Fly Synthesis STORCH CL, STORCH S, STORCH HS Maintenance Manual

STORCH

CL, HS, S VERSION

MAINTENANCE MANUAL

(VALID FOR ROTAX 912 UL/S, 582 UL DCDI AND JABIRU 2200 ENGINES)

01 20/apr/05 Updated manual M. Fiorindo R. Ciotti R. Ciotti

Num.

Date Description

REVISION

Preparation Verify Approvation

The FlySynthesis s.r.l. it reserves him to terms of law the exclusive ownership of the present and it also forbids the partial reproduction of it.

AQ 002 Rev.00 Issued/Verify/Approval M. Garofolo 13/july/02

Identification: MM 002 Rev 01
Page: 2 of 26
Date: 20/april/2005
Issued: M. Fiorindo
Verify: R.Ciotti

Approval: R. Ciotti

Revisions description:

Updated manual

Storch CL, HS, S

Maintenance Manual

(for Rotax 912 UL/S, 914 UL and

Jabiru 2200 version)

Log of revisions

All revisions to this Maintenance Manual must be recorded in the following table.

Revision Number Revision Date Signature

01

Updated manual Apr.05 M. Fiorindo

AQ 002 Rev.00 Issued/Verify/Approval M. Garofolo 13/july/02

Identification: MM 002 Rev 01
Page: 3 of 26
Date: 20/april/2005
Issued: M. Fiorindo
Verify: R.Ciotti

Approval: R. Ciotti

Revisions description:

Updated manual

Storch CL, HS, S

Maintenance Manual

(for Rotax 912 UL/S, 914 UL and

Jabiru 2200 version)

Log of effective pages

Page Date

1 Aprile 2005
2 Aprile -2005
3 Aprile -2005
4 Aprile -2005
5 Aprile -2005
6 Aprile -2005
7 Aprile -2005
8 Aprile -2005
9 Aprile -2005
10 Aprile -2005
11 Aprile -2005
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20 Aprile -2005
21 Aprile -2005
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26 Aprile –2005

AQ 002 Rev.00 Issued/Verify/Approval M. Garofolo 13/july/02

Identification: MM 002 Rev 01
Page: 4 of 26
Date: 20/april/2005
Issued: M. Fiorindo
Verify: R.Ciotti

Approval: R. Ciotti

Revisions description:

Updated manual

Storch CL, HS, S

Maintenance Manual

(for Rotax 912 UL/S, 914 UL and

Jabiru 2200 version)

INDEX

Log of revisions 2
Log of effective pages 3

1 ROUTINE MAINTENANCE 5

1.1 GENERAL 5

1.2 MAINTENANCE SCHEDULE 5

1.3 PRE-FLIGHT INSPECTION 7

1.4 DAILY INSPECTION 7

1.5 10-HOURS INSPECTION 9

1.6 20-HOURS INSPECTION 10

1.7 50-HOURS INSPECTION 11

1.8 100-HOURS INSPECTION 13

1.9 150-HOURS INSPECTION 14

1.10 200-HOURS INSPECTION OR TWO-YEAR INSPECTION (whichever occurs first). 15

1.11 300-HOURS INSPECTION OR TWO-YEAR INSPECTION (whichever occurs first). 15

1.12 ANNUAL INSPECTION 16

2 LUBRICATION 17

SCHEDULE INDEX

fig. 1 Routine Maintenance Table..........................................................................................6

fig. 2 LUBRICANTS and SEALANTS...............................................................................17

fig. 3 Routine Maintenance Schedule - Power plant ............................................................18

fig. 4 Special Inspections Only for Rotax 912 Engine..........................................................22

fig. 5 Routine Maintenance Schedule - Airframe .................................................................23

1

AQ 002 Rev.00 Issued/Verify/Approval M. Garofolo 13/july/02

Identification: MM 002 Rev 01
Page: 5 of 26
Date: 20/april/2005
Issued: M. Fiorindo
Verify: R.Ciotti

Approval: R. Ciotti

Revisions description:

Updated manual

Storch CL, HS, S

Maintenance Manual

(for Rotax 912 UL/S, 914 UL and

Jabiru 2200 version)

1. ROUTINE MAINTENANCE

1.1 GENERAL

No other factors are quite important for the safety and reliability of, the aircraft and its components as a
regular and diligent attention to the routine maintenance steps carried out within the recommended
intervals.
The same applies for a prompt corrective action , introduced for all minor troubles found during the
aircraft in-service life.
This chapter contains the maintenance instructions and checks to be performed on the air-frame,
equipments and engine.
For detailed instructions applicable to the engine and its components (e.g. disassembly, cleaning,
inspection, testing, repair, lubrication, torque loads and reassembly), the operator should refer to the
Operator's Manual and Spare Parts List, last issues, published by engine manufacturer.

1.2 MAINTENANCE SCHEDULE

The maintenance schedule for STORCH is based upon 10 inspections to be accomplished within the
following limits.

PRE--FLIGHT INSPECTION: to be accomplished before each flight.
DAILY INSPECTION: to be accomplished daily, before beginning the flight activity.
10-HOURS INSPECTION: to be accomplished after 10 flight hours.
20-HOURS INSPECTION: to be accomplished after 20 flight hours.
50-HOURS INSPECTION: to be accomplished after 50 flight hours.
100-HOURS INSPECTION: to be accomplished after 100 flight hours.

150-HOURS INSPECTION: to be accomplished a after 150 flight hours.
200-HOURS INSPECTION: to be accomplished after 200 flight hours.
300-HOURS INSPECTION: to be accomplished after 200 flight hours.

ANNUAL INSPECTION: to be accomplished once a year independently of flight hours totalised.

GENERAL OVERHAUL: to be accomplished an airframe and engine at the manufacturer’s facilities after­150 flight hours.

AQ 002 Rev.00 Issued/Verify/Approval M. Garofolo 13/july/02

Identification: MM 002 Rev 01
Page: 6 of 26
Date: 20/april/2005
Issued: M. Fiorindo
Verify: R.Ciotti

Approval: R. Ciotti

Revisions description:

Updated manual

Storch CL, HS, S

Maintenance Manual

(for Rotax 912 UL/S, 914 UL and

Jabiru 2200 version)

fig. 1 Routine Maintenance Table

Flight hours

totalised

New and

General

Inspection

10h

Inspection

20h

Inspection

50h

Inspection

100h

Inspection

150h

Inspection

Q.P.O.

200h

Inspection

Q.P.O.

300h

Inspection

Q.P.O.
New X
10 h X
20 h X X
30 h X
40 h X X
50 h X X
60 h X X
70 h X
80 h X X
90 h X
100 h X X X X
110 h X
120 h X X
130 h X
140 h X X
150 h X X X
160 h X X
170 h X
180 h X X
190 h X
200 h X X X X X
210 h X
220 h X X
230 h X
240 h X X
250 h X X
260 h X X
270 h X
280 h X X
290 h X
300 h X X
Q = Qualified P = Personnel O = Only

AQ 002 Rev.00 Issued/Verify/Approval M. Garofolo 13/july/02

Identification: MM 002 Rev 01
Page: 7 of 26
Date: 20/april/2005
Issued: M. Fiorindo
Verify: R.Ciotti

Approval: R. Ciotti

Revisions description:

Updated manual

Storch CL, HS, S

Maintenance Manual

(for Rotax 912 UL/S, 914 UL and

Jabiru 2200 version)

1.3 PRE-FLIGHT INSPECTION

Refer to related paragraph of Flight Manual - last issue.

1.4 DAILY INSPECTION

Accomplish a complete Pre-Flight Inspection and the following additional operations:

(1) Ensure that the ignition key is REMOVED.

(2) Remove the upper and lower engine cowlings.

(3) Drain the fuel tanks as written in Flight Manual.

(4) In spect the carburettor rubber socket or rubber -flange for damage and security of attachment.

(5) Remove the floating chamber from the carburettor and inspect for cleanliness and absence of

water.

(6) Verify the air filter for security of attachment.

(7) Inspect the ignition cable terminals for security of connections to spark plugs.Inspect. all

other- electrical connections for security.

(8) Verify the electrical starter for security of attachment.

(9) Verify the battery for security of attachment.

(10) Inspect the rubber shock absorbers and of engine mount for condition.

(11) Verify the fuel pump, the fuel filter and relevant hoses f-or security of attachment and fuel

(12) Verify the attaching bolts of drive reduction unit supporting plate for tightening.

(13) Turn the propeller by hand and inspect -For abnormal noise.

(14) Verify engine control cables for security.

(15) Check tires pressure for proper- inflation:

- Main wheels 1.2 - 2.2 kg/cm2 (17 - 31 P.s.i.)

- Nose wheel 0.7 - 1.0 kg/cm

2

(10 - 14 P.s.i.)

AQ 002 Rev.00 Issued/Verify/Approval M. Garofolo 13/july/02

Identification: MM 002 Rev 01
Page: 8 of 26
Date: 20/april/2005
Issued: M. Fiorindo
Verify: R.Ciotti

Approval: R. Ciotti

Revisions description:

Updated manual

Storch CL, HS, S

Maintenance Manual

(for Rotax 912 UL/S, 914 UL and

Jabiru 2200 version)

For aircraft equipped with ROTAX 582 UL engine:

In addition to inspections/checks listed in the previous item (1) through (15), accomplish the following additional
operations:

(16) Verify the radiator mounting -For security. Inspect the radiator for damage and leaks.

(17) Check the coolant level and security of filling cap.

(18) Inspect the coolant hoses for security, leaks and chafing.

(19) Inspect the cylinder heads cylinders and water pump for leaks.

(20) Verify the lubrication oil content in the rotary valve and security of filling cap.

(21) Inspect the oil hoses relevant to rotary valve gear lubrication and oil injection systems for

Security, leaks and chafing.

(22) Verify the integrity of safety locking wires of gearbox, drain and oil level plugs.

(23) BY pushing and pulling the engine shaft along its axis, check the bearings for abnormal play.

For aircraft equipped with ROTAX 912 UL engine:

In addition to inspections/checks listed in the previous item (1) through (15), accomplish the following additional
operations:

(24) Verify the oil and water radiator mounting -For security. Inspect the radiator for damage and leaks.

Check the coolant level and security of filling cap.

(25) Inspect the coolant hoses for security, leaks and chafing.

(26) Inspect the cylinder heads cylinders and water pump for leaks.

(27) Verify the lubrication oil content and security of filling cap.

(28) Inspect the oil hoses relevant to gear lubrication and oil injection systems for Security, leaks

and chafing.

(29) Verify drain and oil level plugs.

(30) BY pushing and pulling the engine shaft along its axis, check the bearings for abnormal play.