M24C PLUS MAINTENANCE SCHEDULE

6.4.5 Equipment and Environmental............................................................................................................ 6.4.6 Engine:............................................................................................................................................... 6.4.7 Rotors ................................................................................................................................................ 6.4.8 Gyroplane Lubrication........................................................................................................................ 10 10 11 21 21 22 22 22 22 23 23 23 25 25 27 27 29 29 29 30 31 5 5 5 5 5 5 6 6 6 6 6 7 7 4 4 4 4 8 8 8 3 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.4.9 Powerplant Installation:........................................................................................................................ 6.4.10 Air Induction....................................................................................................................................... 6.4.11 Exhaust:............................................................................................................................................. 6.4.12 Fuel System....................................................................................................................................... 6.4.13 Electrical System .............................................................................................................................. 6.4.14 Instrument Systems........................................................................................................................... 6.4.15 Ignition .............................................................................................................................................. 6.5 2-Year Check (Not Applicable) .............................................................................................................. 6.6 300 Hour / 3-Year Check ....................................................................................................................... 6.6.1 Flying Controls .................................................................................................................................... 6.7 500 Hour Check ..................................................................................................................................... 6.7.1 Flying Controls .................................................................................................................................... 6.7.2 Rotor ................................................................................................................................................... 6.7.3 Prerotator flexible shaft........................................................................................................................ 6.8 1000 Hour Check ................................................................................................................................... 6.8.1 Powerplant Installation: ....................................................................................................................... 6.9 5-Year Check…………………………………………………………………......………….......................... 6.9.1 Magni Gyro rubber components…………………………………………..………………........................ 7 Lifed Items............................................................................................................................................... 32 32 33 33 33 33 34 34 35 35 36 36 36 36 37 37 37 37 38 4 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 1 FOREWORD 1.1 SCOPE The scope of this document is to provide a detailed breakdown of the maintenance tasks to be carried out to provide continued airworthiness, and the required intervals. Details of the approved method of undertaking the appropriate maintenance is outlined in the Magni Gyro M24C PLUS maintenance manual (Ref 2) The schedule is based upon the CAA publication CAP 412 „Light Aircraft Maintenance Schedule – Helicopters‟ and the Magni Gyro srl maintenance Schedule for the M24C PLUS Gyroplane This document refers only to airframe maintenance and those engine ancillaries which are specific to the M24C PLUS Gyroplane. All engine maintenance should be undertaken in accordance with the appropriate engine manufacturer‟s maintenance schedule. 1.2 ATTACHMENTS 1.3 REFERENCES Ref 1 Ref 2 Ref 3 CAP 412 – Light Aircraft Maintenance Schedule – Helicopters 237-00-24C M24C PLUS Maintenance Manual ROTAX 91S iS Maintenance Manual Issue 2 5 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 2 Responsibilities and Standards 2.1 Owner/Operator Responsibilities Owners/operators are responsible for the accomplishment of the maintenance prescribed in this schedule. 2.2 Certifying Persons Responsibilities Certifying persons must use their engineering skill and judgment in determining the depth of inspection needed and other matters which could affect the airworthiness of the gyroplane. In order to claim any alleviation on subsequent inspections, the gyroplane maintenance records must record the extent of previous inspections upon which the alleviation is based. Certifying persons are responsible for recording in the appropriate log book or worksheet, any defects, deficiencies or additional maintenance required as a result of implementation of the schedule. 2.3 General Inspection Standards The general inspection standards applied to individual task inspections must meet the recommended standards and practices of Magni Gyro and are published in M24C PLUS maintenance manual. In the absence of general inspection standards, refer to CAA CAP 562 Civil Aircraft Airworthiness Information and Procedures (CAAIP) or other CAA recommended standards and practices. Inspections may be carried out without component removal or dismantling unless considered necessary or where required by the schedule. 2.4 Airworthiness Life Limitations (Retirement/Scrap Lives) Airworthiness life limitations shall be those published by the CAA and those defined in Section 7 of this report. Airworthiness life limitations shall be recorded in CAP 543 Time Limited Task, Additional Inspections and Component Change Record, or an appropriate equivalent. 2.5 Airworthiness Directives All applicable Airworthiness Directives and Mandatory Permit Directives, issued by the CAA, must be complied with. Compliance with Airworthiness Directives and Mandatory Permit Directives shall be recorded in the gyro- plane log books (Part C of CAPs 398, 399 and 400), or an approved equivalent 6 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 2.6 CAA Generic Requirements (GRs) All applicable mandatory CAA Generic Requirements (CAP 747) must be complied with. Compliance with CAA Generic Requirements shall be recorded in Part C of the relevant log books, reference CAPs 398, 399 and 400, or an approved equivalent. 2.7 Overhaul, Additional Inspections and Test Periods Overhaul, additional inspections and test periods are those recommended by Magni Gyro UK Ltd. CAA may vary or mandate overhaul and test periods and additional inspections by the issue of an Airworthiness Directive or CAA Generic Requirement. (Note: GR No. 24 and GR No. 17 relate to engines and propellers respectively). The overhaul, additional inspections and test periods shall be recorded in CAP 543 Time Limited Task, Additional Inspections and Component Change Record, or an appropriate equivalent. 2.8 Instructions for Continuing Airworthiness Instructions for continuing airworthiness consist of in-service data published by Magni Gyro UK Ltd and must be considered by the owner/operator in addition to this maintenance schedule in order to ensure the approved maintenance schedule remains valid for the M24C PLUS. Instructions for continuing airworthiness (Service Bulletins, Service Letters, etc.) should be formally technically assessed by the owner/operator and adopted if required to ensure operational safety and reliability. Instructions for continuing airworthiness applicable to the gyroplane shall be included in CAP 543 Time Limited Task, Additional Inspections and Component Change Record or an appropriate equivalent, and form part of this maintenance schedule. Compliance with adopted continuing airworthiness information shall be recorded in Part C of CAPs 398, 399 and 400, or an approved equivalent. 2.9 Changes (Repairs or Modifications) Approved „changes‟ which have been carried out to the gyroplane, engine, components and radio after original manufacture, must be recorded in the appropriate log book(s). Any recurring inspection, or maintenance task resulting from approved „changes‟, shall be recorded in CAP 543 Time Limited Task, Additional Inspections and Component Change Record, or an appropriate equivalent. 2.10 Duplicate Inspections When required to perform a critical task inspection or following initial assembly or disturbance of a control system or vital point, the procedures outlined in British Civil Airworthiness Requirements (BCAR) Section A/B, Chapter A6-2/B6-2 and A5-3/B5-3 shall be applied. must be recorded in the appropriate worksheet, log book or aircraft technical log. 7 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 2.11 Scheduled Maintenance Worksheets Worksheets shown in Section 6 must be issued and the tasks certified for all scheduled maintenance checks. These worksheets become part of the maintenance records required to be kept by the owner/operator. All maintenance carried out in connection with a particular check should be certified on suitably referenced worksheets and included in the gyroplane records. These worksheets must be cross- referenced in the appropriate log book(s) giving general details of the additional maintenance carried out. 2.12 Definitions Throughout the schedule the following terms and abbreviations have the stated definitions; Service/Lubrication (Service/LUB) The term „Service or Lubrication‟ requires that a component or system should be serviced and/or replenished as necessary with fuel, oil, grease, water, oxygen, etc., to a condition specified in the appropriate maintenance manual. The term „service‟ may also be used to require filter cleaning or replacement. Inspect (INSP) An „Inspection‟ is a visual check performed externally or internally in suitable lighting conditions from a distance considered necessary to detect unsatisfactory conditions/discrepancies using, where necessary, inspection aids such as mirrors, torches, a magnifying glass etc. Surface cleaning and removal of detachable cowlings, panels, covers and fabric may be required to be able to satisfy the inspection requirements. Operational Check (OP/C) An „Operational Check‟ is a test used to determine that a system or component or any function thereof is operating normally. Functional Check (F/C) A „Functional Check‟ is a detailed examination of a complete system, sub-system or component to determine if operating parameters are within limits of range of movement, rate of flow, temperature, pressure, revolutions per minute, degrees of travel, etc., as specified in the M24C PLUS maintenance manual. Measured parameters should be recorded. Check (CHK) A „Check‟ is the verification of compliance with Magni Gyro UK Ltd recommendations. Continuing Airworthiness Means all of the processes ensuring that, at any time in its operating life, the gyroplane complies with the airworthiness requirements in force and is in a condition for safe operation. 8 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 3 Permit Maintenance Release 3.1 Maintenance Authorisation When specified on the conditions of the Permit to Fly, except for maintenance permitted to be carried out by the pilot (see Section 3.2), the aircraft shall be certified as fit for flight following maintenance by the issue of a Permit Maintenance Release (PMR). The Permit Maintenance Release shall be issued covering the particular maintenance carried out and is required for scheduled maintenance, overhaul, modification, repair, replacement, defect rectification or compliance with Mandatory Permit Directives. If maintenance is carried out on the aircraft or its equipment whilst operating on a Permit to Fly for test purposes or for ferry purposes, when specified on the conditions associated with the Permit, a Permit Maintenance Release (PMR) shall be issued in respect of the work carried out. The aircraft logbooks/worksheets shall contain particulars of the maintenance carried out and shall include the following certification statement: The work recorded above has been completed to my satisfaction and in that respect the aircraft is considered fit for flight. Signed ......................... Authorisation Ref. ......................... Date ......... ................ Permit Maintenance Release (PMR) shall be issued only by persons specifically authorised by the CAA for the purpose. 3.2 Pilot Maintenance Pilot maintenance in respect of aircraft below 2730 kg MTWA to be operated on a Permit to Fly may be carried out in accordance with either the prescribed repairs and replacement privileges in the Air Navigation Order, Section 3 General Regulations; Regulation 16; or for those aircraft with a Permit to Fly validated by a person approved by the CAA for that purpose, pilot maintenance may be performed to the extent permitted by the procedures of that organisation. NOTE: For pilot maintenance the issue of a Permit Maintenance Release (PMR) is not required. The pilot must enter details of the maintenance carried out and include his pilot‟s licence number with his signature in the appropriate log books. Permitted pilot maintenance includes the following actions: 9 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 1 . Replacement of landing gear tyres. (Including removal and replacement of wheels, cleaning and servic- ing of wheel bearings, application of creep marks, removal and refitting of brake units to the extent required for wheel removal and the removal and the renewal of brake pads/linings when special tools are not required. Replenishment of hydraulic brake system fluid level. 2. Replacement of defective safety wiring or split pins excluding those in engine, transmission, flight control and rotor systems (but including those designed to be pilot-maintainable and shown in the pilots handbook, eg the teeter-bolt split pin and rotor assembly bolts). 3. Repairs to upholstery and decorative furnishing of the cabin or cockpit interior when repair does not require dismantling of any structures or operating system or interfere with an operating system or affect the structure of the aircraft. 4. Removal, replacement and refitting of side doors 5. Repairs (including removal and refitting), not requiring welding, to fairings, wheel spats, non- structural cover pla tes and cowlings. 6. Replacement of safety belts or safety harness. 7. Replacement of seats or seat parts not involving dismantling of any structure or of any operating system. 8. Replacement of bulbs, reflectors, glasses, lenses or lights. 9. Replacement of any cowling not requiring removal of the propeller, rotors or disconnection of engine or flight controls. 10. Replacement of spark plugs (including removal, cleaning, gapping, testing and refitting of all spark plugs). 11. Replacement of batteries. 12. Replacement of rotors, tail surfaces and controls, the attachments of which are designed to provide for assembly immediately before each flight and dismantling after each flight. 13. Replacement of main rotor blades that are designed for removal where special tools are not required (as is the case for Magni gyroplanes). 14. Removal and refitting of rotor blades from/to the hub bar 15. Replacement of VHF communications equipment, only if is not combined with navigation equipment. 16. Manufacture and installation of required cockpit placards and notices. 17. Lubrication of the aircraft (including prior cleaning of hinges) 18. Inspection of engine induction air filter.(including removal, cleaning and refitting (with wirelock). 19. Replacement of fuel filters, including removal, cleaning and refitting). 20. Changing of engine oil (including removal, cleaning/replacement, refitting of oil filter, and wirelock of sump bolt). 21. Adjustment of the lateral position of the trim spring 10 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 4 Check Cycle and Variations 4.1 The Maintenance Check Cycle Check title Content Period Certification Check A Check A Prior to the first flight of the day. Pilot 25 hour check 25 hour check items. Not exceeding 25 flying hours. A3-7 Engineer 100 hour check 100 hour check items. Not exceeding 100 flying hours. A3-7 Engineer Annual check 100 hour and annual check items. Not exceeding 12 months (see Note 5). A3-7 Engineer 300 hour / 3yr 300 hour / 3 year check items 300 flying hours or 3 years, whichever is sooner A3-7 Engineer 500 hour check 500 hour check items Not exceeding 500 flying hours A3-7 Engineer 1000 hour check 1000 hour check items Not exceeding 1000 flying hours A3-7 Engineer 11 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 4.2 Permitted Variations (see Notes) NOTES: 1. Permitted variations may not be applied to applicable airworthiness life limitations, airworthiness directives, Generic Requirements or overhaul and test periods. 2. Permitted variations for tasks controlled by flying hours should not be understood to be a maintenance planning tool, but as an exceptional means to allow the operator to fly for a limited period of time until the required maintenance is performed. 3. Any application of a permitted variation to the maintenance check cycle period must be recorded in the appropriate log book(s) together with the reason for the variation by a person who is authorised to sign the log book entry for that particular check. Details of the permitted variation must be made visible to the pilot. 4. Permitted variations are not required to be deducted from the next scheduled check. 5. The annual check may be anticipated by a maximum period of 62 days without loss of the continuity of the maintenance check cycle. Thus, for example, where the full 62 days is invoked, the following annual check would become due 14 months after the completion of the annual check which was anticipated. The period by which the annual check was anticipated and the date of the next annual check shall be recorded in the appropriate log book(s). Tasks controlled by flying hours Maximum Variation 25 hour 10% 100 hour 10% 500 hour 10% 600 hour 10% Tasks controlled by calendar time Maximum Variation 6 Months 1 Month Annual None 3 year / 300 hours 3 months / 10% Tasks controlled by more than one limit The more restrictive limit shall be applied unless otherwise specified 12 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 5 Pre-Flight 5.1 Pilot’s Pre-Flight Check / Check A – Prior to First Flight of the Day Pre-flight checks / Check A are to be carried out in accordance with the Gyroplane Flight Manual. Note: Initially the daily/pre-flight checks may seem a long procedure, but with experience the pilot will soon become familiar with all aspects of the aircraft and what is correct or not. The check is organised into a logical pattern that makes one complete circuit of the gyroplane and becomes second nature with practice. This pattern starts with the inspection of the instrument panel and continues around the gyroplane. INTERNAL CHECKS A. INSTRUMENT PANEL 1. MASTER .....................................................switch OFF 2. All breakers..................................................OFF (pulled out) 3. Instrument panel and instruments ..............Serviceable 4. Nameplates.................................................markings and placards Installed and readable B. PEDALS 5. Rudder pedals ...........................................Condition and linkage tight Full and free movement over the full range (nose wheel off ground) Function and correct adjustment for the pilots height 6. Control rods ...............................................Condition 7. Pedal .........................................................assembliesCorrectly attached to the floor C. CONTROL STICKS 8. Control sticks............................................. Full and free movement 9. Control rods............................................... Attached correctly and not damaged 10. Pre-rotator lever...................................... Function 13 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 D. INSIDE OF COCKPIT 11. Cargo ............................................................................................................Stored 12. Equipment .....................................................................................................Attached 13. Debris ............................................................................................................None 14. Seats..............................................................................................................Attached and not damaged 15. Pilot and passenger restraint systems ..........................................................Not damaged Free of cuts, chafing, contamination, worn latches, loose or pulled stitching Serviceable E. LEVERS 16. Throttle lever..................................................................................................Full and free movement 17. Brake lever ....................................................................................................Check condition and that maximum braking power is available Lever returns to the OFF position when released F. DOORS 18. Doors ............................................................................................................Correct attachment 19. Opening system and stays ...........................................................................Operational condition 20. Locking system.............................................................................................Operational condition 21. Hinges...........................................................................................................Condition 22. Transparencies and bonding of transparencies to the frame of the door .....Condition DOOR WARNING SYSTEM Functioning of the door locking warning system should be confirmed by the following tests. With both doors in the „OPEN‟ position and the MASTER switch „ON‟ close the pilot’s door and then move the pilots handle to the locked position. Then move the co-pilot‟s handle to the locked position. The warning light should remain illuminated and the rotor rpm gauge should remain inactive because the co-pilots door is open. Move the co-pilot’s handle to the open position; move the pilot’s handle to the open position and open the pilot’s door. Close the co- pilot’s door and move the co-pilot’s handle to the locked position; then move the pilots handle to the locked position. Again the warning light should remain illuminated and the rotor rpm gauge should remain inactive because the pilot’s door is open. Move the pilot’s handle to the open position; close the pilot’s door and move the pilot’s handle into the locked position. The warning light should extinguish and the rotor rpm gauge becomes active as all doors and handles are now closed and locked. Open the co- pilot’s handle to confirm that the light becomes illuminated once more and the rotor rpm gauge de-activates. 14 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 It is essential that the checks on the door warning system are performed as described and in this exact order. This will enable each of the four switches functionality to be determined in turn and a single fault with any of the switches will be able to be detected. EXTERNAL CHECKS A. COCKPIT AND FUSELAGE - RIGHT HAND SIDE 1. External surface of the fuselage....................Condition Foreign objects, Clean 2. Windscreen....................................................Not damaged Clean Visually clear 3. Static port right hand side..............................Clean and not blocked 4. Fuel cap ........................................................Condition Installed correctly 5. Engine hatches..............................................Installed correctly All screws are installed and tight B. UNDERCARRIAGE - RIGHT HAND SIDE 6. Undercarriage leaf spring and mounting bolts ............................................Condition Bolts installed and tight Free of cracks or impact marks and not damaged C. WHEEL AND WHEEL PANT - RIGHT HAND SIDE 7. Wheel attachment, hub and axle...................Condition Bolts are installed and tight 8. Tire.................................................................Correct inflation pressure Condition Free of rubbing marks and not damaged 15 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 9. Brake system.................................................Condition Components are not damaged No fluid leaks or chafing of brake lines Brake line pipes ENGINE COMPARTMENT INSPECTION - RIGHT HAND SIDE A. COOLANT LEVEL 1. Expansion tank ..............................................Correct coolant level. 2. Overflow bottle...............................................Correct coolant level (between minimum and maximum marks) B. ENGINE OIL LEVEL 3. Remove the cap C. ENGINE MOUNT - RIGHT HAND SIDE 5. Welding points ...............................................Free of cracks, signs of corrosion, chafing and not damaged 6. Vibration dampers .........................................Condition and age Bolts are tight 7. Linkages and cables......................................Tight Condition Free of corrosion, leaks or chafing and not damaged 8. Airbox fixing...................................................Tight Condition Free of corrosion or chafing and not damaged 9. Wirings and connections ...............................Tight Condition Free of corrosion or chafing and not damaged 16 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 10. Cooling system ............................................Tight Condition Free of corrosion, leaks or chafing and not damaged 11. Oil reservoir..................................................Tight Condition Free of corrosion, leaks or chafing and not damaged 12. Oil filter.........................................................Tight Condition Free of corrosion, leaks or chafing and not damaged 13. Spark plugs and their connection coverings ...........................................................Tight Condition Free of corrosion, leaks or chafing and not damaged 14. Engine probes, connectors and fasteners....Tight Condition Free of corrosion, leaks or chafing and not damaged 15. Oil and coolant hoses and clamps ...............Tight Condition Free of corrosion, leaks or chafing and not damaged 16. ECU and its mount .......................................Tight Condition Free of corrosion, leaks or chafing and not damaged 17. Exhaust system, joints and mounts...............Tight Condition Free of corrosion, leaks or chafing and not damaged 17 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 18. Pre-rotation assembly, belts, cables and flexible shaft................................Tight Condition Free of corrosion, leaks or chafing and not damaged 19. Battery and connecting wires ..........................Tight Free of signs of overheating, excessive venting, corrosion of terminals or leakage of acid 20. Voltage regulator and starter contactor ...........Free of signs of overheating, short circuits or corrosion D. CONTROL RODS 21. Safety points on the control rods, linkages, bearings and fiberlock nuts....................................Tight Condition 22. Rod end bearings ............................................Insignificant play in the Uniball Free of corrosion and not damaged 23. Control rods .....................................................Shape (straight) Not damaged Free to rotate a small amount around their axis when given a small twist. If unwanted force is necessary or they will not rotate it can indicate a problem with the bearing E. TRIM SYSTEM 24. Trim actuator.....................................................Correct attachment 25. Control cable, springs and electrical connections.............................................................Condition F. CLOSURE OF THE RIGHT HAND SIDE FAIRING Close the right hand engine hatch and tighten the fasteners with a screwdriver a 1/4 turn. Make sure the right hand engine fairing is closed and fastened correctly. 18 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 ROTOR HEAD - RIGHT HAND SIDE 1. Nuts of the rotor head....................................Tight All safety visible locking systems are installed and functional 2. Rotor head and hub bar assemblies .............No cracks, wear, corrosion or rubbing and not damaged 3. Ring gear .......................................................Condition Ring gear teeth are not damaged 4. Flexible shaft and Bendix pre-rotation gear....Sufficiently coated with grease REAR SECTION A. RADIATORS 1. Radiator surfaces ..........................................Free of fluid leaks or chafing and not damaged 2. Clamps and fixing points ...............................Tight 3. Fan and its support........................................Fixed and free to spin B. PROPELLER 3. Whole surface of each blade.........................Not damaged or detached Clean 4. Hub and bolts of the propeller support flange ................................................................Tight C. PREROTATION SYSTEM 6. Pre-rotation assembly....................................Correct position 7. Belts...............................................................Correct tension Condition and wear 8. Pre-rotation system .......................................Function 9. Belt tension pulley lever.................................Free movement 10. Pulley brake shoe ........................................Correct position 11 Pulleys ..........................................................Condition (wear) 12. Tailplane surfaces........................................Free of cracks and not damaged Clean 13. Connecting bolts..........................................Tight 14. Rudder .........................................................Installed correctly Free movement 19 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 15. Tail wheel ....................................................Condition Free movement 16. Rudder cables .............................................Correct tension 17. Wire-locking of the turnbuckles ...................Lock-wire installed and serviceable ENGINE COMPARTMENT - LEFT HAND SIDE Open the cowl by releasing the fasteners. 1. Air filter...........................................................Condition Tight 2. Turbocharger unit and waste gate.................Serviceable 3. Intercooler......................................................Serviceable Tight 4. Fuel pipes and connectors ............................Serviceable Leaks 5. Close the left hand engine hatch and tighten the fasteners with a screwdriver a 1/4 turn. Make sure the left engine hatch is closed and fastened correctly. EXTERNAL CHECKS - LEFT HAND SIDE A. UNDERCARRIAGE - LEFT HAND SIDE 1. Undercarriage leaf spring and installation bolts ..................................................................Condition Bolts installed and tight Free of cracks or impact marks and not damaged B. WHEEL - LEFT HAND SIDE 2. Wheel attachment, hub and axle...................Condition Bolts installed and tight 3. Tire.................................................................Correct inflation pressure Condition, Free of rubbing marks and not damaged 4. Brake system.................................................Condition Components are not damaged No fluid leaks or chafing of brake lines Brake line pipes and cables secured correctly 20 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 C. FUEL LEVEL 5. Fuel level ......................................................Check 6. Fuel pump assembly and fuel filter................Tight D. ROTOR HEAD AND CONTROL RODS - LEFT HAND SIDE 9. Rotor brake and cables .................................Condition Free movement 10. Rotor tachometer pick-up ............................Condition Installed correctly E. COCKPIT AND FUSELAGE - LEFT HAND SIDE 11. External surface of the fuselage ..................Condition Foreign objects Clean 12. Static port left hand side ..............................Clean and not blocked F. NOSE WHEEL 13. Nose wheel...................................................Condition Full rotary movement Operates in the correct direction with the rudder Free to spin, without play in the bearings 14. Tire...............................................................Correct inflation pressure 15. Fork..............................................................Not damaged or bent 16. Axle nut ........................................................Tight G. PITOT INTAKE / HEATED PITOT PROBE (Night VFR version) 17. Pitot intake ...................................................Free of blockages, dirt or other debris 21 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 H. ROTOR BLADES 18. Rotor blades ................................................Serviceable and not damaged Clean LIGHTING SYSTEM 1. Landing light ..................................................Function 2. Navigation lights ............................................Function 3. Strobe lights...................................................Function 4. Anti-collision light ..........................................Function 6 Scheduled Maintenance 6.1 Scheduled Maintenance Worksheets Maintenance Organisation Name: Page 1 of Note: Enter total pages issued Site where maintenance was accomplished: A/C Reg: G- Type: Serial No: Workpack Ref: Engine Type: A/C Total Hours: Check Start Date: Operator: Check Type: [25 FH/6 Months] [100 FH] [300 FH / 3 Year] [1000 FH] [600 FH] [Annual] Note: Delete checks which are not being carried out and identify any not applicable worksheet tasks as N/A. Maintenance Manual Reference Issue/Revision No. Date Airframe: 22 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.2 Final Checks (Include with all checks) 6.2.1 Ground Run: 6.2.2 Certification: 6.2.3 Type Certificate and Schedule Review: Engine: Task No. Task Description Task Nature Task Interval Date Certifying Person 1 Powerplant systems for leaks during and following ground run. INSP All Checks 2 Instruments, systems and services. Radio for electromagnetic interference. OP/C All Checks 3 Workpack and Log Book entries have been completed and certified. Ensure items due in accordance with CAP 543 have been accomplished and certified. CHK All Checks N/A 4 Aircraft and engine - compliance with Type Approval Data Sheet/Airworthiness Approval Note. CHK Annual N/A 5 Mandatory placards are installed and legible. CHK Annual N/A 6 Review the schedule to ensure that the maintenance needs of the aircraft are being met such that continuing safe operation can be assured. Account should be taken of previous maintenance history, operating environment and utilisation. CHK Annual N/A 23 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.3 25 Hour Check (Only to be carried out after first 25 hours / 6 months): 6.3.1 Flying Controls 6.3.2 Engine: Checks only on first 25 hours. Task No. Task Description Task Nature Task Interval Date Certifying Person 7 Check pre-rotator belts tension and re-set if necessary. INSP First 25 FH/ 6 Months 8 Check condition of push-rods and including intermediate pivot station, ensuring that pivot bolt is secured and locked. Check for any excessive movement between bolt rose-joint and bracket. Lubricate rose-joints. INSP First 25 FH/ 6 Months 9 Inspect rudder pedals and cables INSP First 25 FH/ 6 Months Task No. Task Description Task Nature Task Interval Date Certifying Person 24 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 Undertake engine maintenance in accordance with the appropriate Rotax maintenance manual and worksheet for the Rotax 915iS engine. 10 Check Engine Mounts · Inspect engine mounts for condition and security. Check that the mounts are not deformed and that there are no splits or damage present. · Check torque of engine mount fasteners Fuel Filter · Check fuel filter on airframe side CHK First 25 FH See ROTAX service instruction s Lubricate throttle and choke levers and control cables and check for free movement. 25 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.4 100 Hour Check: 6.4.1 Structural/Zonal: Task No. Task Description Task Nature Task Interval Date Certifying Person 11 Check all bolted joints to mast, keel and axle beam for condition and security INSP 100 FH/ 12 Months 12 Check security of nacelle attachment points INSP 100 FH/ 12 Months 13 Check condition of doors, hinges and associated mounting and locking hardware. Ensure gap between face of locking pins (548-08-24) and latching blocks (549-08-24) is less than 1mm when locking handle is in the over-centre locked position. Confirm correct operation of door warning system with doors open and in „latched and locked‟ position. INSP 100 FH/ 12 Months 14 Check security of all cowlings and associated attachment hardware. Ensure that all cowlings can be opened and closed as designed, that hinges are in good condition and that locking hardware is in good condition and working correctly. INSP 100 FH/ 12 Months 15 Check condition of rudder hinges, cables and cable capstan. Clean capstan and ensure cable running grooves are clean and free from grit INSP 100 FH/ 12 Months 16 Check general condition of rudder surfaces and horizontal and vertical stabilizers for stone chips. Fill/re-paint where necessary. INSP 100 FH/ 12 Months 17 Check cable anchor points to the rudder pulley. Ensure good condition and full and free movement of system, front and rear. Check full movement of rudder is obtainable. INSP 100 FH/ 12 Months 18 Check underside of nacelle INSP 100 FH/ 12 Months 26 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 Task No. Task Description Task Nature Task Interval Date Certifying Person 19 Check general condition of mast and keel primarily for rust. Remove rust and re-paint where necessary. Particular attention should be paid to meeting area of rear nacelle and engine bearers for rusting. Check carefully for hairline cracks, particularly near bolt holes. INSP 100 FH/ 12 Months 20 Check presence and legibility of required placards and operating instructions. INSP 100 FH/ 12 Months 27 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.4.2 Landing Gear: 6.4.3 Flying Controls: TaSk No. Task Description Task Nature Task Interval Date Certifying Person 21 Check condition of nose wheel and steering fork. Check for excessive play/shimmy. Check for bearing wear and free running. Check lubrication INSP 100 FH/ 12 Months 22 Check condition of main landing gear bow. Check for cracks, surface abrasions, scratches and corrosion. Check retaining bolts (4 off). (Bolts should be tightened to torque value of 23-26 Nm) INSP 100 FH/ 12 Months 23 Check main wheels, rims, tyres and tyre creep. Inspect condition of brake discs and pads – clean replace where necessary INSP 100 FH/ 12 Months 24 Tyre pressures, hydraulic brake system fluid level. INSP 100 FH/ 12 Months 25 Primary/secondary flight controls and trim systems for full and free movement in the correct sense, friction devices for correct operation. OP/C 100 FH/ 12 Months 26 Check operation of brake levers (including passenger side if fitted) and condition of cables. Check should include parking brake lock is satisfactory to hold brakes at fast idle setting on engine. OP/C 100 FH/ 12 Months 27 Check full and free movement of throttle levers (including passenger side if fitted), check cables. Check security of whole brake/throttle assembly attachments to nacelle OP/C 100 FH/ 12 Months 28 Check throttle lever action. OP/C 100 FH/ 12 Months 28 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 Task No. Task Description Task Nature Task Interval Date Certifying Person 29 Inspect the lower control fork for rust/cracks – use an inspection mirror and an appropriate light source to check all of the welded joints. ANY signs of cracking must be followed by full NDT testing (procedure as specified in ASTM E1417-05e1) and report to Magni Gyro UK Ltd. Check bearings and lubricate rose-joints. INSP 100 FH/ 12 Months 30 Check condition of push-rods and including intermediate pivot station, ensuring that pivot bolt is secured and locked. Check for any excessive movement between bolt rose-joint and bracket. Lubricate rose-joints. Check condition of upper part of control system to rotor head for rust-bowing. Replace if necessary. INSP 100 FH/ 12 Months 31 Ensure full and free movement of both cyclic control sticks and synchronised movement. Check for play, one with the other. Inspect all pivot points at base of sticks, check push-rods of keel mounted control system back to lower control fork. Check carefully for bearing „slap‟. INSP 100 FH/ 12 Months 32 Check full and free movements of trim system. Lubricate inner cable with light oil (WD40 or similar) INSP 100 FH/ 12 Months 33 Check pre-rotator unit, including belts. Tension and re-set if necessary. INSP 100 FH/ 12 Months 34 Check „Bendix‟ gear for excessive wear. Clean and lubricate with grease. Ensure prerotator outer hose is in good condition and that hose is allowed to slide through its supporting bracket during varying control movements. Check „Bendix‟ gear engages/dis-engages freely. INSP/ OP/C 100 FH/ 12 Months 29 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.4.4 Liquid, Air and Gas Systems: 6.4.5 Equipment and Environmental: 6.4.6 Engine: Task No. Task Description Task Nature Task Interval Date Certifying Person 35 Hydraulic and other fluid systems. Check for signs of damage to pipes and evidence of any leakage. Replace if necessary. INSP 100 FH/ 12 Months 36 Check brake fluid reservoir (under rear seat) for leaks. Replenish fluid and bleed system where necessary. Check condition of brake fluid pipes. Ensure that brakes hold against, as near as possible, 3000 rpm. INSP 100 FH/ 12 Months 37 Check fuel tanks for leaks. Ensure low fuel warning system function. Drain system and replace filters. Ensure proper function of drain tap. INSP 100 FH/ 12 Months 38 Pitot/static system vents, pitot head, drains clear. INSP 100 FH/ 12 Months 39 Check condition of seats, belts/harnesses, attachment, locking and release mechanisms (both). INSP 100 FH/ 12 Months 40 Check seats (two) are fully secured INSP 100 FH/ 12 Months Task No. Task Description Task Nature Task Interval Date Certifying Person 30 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.4.7 Rotors: 41 Undertake engine maintenance in accordance with the appropriate Rotax maintenance manual and worksheet for the Rotax 915 iS engine. Fuel Filter · Replace the fuel filter CHK See ROTAX service instructions 42 Lubricate throttle and choke levers and control cables and check for free movement INSP 100 FH/ 12 Months 43 Check rotor head for smooth running. Investigate and repair / refurbish if there are any signs of roughness. ( Note: Repair and refurbishment of the rotor head should only be undertaken by technicians approved by Magni Gyro) INSP 100 FH/ 12 Months 44 Ensure that whilst the nuts are tight and secured with pins, both the roll and pitch axis pivot bolts are allowed full and free movement. INSP 100 FH/ 12 Months 45 Ensure rotor head pivot block is secure and wire locked. INSP 100 FH/ 12 Months Task No. Task Description Task Nature Task Interval Date Certifying Person 46 Ensure the pre-rotator ring gear assembly is free of rust and has film of grease applied INSP 100 FH/ 12 Months 47 Check general condition of rotor assembly centre section for · Rusting – remove where necessary and re-paint · Signs of bending or torsional stress · Condition of teeter stops INSP 100 FH/ 12 Months 31 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.4.8 Gyroplane Lubrication: 48 Clean and check general condition of rotor blades Note: the release of SIL-002-2011, by Magni Gyro, specified the acceptability of specific cracks in the paint/filler situated at the interface of the blade root fitting and the composite aerofoil. These cracks must be vertical in nature and remain within the first 15mm outboard of the aluminium fitting. See figure below. INSP 100 FH/ 12 Months 49 Grease rotor head bolts and bearings through the dedicated grease nipples placed on the rotor head LUB 100 FH/ 12 Months 50 Check rotor brake system operation. Ensure brake works smoothly, without snatching. Lubricate rotor brake cable and check for free movement INSP 100 FH/ 12 Months 51 Lubricate gyroplane in accordance with Magni Gyro recommendations as defined in section 1.7.4 of the maintenance manual. LUB 100 FH/ 12 Months 32 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.4.9 Powerplant Installation: 6.4.10 Air Induction: Task No. Task Description Task Nature Task Interval Date Certifying Person 52 Check engine bearers for rust/cracks. Remove rust and re-paint where necessary INSP 100 FH/ 12 Months 53 Powerplant installation. Check for signs of corrosion, cracks and leaks. Verify engine mounting bolts are torqued to 34-36.5 Nm. INSP 100 FH/ 12 Months 54 Engine cooling installation. Check for signs of corrosion, cracks and leaks. INSP 100FH/ 12 Months 55 Inspect propeller condition (four blades). Remove blemishes and repair any minor damage. If needed remove the propeller and re-set in hub and re-balance whole assembly. Re-attach hub assembly and wire-lock. Refer to Maintenance Manual, Section 3. for allowable damage. INSP 100FH/ 12 Months Task No. Task Description Task Nature Task Interval Date Certifying Person 56 Inspect and clean/replace air filter as required, check for cracks or surface damage, check if the hoses are fitted correctly. Check the integrity of the: Intercooler, intercooler bulkhead, silicone fitting, air filter extension, shaped hose turbo intercooler, and the tightened of the fitting clamps and screws. INSP 100 FH/ 12 Months 33 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.4.11 Exhaust: 6.4.12 Fuel System: 6.4.13 Electrical System: Task No. Task Description Task Nature Task Interval Date Certifying Person 57 Check exhaust units for security/cracks INSP 100 FH/ 12 Months 58 Filters for cleanliness and tank vents unobstructed. Drain samples from all drain points and check for presence of water, foreign matter and correct colour. INSP 100 FH/ 12 Months 59 Check battery is properly seated and secured. Ensure clean connections. Check for leakage. INSP and SERVICE 100 FH/ 12 Months 60 Check condition of wiring – look for signs of abrasion, kinking, heat damage. INSP 100 FH/ 12 Months 61 Check landing light lens/working order. INSP 100 FH/ 12 Months 62 Check strobe units (if fitted) for condition and function/security. Inspect wiring/attachments. Replace where necessary INSP 100 FH/ 12 Months 34 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.4.14 Instrument Systems: If Dynon SkyView HDX equipped: Task No. Task Description Task Nature Task Interval Date Certifying Person 63 Instruments. Legibility of markings and associated placards, band ranges and limit markings. INSP and CHK 100 FH/ 12 Months 64 Readings consistent with ambient conditions. CHK 100 FH/ 12 Months 65 Compass „deviation‟ or „steer by‟ cards - valid until next check. Check calibration of compass. Conduct compass swing verification test (cross check to handheld compass) CHK 100 FH/ 12 Months 66 Ensure good condition of all flight instruments. Pressure check altimeter. Re-calibrate where necessary. Check ASI reading on flight test, or alternative method. CHK 100 FH/ 12 Months 67 A compass calibration needs to be performed for the correct functionality of the SV- ADAHRS-200 system. In order to perform the annual compass calibration, follow the procedures contained in the SkyView HDX System Installation Manual. CHK 12 Months 68 Perform the battery backup Test when 365 days have elapsed since the previous annual backup battery Test. Follow the procedures contained in the SkyView HDX System Installation Manual. CHK 12 Months 35 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.4.15 Ignition: 6.5 2-Year Check (Not Applicable) 6.6 300 Hour / 3-Year Check 6.6.1 Flying Controls: 69 Magnetos, harnesses, leads, switches, starting solenoid, contact breakers, INSP 100 FH/ 12 Months Task No. Task Description Task Nature Task Interval Date Certifying Person 70 Clean and inspect all control cables. Replace as required if signs of corrosion, wear or damage are found. CHK 300 FH or 3 years, whichever is longer 36 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.7 500 Hour Check 6.7.1 Flying Controls: 6.7.2 Rotor: 6.7.3 Prerotator flexible shaft: Task No. Task Description Task Nature Task Interval Date Certifying Person 71 Replace pre-rotation belts and pulleys CHK 500 FH 72 Replace rod end joints on control system linkage (8 places). Part numbers 033-03-24 (2 off), 034-03-24 (4 off) and 035-03-24 (2 Off). CHK 500 FH 73 Overhaul rotor head assembly INSP 500 FH 74 Inspect pre-rotator flexible shaft. Remove bendix gear. Clean the bendix gear at the top of the pre-rotator shaft and re-grease the outer roller bearing. INSP 100 FH/ 12 Months 37 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 6.8 1000 Hour Check 6.8.1 Powerplant Installation: 6.9 5-Year Check 6.9.1 Magni Gyro rubber components If Dynon SkyView HDX equipped: Task No. Task Description Task Nature Task Interval Date Certifying Person 75 Replace engine mount vibration dampers CHK 1000 FH Task No. Task Description Task Nature Task Interval Date Certifying Person 76 Check condition of vibrations dampers, fuel and oil hoses, cooling system hoses and all other Magni Gyro rubber components. Replace them if necessary. This check is specific for Magni Gyro rubber components; for Rotax engine rubber components check and inspection refer to Rotax maintenance schedule INSP 5 years 77 Replace the Dynon SkyView HDX backup battery. CHK 5 years 38 237-00-24C M24C PLUS MAINTENANCE SCHEDULE- ISSUE B 18 July 2023 7 Lifed Items The following components of the M24C PLUS gyroplane have life limitations, as noted: NOTE: THE REPLACEMENT OF THESE ITEMS AT THE SPECIFIED TIME INTERVAL IS MANDATORY COMPONENT LIFE LIMITATION (hours) Pre-rotation Belts & Pulleys 500 Rod End Joints 500 Fuel Filter 100 Engine Mount Vibration Dampers 1000 Rotor Head Bearings, Bushes, theeter bolts, brake pads, Roll &pitch bolts, Main gear sealing 500 Note: This is actioned as part of the rotor head overhaul Engine As specified by the engine manufacturer Rotor Blades 2500 Propeller 2000 Dynon SkyView HDX backup battery As specified by the instrument manufacturer