INSPECTION PROTOCOL 25/100 HRS MT 03 / MTOsport

Transcription

1 Before You Begin / Leading Particulars Verify aircraft documentation is complete, see protocol cover sheet (AG-F-PCS). Identify all relevant - Airworthiness Directives (AD) - Service Bulletins (SB) for airframe (AutoGyro) and power plant (ROTA). Examine Historical / Maintenance Records and Log Book. Identify - Time Change Items (TCI) - Due dates for replacements, overhauls and special activities - Reported problems Note / check all - Serial Numbers - Manufacturer Life Limits (MLL/SLL) - Airworthiness Limitations (AWL) - Inspection/Overhaul Time Limits (TBO) according to Event & Configuration Log (AG-F-ECL), respectively Inspection Protocol Cover Sheet (AG-F-PCS). Preparation Work Inspect teeter angle 14 +/- 1 Remove rotor - teetering parts ( ). Measure dimension D1 ( ) and record value in Event and Configuration Log (AG-F-ECL). D1 measured: mm Clean aircraft. Remove dirt, dust, leak fluids and loose items. Refer to Rotor System Inspect rotor - teetering parts ( ). Disassemble rotor - teetering parts ( ) and inspect rotor blades ( ). Re-assemble rotor - teetering parts ( ). Inspect rotor hub bolts ( ). 200h / 2y Nose gear Inspect nose wheel general condition, correct pressure, condition of tread, correct seating of the valve and cap, secure installation, no play in the wheel bearings. Inspect nose wheel fork general condition, secure installation, freedom of movement, no excessive play, distortion or damage. Page 1/7 - AG-F-PCA-MT-EN-V1.J

2 Cockpit Inspect pneumatic assembly general condition, correct attachment. Inspect wiring and pitot/static lines general condition, correct attachment, chafing, tears/cracks, hardening, kinks or sharp direction changes. Replace if necessary. Inspect correct attachment of instruments, controls and similar. Voice radio ATR833: Check PTT-Button selection according to manufacturer documentation Operation and Installation. Recommended selection: Single mic Nose Gear, Rudder and Control Perform adjustment of pedals and rudder ( ). Inspect nose wheel/rudder control general condition, security, freedom of movement, no damage or chafing. Grease pedals with AG-GRS-01 (WHS 2002), if required. Inspect rudder control cable tension and condition (pedals neutral, use tensiometer S.WZ96) Cable tension 20 lbs (+/- 5 lbs) DOM 11/2009 and later 35 lbs +/- 5 lbs Low cable tension may indicate a hard tail strike with possible damage to other components. Contact AutoGyro customer support. Check turnbuckle secured with safety wire or by shrinking hose. Install if missing. Inspect rudder general condition, correct attachment, freedom of movement, no excessive play, cracks, chafing. Inspect rudder control connections general condition, correct operation, secure installation, cleanliness. Lubricate deflection rollers with AG-LUB-01 (Ballistol Oil). Main Gear and Brakes Inspect throttle/brake unit for correct operation, secure installation, condition of ratchet teeth, brake fluid level, no leaks. If level is low, check brake pad wear! Replenish brake fluid if necessary. Inspect brake line between actuator and reservoir (DOM 02/2011 and later) for condensate. Replace with M.FA if necessary. Inspect main wheels general condition, correct pressure, condition of tread, correct seating of the valve and cap, secure installation, no play in the wheel bearings. Check presence and condition of slip mark. Check wheel spats (if installed) for secure installation and general condition, no cracks. Inspect brake lines for secure installation, no leaks, no chafing. Inspect wheel brakes for secure installation and operation, no leaks. Inspect clearance of brake caliper to suspension bow ends min. 2 mm for free actuation of brake. Inspect brake pads wear state (check wear mark / grove) and condition (burr formation). Change if necessary. Page 2/7 - AG-F-PCA-MT-EN-V1.J

3 Inspect brake discs condition, torque check 4 x support bolts, check presence of serrated washers. Check main gear spring spar general condition, secure installation, no cracks. Remove bolts from main gear spring spar attachment individually and inspect for corrosion. Replace if required. Re-install and torque-tighten with 15Nm. (initially at 400hrs) Pre-Rotator Check clutch alignment and condition, straighten if necessary. Unload belt and inspect play of small pulley. If play is evident, remove and re-install pulley according to ( ). Inspect guide pulleys and brake for wear and replace if necessary. Inspect retraction spring and support for possible damage or cracks. Replace or rework if necessary. Spray clutch belt with Silicone oil. Check adjustment of one way flow control valve, adjust if necessary. Basic setting about ¼ rev. open (grey dial) or about 2 rev. open (black dial). If drive pinion rattles without engaging, close valve further. Inspect the 90-degree-gearbox general condition, secure installation, smooth run, no leaks. Only DOM 06/2012 and before: Check that configuration state of connecting bolts of both cardan joints is documented to conform to version If not, replace with M.PR11 and document. Check pre-rotator drive shaft with sliding shaft coupling for general condition, secure installation, smooth run, no bearing play, distortion or cracks (especially at the flanges). Lubricate sliding shaft coupling with AG-GRS-01 (WHS 2002). Spray drive shaft and cardan joints with (Hohlraumspray). Inspect Viton rings in support plate and replace if necessary. Inspect clearance trim cylinder to pre-rotator drive shaft and modify if necessary. Inspect pre-rotator upper engagement ( ). Check backlash If the play has increased, contact Airworthiness (airworthiness@auto-gyro.com). Grease with AG-GRS-01 (WHS 2002). Rotor Head Inspect rotor head bridge according to Perform torquecheck on main bolt nut (120 Nm). Determine gimbal head configuration state and convert to gimbal head II, if necessary. Proceed acc. to Inspect rotor gimbal head for correct operation and secure installation of all attached parts. Proceed according to and record control angles (see below). Grease with AG-GRS-01 (WHS 2002). Page 3/7 - AG-F-PCA-MT-EN-V1.J

4 Direction Required Measured Fwd: - 1 +/- 1 Aft: 16 /18/ 20 +/- 1 RH: 7 +/- 1 LH: 9 +/ : MT : MTOsport no GKS, Australia 20 : GKS (gekürzte Steuerwege, shortened stick travel) Only gimbal head ll (spring washers): measure breakout force at forward control stick grip ( ). Adjust if necessary. Inspect hang point condition of bolts and locking devices (self-locking nuts). No cracks or deformation. Inspect hang point, no deformation, no cracks in welding seams (particularly at start/end points). Perform a thorough inspection of the frame near the mast root and check for cracks due to overload or vibration. Consider retrofit of tie bars at mast root ( ) Flight Control Inspect flight control stick general condition, operation (freedom of movement for full travel), secure installation, cabling, no damage or chafing. Inspect ball bearings in control stick base hinge. Inspect main control rod and ball joints general condition, freedom of movement, secure installation, no damage or chafing. Replace bolts of flight control base link (M.STE03). Inspect freedom of movement of base link ( ). Inspect condition of ball bearings in both bell cranks. Inspect rotor flight control play ( ). Pneumatic system Check secure connection of all pneumatic lines/harness. Ensure no chafing. Check the pneumatic control and compressor for correct operation, secure installation, no leaks or chafing of the pneumatic lines. Replace dryer cartridge ( ). Fuselage Inspect fwd seat and safety harness general condition, correct operation, secure installation, no damage. Inspect rear seat and safety harness general condition, correct operation, secure installation, no damage. Instructor Mag Switches (if installed): Check presence and condition of safe-guards. Page 4/7 - AG-F-PCA-MT-EN-V1.J

5 Check all cockpit fittings general condition and secure installation, no chafing (wiring harnesses). Especially check cables of radio and transponder. Grease hinge bolt of choke control level. Check front windshield general condition, cleanliness, no cracks. Check presence and condition of slip indicator. Check aft windshield general condition, cleanliness, no cracks. Pitot-Static Inspect pitot /ram-air tube general condition, secure installation, no obstructions. Inspect static ports (if installed) open, placard installed, no blockages, no leaks. Clean and dry all pitot and static lines as required. Proceed according to Propeller General: Inspect propeller blades for cracks, delamination or impact. Dents or score marks may indicate a propeller strike with possible damage to the propeller and other components. HTC: Perform a visual inspection of the hub and re-torque flange bolts with 15 Nm. IVO: Inspect blades (tap test), brushes and tension strips according to manufacturer's documentation. Re-torque flange bolts with 40 Nm. Inspect propeller hub secure installation. Check that all propeller blades have same pitch. IVO Propeller: Inspect cable routing at arm. Inspect spinner with spinner mounting (if installed) general condition, secure installation, no cracks. Unscrew one bolt and confirm spinner bolts are secured with AG-BAS-02 (Loctite 243). Secure and re-install bolt. If necessary, unscrew, secure and re-install all remaining spinner bolts according to Structure / Stabilizer Check keel tube general condition, secure installation, weld seams, no cracks. Inspect stabilizer general condition, secure installation, no chafing, cracks, loose mountings. Check drain holes open. Inspect the engine mounting brackets general condition, no cracks or distortion. Inspect the engine mounting bushes for secure installation and condition of rubber. Replace, if torn or porous. Inspect the engine mounting ring frame for secure installation, no chafing or distortion. Fuel System Inspect fuel tanks secure and correct installation. Empty fuel tanks must have light free play in all directions under force by hand. Page 5/7 - AG-F-PCA-MT-EN-V1.J

6 Inspect fuel tanks general condition, fuel level indication, no leaks, cracks, chafing or distortion. Fuel level markings present. Check function of cockpit fuel level indicator (if installed). Inspect fuel venting lines condition and routing. Check fuel drain valves not leaking. Inspect fuel filters according to and replace, if necessary ( and AG-F-ECL). Inspect the electric fuel pump(s) for correct function (sound on operation), secure installation, no chafing. Inspect all fuel lines condition, secure installation, presence of fire protective sleeve, no hardening, tear, chafing or kinks. Reconfigure fuel shut-off valve, if installed ( ) Open carburettor float chamber, remove and weigh floats. Floats must not weigh more than 3.0 g in drained condition. Removal and installation in accordance with documentation of the engine manufacturer. Engine and Accessories Inspect the oil cooler general condition, secure installation, cleanliness, no leaks, chafing or deformed fins. Inspect all hoses and pipes of the oil system for secure installation, no leaks, chafing, tears/cracks, hardening, kinks or sharp direction changes. Check firm seating of hoses within the fittings. Inspect the thermostat assembly for secure attachment, no cracks, leaks or porous hoses. Inspect all coolant hoses condition, secure installation, routing, no leaks, chafing, tear or hardening/porosity. Check presence/condition of heat protection on coolant hose from cylinder 2 and install/renew, if necessary. Inspect the radiator(s) condition, secure installation, cleanliness, no leaks or damage. Make sure expansion tank is mounted floating to prevent fretting or chafing. Use zip ties and spacers. If loose, remove protection rubber from underside completely. Check starter battery for security, deformation, cracks, chafing, leaks, oxidization, pole cover, charging state/condition. Inspect exhaust system general condition, secure installation, no leaks, cracks (tap test) or loose rivets. Check presence and condition of retaining springs and safety cable. Replace, if necessary. Check the silencer for secure installation of clamps, rivets and safety wire. Check safety wire of the screw clamps. If the securing worm screw is able to rotate, secure through the screw slot to prevent rotation and loss in case of failure. If removed, install propeller ( ). Check the propeller to frame clearance approx. 5 cm. Page 6/7 - AG-F-PCA-MT-EN-V1.J

7 Power Plant Perform power plant maintenance according to the engine manufacturer s documentation and include supplementary procedures below. Check the manufacturer's website and make sure to have the latest version available. Also check for applicable airworthiness directives, service bulletins and service instruction. Use the engine manufacturer's maintenance protocol/checklist and attach to this protocol. Supplementary Procedure: Oil Change When draining, let the oil run through a 190 micron screen and attach photo to this protocol. Supplementary Procedure: Inspection of Magnetic Plug Photo-document magnetic plug (before cleaning) and attach photo of magnetic plug to this protocol. Supplementary Procedure: Inspection of Old Oil Filter Attach photo of the filter mesh of the cut-open oil filter to this protocol. Supplementary Procedure: Refilling of Oil Record type of oil in protocol cover sheet (AG-F-PCS). Perform Ground Test Run ( / AG-F-PGR-CD). Finalization Work Carry out a tool and loose-article check. Re-install all service covers ( ). Date Signature of inspector / responsible Interval Initial Remarks DOM : perform item each time???h: perform item each??? hours (example: 200h)?y: perform item every? years (example: 2y)???h/?y: perform item every??? hours or? years, whichever occurs first (example: 400h/4y) Put initials when performed or complied with. Put N/A for not applicable or N/P for not performed. Remember to enter initials and full name on cover sheet for identification Make a unique note (i.e. subsequent number), fill in remark on extra sheet and attach sheet(s) or any additional material (such as photos) to this protocol Date Of Manufacture Page 7/7 - AG-F-PCA-MT-EN-V1.J