front attachment of vertical stabilizer; inspection of aft struc- ture and of cables for rudder control. 3 - Tailcone end-fairing - access to stabilator torque tube and attachments to control lever; -attachment of vertical stabilizer aft spar; -rudder bellcrank; -trim actuator and pushrods. 4 - Aft cabin bulkhead and baggage compartment floor - inspection of aft fuselage section and attachments; -inspection of stabilator control system and of cable pulleys for rudder control; - access to flap actua- tor; Remove the seats to get the access to the aileron control cable turnbuckles. 5 - Forward cabin central fairing - access to the fuel valves and to the rudder control cables and turnbuckles. 6 - Instrument panel cover - access to instrumentation and radio. 7 - Engine cowling - access to engine and related systems; - access to main components of electrical system - access to nose gear strut and steer- ing assembly mechanism. 8 - Propeller spinner - access to propeller hub. P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-18 2st Edition, April 22th, 2008 INSPECTION & SERVICING 13 INSPECTION 13.1 INTRODUCTION • TECNAM considers inspection schedule outlined below compulsory for the oper- ational safety of the airframe and of the systems over an extended period of time. Described servicing requirements pertain to operation in non-extreme climatic conditions. • For the Rotax 912ULS engine, unless otherwise stated in the present Manual, it is compulsory to adhere to maintenance requirements as reported in the Engine Maintenance Manual furnished by the engine’s manufacturer (p/n 899372 Issue 0 of 1/9/1998 and later versions). • For the Tonini propeller, please refer to its Maintenance Manual • Airframe and systems inspection schedule is as follows: A. Inspections for airworthiness before first flight of day as specified in Flight Manual. B. Periodic inspections at every 100 hours. C. Special inspections, added to normal periodic. D. Singular inspection, when aircraft has been exposed to fortuitous events that may have damaged one or more of its components. If aircraft is rarely used, inspection at 100 hours must be performed yearly. * Replacement of parts subject to usage limitations are specified in par. 14.2 * Inspections and checks, unless specifically indicated, apply to the following STRUCTURES IN GENERAL - Condition of panel covers, ribs, frames, stringers etc., absence of cracks, deformation, rivet slackening, corrosion and any other ap- parent sign of damage. MOVING PARTS - Lubrication, security of attachment, safetying of bolts, absence of excessive play, proper adjustment, proper travel, condition of attachments and hinges, absence of corrosion, deformation, rivet slackening, cleanliness. FLUID LINES AND HOSES - Absence of leaks, cracks, dents, chafing, proper radius, deterioration. BOLTS AND ATTACHMENTS - Proper tightening and safetying, absence of cracks or nicks, damage to thread, wear and excessive play. P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-19 2st Edition, April 22th, 2008 INSPECTION & SERVICING 13.2 PERIODIC INSPECTIONS The first column in the following table describes the type of inspections to be carried out “Nature of Inspection”; the second column, divided in three parts, shows the “Inspection Intervals”. The symbol “” marks the relative inspection interval: 100 hours and the prospective interval for a special in- spection. Every porthole, fairing, panel etc. shall be removed to allow for inspection. Procedures explained in SERVICING (Chap. 10) are included in the in- spections. Instructions for actions following inspection are detailed in specific sec- tions pertaining to the aircraft group or system. It is suitable to use TECNAM-prepared inspection checklists. 13.3 SERVICING REQUIREMENTS NATURE OF INSPECTION INSPECTION INTERVALS (HRS) 100 Special ENGINE COMPARTMENT 1 Remove cowling and check for fuel, oil and coolant leaks; clean engine compartment  2 Visually inspect electric pump connections  3 Visually inspect engine mount and silent-blocks attachments  4 Visually inspect exhaust manifold, muffler and heat exchanger  5 Visually inspect air intake and carburetor feed circuit  6 Visually inspect coolant reservoir, radiator and circuit line  7 Visually inspect oil reservoir, radiator and circuit line  8 Check wires and electrical connections (low and high tension)  9 Check carburetor control and throttle movement  10 Clean electric fuel pump filter  11 Check density of battery electrolyte  (a) (a) Every 100h or more frequently in warm climate. P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-20 2st Edition, April 22th, 2008 INSPECTION & SERVICING NATURE OF INSPECTIONS INSPECTION INTERVALS (HRS) 100 Special FUEL SYSTEM 1 Check circuit lines for integrity and wetness  2 Check shutoff valves  3 Rinse tanks and clean exit filters 1200 FLIGHT CONTROLS 1 Check cables, terminals, pulleys and turnbuckles for integrity and proper condition of aileron and rudder control  2 Check pushrod terminals, lever hinge bushings, stabilator control pass-through  3 Check pushrod terminals and aileron control pass-through  4 Check flaps pushrod terminals  5 Check flaps actuator for integrity and play, attachment of termin- als and electrical connections 600 6 Check torque tube, levers and attachments for flaps control  7 Check resin control lever for trim actuator 600 8 Check trim control levers and pushrods for integrity and play  9 Check rudder pedals for integrity and play  10 Check control stick group for integrity and play  11 General check for proper tension level for control cables 600 MOVING SURFACES 1 Visually inspect integrity of the stabilator’s dacron wrap-around (if installed) for cracks, chinks, etc.  2 Visually inspect and check integrity of wrap-around paneling for rudder and flaps.  3 Check integrity and play of flaps and aileron hinges  4 Check integrity and play of stabilator attachments  5 Check integrity and play of trim-tab hinges  6 Check play and proper fastening of stabilator tubular spar  7 Check integrity of balance weight support  8 Check integrity and play of rudder lever and hinges  P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-21 2st Edition, April 22th, 2008 INSPECTION & SERVICING NATURE OF INSPECTIONS ISPEZIONE INTERVALS (HR) 100 Special WING 1 Visually check general condition of wrap-around skin and rivets  2 Disconnect wings from fuselage and check condition of attach- ments and for possible play 1200 3 Check condition of spar and wing structure through dedicated openings 600 4 Check integrity of stall warning unit (if installed)  FUSELAGE and EMPENNAGES 1 Visually check general condition of wrap-around skin and rivets  2 Inspect cabin truss for deformations and corrosion 600 3 Check seat rails and stops and safety belt attachments  4 Check internal condition of tailcone structure 600 5 Check attachment between vertical stabilizer and tail beam 600 6 Check integrity and fastening of stabilizer support assy 600 7 Check integrity and general condition of transparent surfaces and canopy  8 Check canopy rails and ball bearings for smooth movements  9 Check electric circuit wiring and antennae attachments from in- side of tailcone 600 10 Visually check the Wing Carry-Through beam and wing’s at- tachments. 600 MAIN LANDING GEAR 1 Check brake system (reservoir, master cylinder, lines and cali- pers)  2 Replace brake pads 600(a) 3 Visually check steel spring struts, connection clamp and fasten- ing of bolts  4 Remove legs and check for proper curvature and integrity 1200 5 Inspect main wheels for condition and fastening  6 Remove wheels, clean and grease wheel bearings 600(b) 7 Check fairing integrity and attachments  (a) when brake pad thickness is below 2.4 mm (b) initially at 100 hours P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-22 2st Edition, April 22th, 2008 INSPECTION & SERVICING NATURE OF INSPECTIONS INSPECTION INTERVALS (HR) 100 Special I NOSE GEAR 1 Inspect support truss for gear strut and attachment hinges  2 Check proper movement of steering levers and pushrods  3 Check integrity and play of strut-to-fork hinge attachment 600 4 Check shock hinge attachments 600 5 Check shock for general condition and state of rubber disks  6 Inspect wheel for condition and fastening  7 Remove wheel, clean and grease wheel bearings 600(c) 8 Remove nose gear assy for general safety check and inspection 1200 9 Check integrity of fairing and fairing attachments  L INSTRUMENT PANEL 1 General inspection of operation of flight and engine instruments  2 Check acoustic stall warning (if installed)  3 Check compass alignment 48 months 4 Check calibration of airspeed indicator and altimeter 1200 5 Check operation of avionic instrumentation (if installed)  6 Check operation of switches and fuses/breakers  7 Check generator charge  (c) initially at 100 hours. P2002 Sierra SECTION B M A I N T E N A N C E M A N U A L pag. B-23 2st Edition, April 22th, 2008 INSPECTION & SERVICING REFERENCE MEASUREMENTS SUMMARY TIGHTENING MOMENT FOR ATTACHMENT BOLTS AS A FUNCTION OF SHANK DIAMETER BOLT Class of resistance 8.8 TIGHTENING MOMENT FOR “UNI” ATTACHMENT BOLTS ∅ 4 = 3.1 Nm ∅ 6 = 10.4 Nm ∅ 8 = 24.6 Nm Attention: bolts connecting propeller to support flange albeit ∅ 8 must be tightened to 18 Nm. TIGHTENING MOMENT FOR “AN” ATTACHMENT BOLTS MIN MAX ∅ 6.35 = 9 Nm = 10 Nm ∅ 7.94 = 11 Nm = 16 Nm ∅ 9.52 = 18 Nm = 22 Nm CONTROL CABLES TENSION (FOR AILERON AND RUDDER ) VALUE : 20 dN ± 2 dN TIRE PRESSURE NOSE 15 PSI (1.0 BAR) MAIN 23 PSI (1.6 BAR) CONTROL SURFACES TRAVEL Ailerons Up 18°down 15° ±2° Stabilator Up 15°down 4° ±1° Trim 2° 12° ±1° Rudder RH 25° LH 25° ±2° Flap 0° -35° ±2° 2st Edition, April 22th, 2008 P2002 Sierra M A I N T E N A N C E M A N U A L SECTION C AIRFRAME pag. C-1 SECTION C AIRFRAME TABLE OF CONTENTS 1. WING ................................................................................................................. 2 2. RIGGING AND DE-RIGGING OF WING .................................................... 3 2.1. FLAP CONTROL (SEE FIG. C-4)............................................................................ 5 2.2. AILERON CONTROL (SEE FIG. C-5) ..................................................................... 5 3. HORIZONTAL TAIL....................................................................................... 7 3.1. STABILATOR BALANCE .................................................................................... 10 4. VERTICAL TAIL ........................................................................................... 10 5. FUSELAGE ..................................................................................................... 12 6. LANDING GEAR............................................................................................ 15 6.1. REMOVAL OF THE MAIN LANDING GEAR WHEEL (SEE FIG. C15)...................... 17 6.2. REMOVAL OF THE MLG WHEEL ROLLER BERINGS (SEE FIG.C16) ..................... 19 6.3. NOSE LANDING GEAR....................................................................................... 20 6.4. NLG WHEEL REMOVAL (SEE FIG.C-18)............................................................ 21 2st Edition, April 22th, 2008 P2002 Sierra M A I N T E N A N C E M A N U A L SECTION C AIRFRAME pag. C-2 INTRODUCTION The airframe consists of the following main groups as shown in figure C-1: 1) WINGS 2) FUSELAGE 3) EMPENNAGE 4) LANDING GEAR 5) POWERPLANT FIGURE C-1 MAIN GROUPS 1. WING Each wing is connected to the fuselage by means of three pin attachments. Wings are made up of a central light alloy torsion box (1); a light alloy leading edge (2) is attached to the front spar (5), while flap (3) and aileron (4) are at- tached to rear fake spar (6) through two hinges each. The torsion box, as shown in figure C-2 and with reference to numbers in paren- thesis, consists of a main spar (5) and a fake spar (6) that make up its front and rear vertical walls; A series of ribs (7) and wrap-around panels complete the structure. Front and aft spars are complete with wing-to-fuselage attachment fit- tings (8). Aileron uses "piano-hinges" type MS 20001-4 for direct attachment of aileron spar to wing spar. Flap hinges are external to wing torsion box and feature SKF GE10E type ball bearings. 2st Edition, April 22th, 2008 P2002 Sierra M A I N T E N A N C E M A N U A L SECTION C AIRFRAME pag. C-3 FIGURE C-2 RIGHT WING STRUCTURE The aileron is constructed of an aluminium spar to which a formed sheet metal skin and metal ribs are attached. Flaps are constructed of a centre spar to which front and rear ribs are joined; aluminium skin panels wrap-around flap structure. Wing tips are moulded epoxy resin, fibreglass reinforced. At the inboard end of the wing's leading edge is an integrated aluminium fuel tank with individual filler cap. Fuel tanks vent through tubes exhausting in the wing tip trailing edge. 2. RIGGING AND DE-RIGGING OF WING A. Drain fuel tank using drain tank and closing opposite side tank fuel circuit. B. Remove the wing’s composite root-leading edge. C. Remove all of the wing to fuselage fairings. D. Remove the fuel tank outlet inspection panel. Unfasten and remove the fuel hose from the tank’s outlet. Place temporary a cap on line to prevent spillage. Only for the left wing, disconnect also the fuel return line. E. For the right wing, disconnect stall-warning system wires (if installed). 2st Edition, April 22th, 2008 P2002 Sierra M A I N T E N A N C E M A N U A L SECTION C AIRFRAME pag. C-4 F. Disconnect the fuel quantity sensor wiring and, if present, the position lights wir- ing. G. Disconnect flap control (see fig. C-4) by removing roller bearings (6) that link push-pull rods (6) to flap control plate. H. Remove the luggage compartment floor to get the access to the aileron control circuit. I. Disconnect aileron control (see fig. C-5) by removing pins (4) that connect the small bar (3) to the pushrods (5). J. While supporting the wing, release at first the rear spar pin and then the two main spar’s pins. K. Replace pins in their original location and cap fuel lines. Reverse above procedure for reinstallation paying close attention to tighten main spar bolts to the recommended value (NAS 6608-28 torque 100 Nm). FIGURE C-3 WING FITTING PINS 2st Edition, April 22th, 2008 P2002 Sierra M A I N T E N A N C E M A N U A L SECTION C AIRFRAME pag. C-5 2.1. FLAP CONTROL (SEE FIG. C-4) Flap control system is push-pull type. The torque tube (1) is hinged to the cabin truss and connects the two moving surfaces by two levers (2). An electric linear actuator (4) governed by a switch on instrument panel controls the torque tube movements via a lever (3). Bolt, nut and cotter pin secure link. Two push-pull rods (5) are connected to the ends of the torque tube (1) and are located in the area between wing and fuselage thus facilitating inspection. The two push-pull rods controlling flap movement feature an adjustable linkage just before the roller bearings allowing trailing edge alignment. FIGURE C-4 FLAP CONTROL 2.2. AILERON CONTROL (SEE FIG. C-5) Aileron control system uses push-pull rods and bellcranks inside wing and steel cables and pulleys inside fuselage. Layout of flight control system inside cabin includes two pairs of pulleys which transmit movement from the two control sticks (1), linked in parallel by a rod (2), to a small bar (3) located under the baggage compartment floor in correspondence with main pushrods (5) issuing from the wings. Main rods (5) are connected to the small bar (3) using two pins (4). The two main rods (5), are routed through the ribs and are attached at opposite end to a bell crank (6) and a push-pull rod (7). 2st Edition, April 22th, 2008 P2002 Sierra M A I N T E N A N C E M A N U A L SECTION C AIRFRAME pag. C-6 The push-pull rod then crosses the wing’s fake spar to transmit motion. Linkage length is adjustable. FIGURE C-5 AILERON CONTROL To remove aileron, disconnect one end of push-pull rod and remove pins from hinges. Reverse above procedure to reinstall aileron insuring that, with stick vertical, the aileron’s trailing edge is aligned with wing’s trailing edge. Through access panels located on wing’s bottom, check that the bellcrank lever is in neutral position, i.e. the inside arm at right angle with spar axis. To remove a wing, release pins (4) that secure short bar (3) to main rods (5). The steel cable system is designed to insure proper cable tension without the need to check whenever the wings are removed. It is however recommended that periodic checks be carried out and proper tension applied by acting on the two turnbuckles (8) located below the two seats. Also check periodically that pulleys rotate freely and tolerance for entire linkage is within standards (ref. Section B).