Inspection Program Doe, John Q. Lancair Evolution
Contents
1. Page Revision Revision Page Revision Revision Number Number Date Number Number Date 1 Original 4 Jun 11 20 Original 4 Jun 11 2 Original 4 Jun 11 21 Original 4 Jun 11 3 Original 4 Jun 11 22 Original 4 Jun 11 4 Original 4 Jun 11 23 Original 4 Jun 11 5 Original 4 Jun 11 24 Original 4 Jun 11 6 Original 4 Jun 11 25 Original 4 Jun 11 7 Original 4 Jun 11 26 Original 4 Jun 11 8 Original 4 Jun 11 24 Original 4 Jun 11 9 Original 4 Jun 11 28 Original 4 Jun 11 10 Original 4 Jun 11 29 Original 4 Jun 11 11 Original 4 Jun 11 30 Original 4 Jun 11 12 Original 4 Jun 11 31 Original 4 Jun 11 13 Original 4 Jun 11 32 Original 4 Jun 11 14 Original 4 Jun 11 33 Original 4 Jun 11 15 Original 4 Jun 11 34 Original 4 Jun 11 16 Original 4 Jun 11 17 Original 4 Jun 11 18 Original 4 Jun 11 19 Original 4 Jun 11 EXAMINED AND APPROVED DATED Registration No N Lancair Evolution Inspection Program 4 Jun 11 7 This Page Intentionally Left Blank Registration No N Lancair Evolution Inspection Program 4 Jun 11 8 A Preface 1 Airworthiness Certificate Limitation The Experimental Airworthiness Certificate for N will contain the following limitation No person must operate this aircraft unless within the preceding 12 calendar months it has had a Condition Inspection performed in accordance with this FAA approved program and was found to be in a condition for safe operation This inspection will be recorded in the aircraft maintenance records2. Inspections must be recorded in the aircraft maintenance records showing the following or a similarly worded statement T certify that this aircraft has been inspected on insert date in accordance with the scope and detail of the Maintenance and Inspection Program for DOE JOHN Q Lancair Evolution Serial Number EVO FSDO approved program dated insert date and found to be in a condition for safe operation The entry will include the aircraft total time in service and the name signature certificate number and type of certificate held by the person performing the inspection If there is any disagreement between this manual and the aircraft Operating Limitations issued to this aircraft by the FAA the Operating Limitations will take precedence and the Inspection Program will be revised in accordance with Paragraph 10 to correct any disagreement with the Operating Limitations 2 Inspection Program a This inspection program was selected in accordance with Part 91 409 f 4 and is identified in the aircraft maintenance records as Doe John Q Lancair Evolution Serial Number EVO N b No person may operate this aircraft unless the replacements for life limited parts specified herein are complied with The aircraft including the airframe engine propeller appliances survival equipment and emergency equipment must be inspected in accordance with this program c The specified inspection intervals shall
3. be complied with and at least one complete condition inspection must be accomplished every 12 calendar months by a properly rated repair station a certificated mechanic or the holder of the repairman certificate for this aircraft Registration No N Lancair Evolution Inspection Program 4 Jun 11 9 3 Responsibilities a Responsible Person The owner responsible for scheduling inspections required under this inspection program is Registered Owner John Q Doe Address 1234 Main St Your town Your state Your Zip Code Phone 555 555 5555 If the registered owner of this aircraft should change for any reason the new registered owner must apply for a revision to this program prior to the next due inspection The revision must be submitted to and approved by the geographically responsible FAA Flight Standards District Office b Duties and Responsibilities The person organization listed above shall 1 Maintain the Aircraft in accordance with the Maintenance amp Inspection Program listed herein 2 Ensure compliance with the airworthiness limitations sections of all appropriate manufacturer s maintenance manuals as well as all Airworthiness Directives 3 Maintain a complete record of all maintenance performed on the aircraft This record shall not be kept or carried onboard the subject aircraft Ensure that only qualified personnel maintain the aircraft Ensure that the aircraft is in safe operating condition before be
4. stick switches wiring air ducts Aileron and elevator push pull tubes Cabin Side Trim Copilot s side runs from communication wiring control stick Panels control stick to rear seat back switches wiring common wire bundle air ducts Baggage Floor of aft baggage Elevator push pull rods Elevator Compartment compartment autopilot servo Elevator push rod rudder control cables Pressure Bulkhead Aft of baggage area air conditioning condenser AHRS magnetometer ELT Vertical stabilizer left and right Access Panels 2 side FUSELAGE EXTERIOR Cabin Side Trim Pilot s side runs from control Panels stick to rear seat back FUSELAGE INTERIOR Right side of rudder middle Access Panels 3 Left Elevator lower surface Left Aileron lower surface Trim tab servomotor rudder autopilot trim servo TRIM CONTROLS Registration No N Lancair Evolution Inspection Program 4 Jun 11 24 D Pratt amp Whitney PT6A 135A Inspection Program 1 General The Engine Inspection Program specifies the frequency and extent of required inspections and maintenance of the engine and related systems All required inspections and maintenance are to be accomplished by appropriately certificated personnel experienced with the maintenance and operation of turboprop aircraft engines The engine Inspection Program contains numerous references to specific chapters and pages in the complete Pratt amp Whitney PT6A 135A Maintenance
5. ventilated area and avoid inhaling fumes from fuel or oil Standard aviation shop safety practices should be observed at all times Initial Installation and Startup After initial installation or after removal and subsequent re installation of the engine follow Pratt amp Whitney initial run check list Rotor Components Service Life Refer to P amp WC S B No 14002R 13 to determine cycles E Hartzell Propeller Inspection Program 1 General The Propeller Inspection Program specifies the frequency and extent of required inspections and maintenance of the propeller and related systems All required inspections and maintenance are to be accomplished by appropriately certificated personnel experienced with the maintenance and operation of turboprop aircraft engines Appropriate and accurate records of inspections and maintenance accomplished in compliance with this program are to be maintained in appropriate logbooks Registration No N Lancair Evolution Inspection Program 4 Jun 11 28 2 Time Limits The Hartzell Propeller shall be overhauled every 4000 hours TIS or 72 months whichever comes first in accordance with the Hartzell Propeller Owner s Manual 149 3 Safety Practices Only qualified and trained personnel experienced with the maintenance and operation of turboprop aircraft engines should be permitted within close proximity of the engine when performing engine operational checks A fire extinguisher should be r
6. ED TT TSHSI 3 Propeller MAKE AND MODEL Your propeller make and model SERIAL NUMBER Your propeller serial number STATUS WHEN INSTALLED TT TSHSI Registration No N Lancair Evolution Inspection Program 4 Jun 11 12 C Airframe Inspection Program 1 Inspection Requirements a Condition Inspections Part 91 409 e requires that DOE JOHN Q Lancair Evolution N S N EVO receive a condition inspection by an authorized person each 12 calendar months in accordance with this approved inspection program and be in a condition for safe operation b Unscheduled Inspections If the limitations of the engine or airframe are exceeded such as a hard or overweight landing the likely affected components and systems must be inspected as indicated in this inspection program Refer to Appendix B and Appendix C c Component Inspections Time limits and special inspection requirements may exist for equipment manufactured by other suppliers and installed on this aircraft auto pilot air conditioning etc These inspections and recommendations are determined by that manufacturer and shall be followed to ensure continued airworthiness using current manufacturer s maintenance and inspection manuals as revised for that component Registration No N Lancair Evolution Inspection Program 4 Jun 11 13 2 1 2 2 6 7 10 11 12 13 14 Re
7. Inspection Program Doe John Q Lancair Evolution Serial Number EVO Registration Number N Address 1234 Main St Your town Your state Your Zip Code 555 555 5555 EXAMINED AND APPROVED DATED Registration No N Lancair Evolution Inspection Program 4 Jun 11 1 This Page Intentionally Left Blank Registration No N Lancair Evolution Inspection Program 4 Jun 11 2 Table of Contents REVISIONS rd Nan tues o etais 5 Liston Effective Pa pes Sue ii het ange Mian a ne en ee tn aa nt 7 Aas Prepac sinus alu ent tales apices crea tuler omen Geet tees 9 1 Airworthiness Certificate Limitation is non tante annee cae ida 9 Deke ASPE Prostam an ch OE 9 Di Responsibilities En nine men e isis 10 4 UPS ALAA EEE LS Se Re ee Sia ga e ne e ts 10 5 Inspection Program Operation ss inn iraniens 11 6 COMO O e IO ee at 11 To AUTOR MINES DIE A A A Re Mie 11 8 Defects Found During the Inspection icon did dais nina 11 9 Revisions to the Inspection Programs less A tre ee nt gere 11 VO TES RP nn edie nn gee A a e es 11 B o A MP e he a M M TR NN aaao Tes 12 Le SPATE CRATE Se laa ie E ERE E a de E E ne EE E aes 12 2 Power Plant san nt et A den due AET EES Ea ct dt 12 3 GEES CL sre yet sates cana a e E R en dde se de eee Re daniel eee 12 Cy Airivame Inspection Prop A OE ee ne eS 13 Le Inspection Requirements td 13 2 Time LS fe sind a EEEE AEE ERE VSE D ATE EREA lan tn de test 14 Recommended Replacements ia an
8. Jun 11 11 B Introduction This program lists the minimum inspection requirements for the DOE JOHN Q Lancair Evolution aircraft listed below At a minimum the aircraft will be inspected in accordance with the inspection program requirements prescribed herein A complete condition inspection must be accomplished every 12 calendar months The inspection maintenance procedures methods and standards of airworthiness for the Pratt amp Whitney engine recommended by the engine manufacturer will be complied with in accordance with the Pratt amp Whitney Maintenance Manual 3043512 as revised All other inspection and maintenance procedures will be done in accordance with standard aircraft requirements The inspection maintenance procedures methods and standards of airworthiness for the Hartzell propeller recommended by the propeller will be complied with in accordance with the Hartzell Propeller Owner s Manual No 149 as revised All other inspection and maintenance procedures will be done in accordance with standard aircraft requirements The inspection program and manufacturer s recommendations and procedures described herein are applicable to the following 1 Aircraft MAKE AND MODEL DOE JOHN Q Lancair Evolution BUILT BY John Q Doe SERIAL NUMBER EVO REGISTRATION N 2 Power Plant MAKE AND MODEL Your engine make and model SERIAL NUMBER Your engine serial number STATUS WHEN INSTALL
9. and any signs of obvious damage 83 Wing Spar Bolts Inspect for cracks and security of attachment to fuselage 84 Floor amp Supporting Structure Inspect for cracks holes and compression damage 5 85 Flight Controls Forward Fuselage through Pressure Vessel Inspect for nicks scratches and dents in push pull rods play in rod end bearings security of elevator linear bearing mounts and attachment of rudder cable guide tubes to fuselage 86 Baggage Compartment Floor Inspect for cracks holes and security 87 Emergency Locator Transmitter ELT Remove from tray and remove battery cover Inspect for battery corrosion and any obvious internal or external damage to housing Verify replacement date on battery matches date on housing placard Reinstall battery cover Test operation of G switch in strict accordance with instructions in Kannad Operation Manual DOCO6006A Ref 0141922A page 604 Sec C Record battery replacement due date 88 ELT Installation amp Support Shelf Inspect ELT wiring and antenna cable for security routing and chafing Check connectors for security of pins and proper connection Inspect ELT tray and support shelf for cracks and security Replace tray if any cracks are found Check operation of remote switch NOTE This check shall only be conducted during the first five minutes of any UTC coordinated universal time hour and restricted in duration to not more than five seconds Be
10. bonding strap 37 Flap Motor amp Flap Actuators Clean and cycle the flaps up and down to check for smooth operation 38 Flap Deflections Ensure that flaps extend equally on each side of the airplane in both the takeoff and landing configurations Measure the down deflection on each side using neutral ailerons as a reference point The difference in static deflection should not be greater than 3 degrees 39 Fuel Leaks Check the security of the fuel tanks by inspecting the outer skin tank areas for evidence of fuel stains 40 Fuel Filler amp Caps Inspect for proper locking condition of o ring and receptacle and presence and legibility of placards 41 Wing Interior Inspect the wing spar through the outer access panel for signs of cracking or debonding Inspect visible bonded areas of ribs and other structures 42 Fuel Vent Hoses Check for proper connection of the fuel vent hoses to the wing end rib tubes Check the condition of the hoses 43 Flight Controls Inspect all push pull rods rod end bearings and bellcranks for condition play and security of attachment Ensure all rod end jamb nuts are tight 44 Contamination Test Take fuel samples from both wings and fuel strainer Inspect for contamination water particulate and microbiological and proper grade of fuel 45 Gascolator Replace or clean the fuel filter and screens as necessary Re assemble the gascolator and perform a boost pump pr
11. brake discs for cracks pitting and signs of overheating Inspect all hardware for signs of loss of torque in accordance with Cleveland Maintenance Manual AWBCMMO0001 2 USA Measure and record brake disc thickness Left inches Right inches 54 MLG Tires Inspect for flat spots wear splitting and dry rotting Check tire pressure and service as necessary Maintain main gear tire pressure at 100PSIG Nitrogen is preferred but compressed air may be used if nitrogen is not available 55 MLG Wheel Assemblies Rotate and check for binding unusual noises excessive friction play in bearings and security of attachment of axles 56 NLG Assembly Verify operation of the NLG centering lock with the strut fully extended 57 NLG Strut Inspect for cracks corrosion and scratches on piston fluid leakage and signs of overstress Check for security of attachment of strut to engine mount Check for presence of steering limit markings 58 NLG Fork Assembly Inspect for cracks corrosion signs of overstress and side loading Inspect towing lug assemblies for cracks distortion and security of attachment 59 NLG Wheel Assembly Inspect for cracks and corrosion Check all hardware for signs of loss of torque 60 NLG Tire Inspect for flat spots wear splitting and dry rotting Check tire pressure and service as necessary Maintain nose gear tire pressure at 45 PSIG 61 Wheel Bearings All Every 400 hours clean and inspe
12. ch main gear remove the wheels axles and landing gear doors Perform detailed inspection of the landing gear legs Look for evidence of metal fatigue corrosion cracks and deformation Remove the Circuit Breaker Panel Check the distribution bus and related wiring for chafing and security of electrical connections 14 Time Period 24 Months 24 Months 24 Months 36 months Every 5 Years 100 Hours or Annually 100 Hours or Annually 200 Hours or Annually 400 Hours 1 000 Hours 1 000 Hours or Every 5 Years 1 000 Hours or Every 5 Years 1 000 Hours or Every 5 Years 1 000 Hours or Every 5 Years Lancair Evolution Inspection Program Reference Document CFR 91 207 CFR 91 411 CFR 91 413 Concorde Instructions for Continued Airworthiness 49 CFR 180 Manufacturer s Documents Construction Manual Construction Manual Oildyne Service Manual Construction Manual Construction Manual Construction Manual Construction Manual 4 Jun 11 3 Recommended Replacements The Recommended Replacements table lists items that should be periodically replaced Recommended Replacements 1200 hours or Outflow earlier as Valve warranted by Installation visual inspection Manual 1 Cabin Pressurization Outflow Valve Filter Construction 2 Fuel Filter Annually Manual Emergency Oxygen Bottle Replacement This Bowe 3 BETSY N Es paes 15 years Manufacturer s recommendation applies to compo
13. contaminates from the system If the static system is opened to remove water or contamination a pitot static system test is required CAUTION Do not apply compressed air to the system since this will result in damage to the static air flight instruments Drain amp Vent Lines Inspect for security condition and obstructions 22 Brake Fluid Reservoir Inspect for condition security and fluid level Service as necessary 23 Foreign Objects Check the engine compartment for foreign objects 24 Rudder Inspect for signs of damage looseness and condition of hinge attachments Check security of static balance weight Ensure the system makes full contact with the left and right capstan rudder stops with no interference 25 Horizontal Stabilizer Perform generalized inspection of the horizontal stabilizer for visible damage and evidence of latent damage Inspect the hinge attach points for security and condition 26 Elevators Inspect for signs of surface damage looseness and condition of hinges and elevator horn Ensure the elevator system makes full contact with the up and down elevator stops 27 Elevator Trim Tab amp Actuator Inspect for condition and security 28 Rudder Trim Inspect for condition and security Registration No N Lancair Evolution Inspection Program 4 Jun 11 18 Wings 29 Wing Skins amp Exterior Inspect for obvious signs of damage including cracks holes buckling and
14. control The aircraft owner is responsible for all aircraft records 7 Airworthiness Directives AD bulletins that are applicable to engine propeller and or accessories or component shall be complied with 8 Defects Found During the Inspection All defects found during an inspection and any corrective action taken will be maintained as a permanent part of the maintenance records 9 Revisions to the Inspection Program Revisions to this program determined as necessary due to maintenance and repair experience or modification of the aircraft s systems shall be made on an as needed basis Revisions must be submitted to and approved by the local FAA office prior to issuing The coverage of the original document and the record keeping requirements described herein shall not be minimized by any revisions A history of revisions will be maintained 10 Testing All flight testing results will be recorded in the aircraft maintenance records Any major changes alterations will require that the aircraft be flight tested again for a period of time to be agreed upon with the FAA The action to be taken after the incorporation of any major changes alterations shall be complied with in accordance with this aircraft s airworthiness certification operating limitations This may require notification of the geographically responsible FSDO and entering into Phase I of operating limitations Registration No N Lancair Evolution Inspection Program 4
15. ct for damage wear and corrosion Inspect bearing races for wear and damage Repack with appropriate grease in accordance with Cleveland Maintenance Manual AWBCMMO0001 2 USA NOTE Always wear rubber gloves when handling dry or repacked bearings 62 Gear Retraction Test Perform retraction test through 5 cycles On third extension utilize the emergency gear extension system Ensure entire retraction system operates normally following emergency extension test Check all actuators for leaks and security It is acceptable for the emergency gear to extend but not lock the main gear down as air loads yawing is used to assist the extension Registration No N Lancair Evolution Inspection Program 4 Jun 11 20 Landing Gear Safety Switch Verify proper operation of the pitot pressure actuated landing gear safety switch by simulating airspeed at the pitot tube to initiate gear retraction after gear up has been selected in the cockpit CAUTION Do not apply excessive pressure to the pitot system Avionics damage may occur All Landing Gear Verify freedom of movement of gear doors Ensure that gear retraction and extension are not inhibited by door interference and that doors fit and fair Inspect gear doors for cracks and condition Lowering Airplane Ensure all obstructions are clear from under the aircraft landing gear indicates down and locked and is ready for aircraft weight then lower aircraft Fuselage Interio
16. e g rags plastic bags etc Chip detection Circuit Completion and or Debris in Oil Filter Propeller Sudden Stoppage or Strike Propeller Lighting Strike Propeller Electrical Leads Shorting Heavy Hard Landing Aircraft Flown Through Volcanic Ash or Smoke Sustained Running at Oil Temperature Outside Limits Loss of Oil Oil Pressure or Low Oil Pressure Oil Pressure Follows Throttle Contamination by Fire Extinguishing Agents Audible Rubbing Binding or Scraping Propeller Windmilling after In Flight Shutdown Lancair Evolution Inspection Program 4 Jun 11 27 3 Contamination of Oil with Non Metallic Foreign Material Starter Generator Replacement Post Inspection Test Run Results After completion of required inspections the engine shall be run to determine satisfactory performance in accordance with the manufacturer s recommendations Readings and observations shall be recorded in Appendix A Engine Limitations and Test run results Safety Practices Only qualified and trained personnel experienced with the maintenance and operation of turboprop aircraft engines should be permitted within close proximity of the engine when performing engine operational checks A fire extinguisher should be readily available and no smoking or open flame should be permitted near the engine Avoid direct skin contact with fuel or oil Wash thoroughly with soap and water immediately following accidental contact with engine fluids Work in a well
17. eadily available and no smoking or open flame should be permitted near the engine Avoid direct skin contact with fuel or oil Wash thoroughly with soap and water immediately following accidental contact with engine fluids Work in a well ventilated area and avoid inhaling fumes from fuel or oil Standard aviation shop safety practices should be observed at all times 5 Propeller Inspection Hartzell Propeller Owner s Manual Section Inspection and Check 61 00 49 latest revision Section 4 pp 5 7 amp 5 8 represent the Periodic Inspection and Maintenance schedule for the Hartzell propeller related to the Lancair Evolution This includes the Inspection Procedures as defined in the owner s manual as 61 00 49 Section 5 pp 5 18 thru 5 21 Propeller overhaul is to be accomplished every 4000 hours or 72 months whichever comes first Required Periodic Inspection and Maintenance e Detailed Inspection Every 400 Hours NTE twelve 12 months 1 Blade Damage 2 Grease or Oil Leakage 3 Vibration 4 Tachometer Inspection 5 Blade Track 6 Loose Blades 7 Preload Plate Set Screw 8 Corrosion 9 Spinner Damage 10 Ice Protection System Registration No N Lancair Evolution Inspection Program 4 Jun 11 29 e Special Inspections Hartzell Manual 61 00 49 Sect 6 pp5 32 thru 5 42 1 Overspeed Overtorque 2 Propeller Ground Idle Operating Restrictions 3 Lightning Strike 4 Foreign Object Strike Ground Strike 5 Fire Da
18. eseal Mount Rings 72 50 05 Exhaust Ducts Maintenance Practices 72 10 00 Propeller Shaft Seal 73 10 07 08 Accessories 72 60 00 Starter Generator 72 60 00 Oil System 79 20 04 Oil Filter Elements Maintenance Practices 79 20 02 04 Magnetic Chip Detector Inspection Check 72 60 00 AGB Internal Scavenge oil pump inlet Cleaning Inspection Additional references of the Pratt amp Whitney periodic inspection include but are not limited to the following documents continued 73 10 02 06 Fuel System 73 20 00 FCU 73 10 04 05 Fuel System Flow Control 73 10 01 Oil to fuel heater Registration No N Lancair Evolution Inspection Program 4 Jun 11 26 74 10 00 74 20 00 73 10 07 75 30 00 Ignition System Ignition Cables and Igniters glow plugs P3 Filter Bleed Valve Reference Pratt amp Whitney Maintenance Manual Part No 3043512 Table 602 Periodic Inspection Unscheduled Inspections are done when the engine is subjected to unusual stress or operating conditions or exceeds operating limitations or gives unsatisfactory performance handling P amp W 72 00 00 Please refer to the Pratt amp Whitney Maintenance Manual Part No 3043512 for explicit instruction of the following Registration No N Overspeed Inadvertent Cut Off and Relight During Taxi Overtemperature Overtorque Immersion in Water Dropped Engine or Component Material Ingestion e g ice stone etc Bird Strike Soft Material Ingestion
19. essure test Check for leaks Registration No N Lancair Evolution Inspection Program 4 Jun 11 19 Landing Gear 46 Hydraulic Fluid Check the level of landing gear hydraulic fluid 47 Service Nose Strut Check the inflation pressure of the nose gear and service as required Strut should show 3 4 of chrome at proper inflation 48 Nose Gear amp Shimmy Dampener Place the nose gear on a rotating table shallow height sometimes referred to as a Grease Plate with the normal static weight of the airplane applied to the table A firm and consistent resistance to the steering rotation should be felt through the full range of movement 49 Lifting Airplane Jack the aircraft until all tires clear the floor by 2 inches 50 Hydraulic Brake Lines Inspect the brake lines for security and evidence of chaffing Check for leaks as evidenced by the presence of hydraulic fluid stains Check for bends and kinks in the brake lines as the gear swings and the struts move 51 Brake Calipers amp Brake Lines Clean and inspect for condition fluid leakage and security of components Check the caliper for small amount of free floating motion in the torque plate Clean the anchor bolts and torque plate if the caliper does not free float Do not lubricate anchor bolts 52 Brake Linings Inspect brake linings and replace if the wear lines are not visible 53 Wheels amp Brake Discs Inspect for cracks and corrosion Inspect
20. ghts electro luminescent panels and all dimming rheostats 4 Annunciator Lights Check operation Flight Controls Check for smooth operation of all flight controls with flaps in retracted and extended positions Operate controls through full range of motion feeling for binding ratcheting and sloppiness and listening for unusual noises Check and record the control deflections on the ailerons flaps elevator and rudder using a smart level and compare with construction manual values 6 Door Seal Check operation of the door seal air pump and inspect for air leaks in seals 7 Trim Actuators Check operation of all actuators and the accuracy of position indicator LED s 8 Brakes Check for the absence of sponginess 9 Aircraft Batteries Fully charge clean the battery exterior surfaces and clean the battery cables Check the batteries for evidence of leakage 10 Access Panels Fairings Seats Carpets Covers Side Panels amp Spinner Remove for complete access for inspection Check for missing or stripped screws Aircraft Records 11 Aircraft Logbooks Determine total times times since overhaul and times since last required or recommended maintenance checks and record on Inspection Coversheet 12 Airworthiness Directives AD s amp Service Bulletins Check for new and recurring AD s which may need to be complied with during this inspection Also check for applicable manufacturer s Service Bullet
21. gistration No N Time Limits The Time Limits amp Special Inspection Items table identifies either component time limits and or required special inspections These inspections must be incorporated into a scheduled or annual inspection as applicable If it is anticipated that the component time limit and special inspection will occur before the next applicable required inspection it must be incorporated in the current required inspection Time Limits amp Special Inspection Items Special Inspection Item Manufacturer Emergency Locator Transmitter Alkaline Battery replacement Altimeter amp Static System Inspection Refer to AC 43 203B and Appendix E of Part 43 Automatic Pressure Altitude Encoding System amp Transponder inspection and test Refer to AC 6A amp Appendix F of Part 43 Main Aircraft Battery replacement Concorde Emergency Oxygen Bottle Re Certification Sorcerer Trutrak Autopilot operational check Fire Extinguisher Bottle Inspection if installed Service nose strut Repack new wheel bearings nose and main landing gear after first 100 hours then every 400 hours thereafter This should be done more frequently if experience indicates the need based on the type of operations conducted Landing gear hydraulic pump brushes replace Oildyne service manual Check and record the control deflections on the ailerons flaps elevator and rudder Remove the rudder and check the hinges On ea
22. ing returned to service poe 4 Availability A copy of this inspection program a Shall be kept in the possession of the person identified under Responsibilities b Shall be presented to any person performing inspections tests checks and life limited parts replacement required by this inspection program c Shall be made available to the local Flight Standards District Office upon request Registration No N Lancair Evolution Inspection Program 4 Jun 11 10 5 Inspection Program Operation a The status of this inspection program can be determined by referring to the aircraft records b The person identified under Responsibilities oversees updates and monitors the operation of this program c The person identified under Responsibilities reviews the inspection and maintenance requirements and then provides the person who is to perform the work with a list of work to be performed Upon completion of the work the Responsible Person will review the maintenance repair order and or the inspection worksheets to ensure that all inspections discrepancies and Airworthiness Directives have been appropriately repaired or inspected at their prescribed intervals and recorded in the aircraft s permanent records 6 Control of Inspection In performing the inspection program of the airframe engine propeller and appliances including the emergency equipment required to be inspected the aircraft records will be used as a means of
23. ins 13 Aircraft Records Check for presence and condition of aircraft federal registration form and airworthiness certificate and associated limitations Verify that weight and balance information is current and correct Registration No N Lancair Evolution Inspection Program 4 Jun 11 17 Fuselage Exterior amp Empennage 14 Fuselage Exterior Surface Inspect for obvious signs of damage including cracks holes buckling and rippling Check condition of the paint and cleanliness Check drain holes for obstructions 15 Windows Inspect for cleanliness condition and sealing 16 Cabin Door Inspect for security and fit Inspect skin hinges gas strut latching mechanisms door seal and upholstery Lubricate hinges and all moving parts with a quality petroleum or silicone based oil Check that the door seal inflates properly 17 Baggage Door Inspect for security and fit Inspect door skin upholstery seal hinge and latching mechanism Lubricate the hinges and all moving parts with a quality petroleum or silicone based oil Entry Assist Step Inspect for security and condition Pitot Port Inspect for obstruction of the pitot signs of damage which may affect proper airflow and security of attachment Remove the pitot port before attempting to clear any obstructions Test for proper operation after reinstallation Static System Check the static system for evidence of water Remove any water or other
24. ity in composite structures please see the ultrasound inspection device manufacturers instruction when performing ultrasound inspection on laminated carbon fiber composite structures as used in the Lancair Evolution The Coin Tap method can be utilized with accurate results A crisp and solid sound is heard when a good region without defects or damages is tapped with a piece of metal such as a washer or a coin When testing a bad section that has possible crushing and delamination damage a dull thud or thunk sound exists This method can also be used to find spars and determine connecting points within the structure To increase accuracy draw a grid in the region of testing and tap repeatedly in the suspected damage area to include the surrounding areas while listening for sound change This will determine the estimated maximum area damaged Please inspect any depressions dents or scratches at a minimum of a tap test should be performed It is suggested that tap testing be performed every 3000 hours for the following areas Bonding of the two fuselage halves Areas where the top and bottom of the wing skin are bonded to the spars and ribs Seam area around the leading and trailing edges of the wing Seam area around the leading and trailing edges of the flaps Seam area around the leading and trailing edges of the Ailerons Seam area around the leading and trailing edges of the rudder Additionally aileron rudder and flaps should be
25. mage or Heat Damage Registration No N Lancair Evolution Inspection Program 4 Jun 11 30 F Appendices Appendix A Engine limitations Pratt amp Whitney PT6A 135A Engine Limitations Table 1 REF 71 00 00 or N2 Np ITT Oil Temp 8 Oil Press 2 CRE o Terme OF IR eee ay 101 6 1900 NON 2080 10 to 99 85 to 105 Continuous me E oom mem 52 6 e fae P e IET Takeoff 750 101 6 1900 MON 2080 10 to 99 85 to 105 Transient 102 6 4 2090 10 880 4 2400 11 85 to 105 GENERAL NOTE The operating parameters in this Table are individual limits for each engine parameter and do not apply simultaneously 1 All limits are based on sea level and ambient temperatures as specified 2 Minimum oil pressure above 27 000 Ng is 85 psig 3 For over temperature and over torque action refer to Figures 501 502 503 and to Chapter 72 00 00 Unscheduled Inspection 4 These values are time limited to two 2 seconds 5 Increase Ng to keep within this limit 6 If maximum torque is used Np must be set so as not to exceed power limitations Reverse power operation is limited to one 1 minute 7 Starting temperatures above 880 C 1616 F should be investigated for cause 8 For increased oil service life an oil temperature below 80 C 176 F is recommended 9 In the event of failure of the propeller governor toward overspeed it is permissible to complete a flight with propeller c
26. manual containing detailed technical specifications inspection and maintenance procedures applicable to the corresponding tasks Appropriate and accurate records of inspections and maintenance accomplished in compliance with this program are to be maintained in appropriate logbooks Pratt amp Whitney Maintenance Manual Manual Part No 3043512 Volume 1 Section 72 00 pp 601 652 represents the inspection procedures for the various sections and mechanics of the PT6A 135A engine to include corrosion and sulphidation inspection wash and corrosion inhibition procedures Pratt amp Whitney defines inspections as ROUTINE that coincides with the daily or preflight airframe inspection MINOR inspection coincides with localized airframe inspection Registration No N Lancair Evolution Inspection Program 4 Jun 11 25 2 Time Limits Hot section inspections are outlined in the applicable approved service bulletins which is updated on service experience and time between overhauls TBO P amp W 72 00 00 latest revision Hot sections are required every 1800 hours TIS and engine overhaul every 3600 hours TIS in accordance with PW amp C SB 1803 Reference Pratt amp Whitney Maintenance Manual Part No 3043512 Table 602 Periodic Inspection Additional references of the Pratt amp Whitney periodic inspection include but are not limited to the following documents 72 20 00 Air Screen Inlet 72 30 04 Gas Generator Case 72 30 01 02 Fir
27. n record with engine logbook Registration No N Lancair Evolution Inspection Program 4 Jun 11 32 Appendix B Special and Un scheduled Inspections Whenever the aircraft is subject to handling operations or other conditions which present extraordinary or unexpected stresses on the airframe engine propeller or aircraft systems the aircraft must be inspected in accordance with each component s Manufacturer s maintenance manual propeller s owner s manual and Pratt amp Whitney Maintenance manual to ensure that the affected areas and or systems are free from damage or excessive wear Defects found during the inspections will be recorded and will be corrected before the next flight All defects found during an inspection and the corrective action taken will be maintained as a permanent part of the maintenance records Appendix C Composite Inspections Composite Structures are utilized throughout this aircraft Most failures of composite structures are either through crushing or striking of objects dents cracks etc or fatigue that can cause delamination of the various layers of structure One method of inspection that can be utilized is through non destructive testing NDT is ultrasound When using ultrasound as a method of inspection discontinuities of the structure can be discovered through the loss of ultrasonic energy through attenuation via absorption and dispersion Various frequency wavelengths can determine discontinu
28. ner et 15 4 inspection Checklists semeen en A AS 15 D Pratt amp Whitney PT6A 135A Inspection Program se 25 Je G n ral unies tdi d 25 2e MME LIMIS sra en a ate ree R N a E esr wet A nn 26 a POSE Imspechon Test Run RU a Led dd 28 4 Safety PRACUCES rei A E e ROAT STE Area A ri 28 da initial Installation and Startup cse tin noel ne TE ne Tin sense 28 6 7ROtor components SEVIS Lifessa M o nn 28 E Hartzell Propeller Inspection Program A ce sated a ti Aer au ce 28 es OAI RTS ane A Nes R Su 28 mie Me MIS Re Re de Sen ne Re E ean ee Re find 29 Sir Safety Practices 20 4 Propeller Inspection sienne nnau nella A a E e 29 Es Appendices rinn acetate ot nn A A A Re bl 31 Appendix A Engine IAS A M a dd 31 Appendix B Special and Un scheduled Inspections ss 33 Appendix C Composite Inspections misionera jieniseaead ss losdgachovendesvendeaeus ennui 33 Registration No N Lancair Evolution Inspection Program 4 Jun 11 3 This Page Intentionally Left Blank Registration No N Lancair Evolution Inspection Program 4 Jun 11 4 Revisions Pages Effected Registration No N Lancair Evolution Inspection Program 4 Jun 11 5 This Page Intentionally Left Blank Registration No N Lancair Evolution Inspection Program 4 Jun 11 6 List of Effective Pages
29. ontrol via the overspeed governor on engines so equipped providing this limit is not exceeded 10 Inthe event of failure of the propeller governor toward overspeed it is permissible to complete a flight with propeller control via the overspeed governor on engines so equipped providing this limit is not exceeded 11 These values are time limited to twenty 20 seconds Registration No N Lancair Evolution Inspection Program 4 Jun 11 31 TEST RUN RESULTS TABLE 2 Total Flight Time Since Installation C RPM C C PSD w o 7 Maximum Continuous Date Certificate Number Signature TEST RUN RESULTS Total Flight Time Since Installation RPM C C PSD Idle Maximum Continuous Date Certificate Number Signature TEST RUN RESULTS Total Flight Time Since Installation RPM O C PSD w o Maximum Continuous Du Date Certificate Number Signature TEST RUN RESULTS Total Flight Time Since Installation WINE N1 NG N2 Np ITT TORQUE OIL TEMP OIL PRESS C C Idle po Na EA Maximum Date Certificate Number Signature 1 Refer to Pratt amp Whitney Maintenance manual section 71 00 00 for procedure on how to attain and interpret data for this table and take corrective action as necessary 2 Do not exceed any limitation in Table 1 during data collection procedure 3 Make photocopy of Table 2 for collection of data and maintai
30. or write actual indication Main Battery 2 Due Altimeter Transponder Test Due System Pre inspection Post inspection Main Fuel Pump Se EE Electric Fuel Pump a RC i Pressure o PSI ae Nn Chat ging System Paina VOLTS AA js NA NA J tetra o i o omm amp Nav a A a Oil Temperature Discrepancies Noted During Run up Prop Reporte CAUTION Ensure Temperatures in Green Range Stato RPM Fuel Flow at Static RPM ITT Indication Defrost Cabin heat Oil pressure Idle RPM CAUTION Engine Shutdown in Accordance with P amp W Maint Manual ParNo 3043512 71 00 00 All Annunciator Lights Off Check for Fuel Odors in Cabin Check Fuel Valves Verify fuel flows from each See last page for additional comments tank N A C alw alaloje Ele S z o j a D DIDID A z Q a am mim e dl Registration No N Lancair Evolution Inspection Program 4 Jun 11 16 DOE JOHN Q Lancair Evolution Condition Instructions for Continued Airworthiness Inspection and Maintenance Checklist Post Run up Checks 1 Exterior Lights Check operation of the taxi and landing lights position lights and strobe lights 2 Pitot Tube Heater Check operation WARNING Heater gets extremely hot Check within 60 seconds after switching on Do not operate longer than 2 minutes on the ground 3 Interior Lights Check operation of the panel lights instrument lights overhead li
31. r 66 Main Battery Left Inspect for security of mounting and condition 67 Main Battery Right Inspect for security of mounting and condition 68 Flight Controls Inspect for nicks scratches and dents in push pull rods play in rod end and linear bearings security of linear bearing mounts and rudder cable guide tubes to fuselage 69 Seats Inspect all seat structures for cracks corrosion and general condition Check seat controls for positive locking Inspect cushions and upholstery for condition 70 Seat Tracks amp Stops Inspect for cracks wear of latching holes and tracks and security D of tracks and stops 71 Restraint Systems Inspect belts for cuts fraying and broken stitching Check all buckles for proper locking and release Check inertia reels for proper operation Check attach points to structure for all belts 72 Upholstery amp Trim Inspect for general condition attachment and cleanliness 73 Placards Inspect for presence and condition of all required interior placards 74 Instruments Check security of instruments in panel and legibility of markings Ensure that no magnetic tools are used during this procedure 75 Avionics Check security of displays audio panel indicators and controls on panel and center console touch screen switches on main panel and overhead legibility of markings and operation of knobs security and cleanliness Ensure that no magnetic tools are used during
32. required entries per Part 43 97 Completed Engine Inspection Checklist 98 Completed Propeller Inspection Checklist 99 Mechanics signature License number 96 Aircraft Records Complete entries in logbooks AD compliance lists Lancair LE Registration No N Lancair Evolution Inspection Program 4 Jun 11 23 DOE JOHN Q Lancair Evolution Inspection Access Areas Area Type of Access Inspection amp Maintenance Items End of left wing outboard Pitot tube amp fuel vent Fuel System Inboard from root to fuselage Fuel lines amp electric wiring Access Panel Underage Of wing sn ONL or Fuel lines landing gear End of right wing outboard Fuel System Inboard from root to fuselage Fuel lines amp electric wiring Access Panel ie ENST Fuel lines landing gear Rudder bellcrank elevator push pull rod Access Panel Tail cone left side autopilot pitch amp yaw servos yaw damper Elevator bellcrank elevator pushrod tail nav amp strobe wiring tail surfaces trim wiring Tail Cap Tail Cap GPS Antenna VOR Antenna ELT Antenna Engine Cowling Forward of fuselage firewall All engine and propeller parts and Top and Bottom components Rear seat foot well Wing attachment bolts aft spar y Voltage regulator primary bus US distribution block pilot O2 system Floor Co Pilot Side Climate Control Unit CCU fuel lines hydraulic lines Aileron and elevator push pull rods circuit breaker panel control
33. rippling Check condition of paint and placards Check fuel sumps for obstructions Check fuel tank vents for obstructions 30 Landing amp Taxi Light Assembly Inspect for cracks security of mounting and cleanliness and condition of lens cover Operate taxi and landing lights in a dark area and ensure that both lights are properly aimed If the lights are not properly aimed adjust as required 1 Aileron amp Flap Attach Points Inspect for security of attachment to the wing 32 Aileron Left amp Trim Tab Inspect for damage looseness or play in attach bearings and condition of attachment Check security of static balance weights Inspect bonding straps and static wicks for condition Check for obstruction of vent hole 33 A leron Right Inspect for damage looseness or play in attach bearings and condition of attachment Check security of static balance weights Inspect bonding straps and static wicks for condition Check for obstruction of vent holes 34 Aileron Trim Tab Clevis Inspect trim clevis and related hardware for evidence of corrosion and pitting Check for proper security 35 Aileron Deflections Ensure that both aileron bellcranks seat properly on their stops 36 Flaps Inspect skins for condition and signs of debonding Check hinges for play and attachment to wing and flap Check hinges for corrosion Check flap push pull rods and rod end bearings for condition and lubricate Inspect condition of
34. site bottles only Documents 4 Disassemble the nose gear and replace all seals Every 2000 Gon ida Hours Manual 4 Inspection Checklists a This section contains the inspection items for the required and recommended inspections described above b Prior to each annual inspection an engine start up should be performed using the Initial Startup Checklist c Depending on the specific types of operations the owner or operator may need to modify and or increase the frequency of some inspection and or servicing items d Persons performing an inspection under this program must use the appropriate checklist in this program This checklist must be accompanied by the appropriate manufacturer s maintenance manual as currently revised for the component being inspected NOTE All inspections and maintenance procedures must be in accordance with applicable Federal Aviation Regulations Please refer to parts 91 207 91 403 91 409 91 411 and 91 413 Registration No N Lancair Evolution Inspection Program 4 Jun 11 15 DOE JOHN Q Lancair Evolution Instructions for Continued Airworthiness Inspection and Run up Checklist Registration Number Serial Number Owner N EVO John Q Doe Date Started Date Completed Work Order Inspection Type Annual Condition Garmin 900 Engine Time Eng TSN Prop TSN Mechanic s Name Eng TSO Prop TSO ELT Battery Due RUN UP CHECKS Main Battery 1 Due DT O Check Y if okay
35. sure to notify any nearby control tower of your intentions 91 2076d Empennage Interior Structure Inspect for cracks debonding or other signs of damage Verify that all drain holes are clear of debris Access Panels amp Fairings Inspect for condition Check fasteners and receptacles for condition Air Conditioning Inspect all hoses wiring function test and if service is necessary service IAW manufacturer s recommendations Pressurization Check cabin pressurization for leaks and cabin altitude warning system for proper operation Registration No N Lancair Evolution Inspection Program 4 Jun 11 22 Inspection Wrap up 93 Fuselage amp Wings Verify the aircraft is free of any tools parts and debris and reinstall all access fairings panels carpeting seats etc removed for this inspection 94 Engine Verify the oil sump is properly serviced with oil and the engine compartment is free of tools rags and debris Remove red debris dust cover when complete with inspections and or maintenance 95 Engine Run the engine and verify proper operation of all systems After shutdown check for leaks at fluid hose connections fuel nozzles and any other components removed during this inspection Operate engine systems at appropriate engine speeds and complete all checks listed on Inspection Coversheet If no leaks are noted install cowlings International Factory Service Bulletins and any other
36. this procedure 76 Magnetic Compass Inspect for security clarity of glass and signs of oil leakage Inspect compass correction card for presence and legibility of all headings Ensure that no magnetic tools are used during this procedure Perform compass swing to verify correction card values 77 Instrument Panel Backside Remove the glare shield and inspect all wires lines hoses control cables instruments etc for any interference chafing and loose or stressed connections Inspect structure of forward bulkhead engine mount support structures etc for cracks debonding and general condition Inspect soundproofing material for condition and adhesion to forward bulkhead 78 Auto Pilot Servos Inspect for security of installation wiring connection and security of linkage for pitch roll and yaw servos Registration No N Lancair Evolution Inspection Program 4 Jun 11 21 79 Reinstall Glare Shield Check security of attachment and condition Check pullout shield for freedom of movement condition and security 80 ECS Ducts Inspect for cracks holes routing and chafing 81 Rudder Pedals Inspect for security cracks and play Check for leakage from brake cylinders Lubricate rudder cable clevis bolt and brake cylinder attach points with high quality petroleum or silicone based oil Do not lubricate rudder pedal torque tube pillow blocks 82 Seat Box Structure Inspect for cracks debonding
37. visually inspected annually and a tap test should be performed to aid in detection of any latent damage delaminations or debonds Registration No N Lancair Evolution Inspection Program 4 Jun 11 33 This Page Intentionally Left Blank Registration No N Lancair Evolution Inspection Program 4 Jun 11 34
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