TYPE: MAINAIR BLADE (1) MANUFACTURER: P & M Aviation Ltd, Unit B, Crawford Street, Rochdale, Lancashire, OL16 5NU (2) UK IMPORTER: - (3) CERTIFICATION: BCAR Section, Advance Issue as amended October 1988 + all applicable Working Draft Papers (4) DEFINITION OF BASIC STANDARD: Betawing Drawing Register 27 th April 1994 Gemini 4 Drawing Register 27 th April 1994 (as amended) (5) COMPLIANCE WITH THE MICROLIGHT DEFINITION (a) MTOW (b) No. Seats 2 (c) Maximum Wing Loading (d) Vso (e) Permitted range of pilot weights (f) Typical Empty Weight (ZFW) 390 kg 25 kg/m² 30 mph IAS 55 90 kg per seat. 174 kg (Rotax 582 version) 160 kg (Rotax 503/462 version) (g) ZFW + 172 kg crew + 1 hr fuel (litres / kg) (h) ZFW + 86 kg pilot + full fuel ( litres / kg) With 65 litre tank (Mod 99) (i) Max ZFW at initial permit issue (503) 347 kg (462) 351 kg (582) 364 kg (503) 278 kg (462) 278 kg (582) 292 kg (503) 293 kg (462) 293 kg (582) 307 kg 205 kg TADS BM47 Issue 11 Page 1 of 10
(6) POWER PLANTS Designation Blade 582 Blade 582 Blade 462 Blade 462 Blade 462 Blade 503 Blade 503 Blade 503 Engine Type Rotax 582-2v Rotax 582-2v Rotax 462 Rotax 462 Rotax 462 Rotax 503-2V Rotax 503-2V Rotax 503-2V Ignition System Rotax dual cdi Rotax dual cdi Single points system Single points system Single points system Single points system or Rotax dual cdi Single points system or Rotax dual cdi Reduction Gear 3.47:1 3.47:1 2.58:1 2.58:1 2.58:1 2.58:1 2.58:1 2.58:1 Exhaust System Rotax Side Mounted with after muffler Rotax Side Mounted with after muffler Rotax Side Mounted with after muffler Rotax Side Mounted with after muffler Rotax Side Mounted with after muffler Rotax Side Mounted with after muffler Rotax Side Mounted with after muffler Intake System K & N Intake Filter or Rotax Intake Silencer K & N Intake Filter or Rotax Intake Silencer Rotax Intake Silencer Rotax Intake Silencer Rotax Intake Silencer K & N Intake Filter or Rotax Intake Silencer K & N Intake Filter or Rotax Intake Silencer Single points system or Rotax dual cdi Rotax Side Mounted with after muffler K & N Intake Filter or Rotax Intake Silencer Propeller Type Propeller Dia x Pitch Noise Type Certification No. AAN approving configuration Mainair WD Ground adjustable 4 Blade 62" diameter pitch 123º at 12" Arplast 152 DAS 4875/4 or 152 DAS 6275/4 4 blade 152 cm diameter pitch 22 at 54.5 cm radius 150M Issue 1 Mainair Mainair Ground Adjustable 62" x 44" 3 Blade 62" 107 at 12" Mainair WD Ground Adjustable 3 Blade 62" 113 at 12" Mainair Mainair WD Ground Ajustable 62" x 40" 113 at 12" 3 Blade 62" Mainair Ground Ajustable 110 at 12" 3 Blade 62" 150M 35M 35M 35M 133M 133M 133M Issue 1 Issue 6 Issue 6 Issue 6 Issue 2 Issue 2 Issue 2 24302 24302 Add 1 24302 Add 3 24302 Add 3 23402 Add 3 24302 Add 2 24302 Add 2 24302 Add 2 TADS BM47 Issue 11 Page 2 of 10
(7) MANDATORY LIMITATIONS: (A) Max Take-Off Weight 390 kg (B) CG Limits N/A (C) CG datum N/A (D) Cockpit Loadings Front Rear Total Min 55 kg 15 kg 70 kg Max 90 kg 90 kg 180 kg (E) Never Exceed Speed (F) Manoeuvring Speed 101 mph 60 mph (G) Permitted Manoeuvres Max Bank 60 Pitch 30 Non Aerobatic (H) Fuel Contents (Max Useable) (I) Power Plant 22 litres Option 22 litres 65 litres (Mod 99) See Table TADS BM47 Issue 11 Page 3 of 10
Engine Rotax 582-2V Upright Rotax 462 Upright Rotax 503-2V Upright Max RPM 6800 6800 6800 MAX CHT 150 deg C 150 deg C (300deg F) 250 deg C (480 deg F) MAX EGT 650 deg C 650 deg C (1200F) 650 deg C (1200F) Fuel Spec 83 MON or 90 RON minimum unleaded to BS(EN)228 or 97+ octane 4-star /MOGAS leaded fuel to BS 4040, or AVGAS 100LL. Engine Oil Spec 2 stroke 2 stroke 2 stroke Gearbox oil spec AP1 GL5/GL6 AP1 GL5/GL6 AP1 GL5/GL6 Fuel/Oil Mix 50/1 50/1 50/1 Coolant Temperature 80 80 N/A Oil Pressure N/A N/A N/A Oil Temperature N/A N/A N/A Fuel Pressure (8) INSTRUMENTS REQUIRED: ASI Altimeter RPM CHT / Compass Coolant Fuel VSI Slip ball EGT temp Pressure Required Required Required for dual ignition engines only - - - - - - (9) CONTROL DEFLECTIONS: N/A Elevator UP: ± Tailplane trim UP: ± Elevator DOWN: ± Tailplane trim DOWN ± Ailerons* UP: ± Rudder LEFT: ± Ailerons* Down: ± Rudder RIGHT: ± TADS BM47 Issue 11 Page 4 of 10
(10) PILOT'S NOTES, MAINTENANCE MANUALS REFERENCES: 10.1 Manuals approved for use with this aircraft. BD Manual (as amended). 10.2 The following placards are to be fitted:- (a) Flight Limitations Placard (to be visible to pilot) See Annex D. (b) Engine Limitations Placard (to be located near to engine instruments) See Annex D. (c) Fuel Limitations Placard (to be located near to filler cap) A placard is to be fitted showing fuel capacity ( litres), fuel type(s), fuel:oil ratio (if relevant) and if MTOW can be exceeded with full fuel and maximum cockpit weight, the fuel loads at MTOW for fuel capacity in increments of 10 litres intervals down to the maximum fuel load. An example is shown at Annex D. (d) Switches See Annex D. (11) MANDATORY MODIFICATIONS / SERVICE BULLETINS / AIRWORTHINESS DIRECTIVES ETC: See Annex A for required modifications. (12) MINIMUM PERFORMANCE AT MAX TAKE-OFF WEIGHT Rate of Climb: Climb Speed: Stall or Minimum Flying Speed: 800 ft/min (582 version) 600 ft/min (462 version) 500 ft/min (503 version) 55 mph 30 mph TADS BM47 Issue 11 Page 5 of 10
Issue No. 1 12/05/94 K D Russell 2 06/06/94 K D Russell Issue History 3 07/06/94 Further editorial changes K D Russell Reason and signatory 4 20/10/94 Addition of Arplast propellers (Mainair Modification No. 79) K D Russell 5 28/11/94 Addition engine types (Mainair Modification No. 78 and 81 refers) K D Russell 6 03/01/95 Correction of Editorial omissions of design standard and current three view drawing K D Russell 7 20/04/01 Addition of Rotax 582 (99 model) - Mainair Minor Modification 97 R J Hardy 8 07/02/02 Addition of Mandatory Modification 98, which introduces passenger upper torso restraints. J BARRATT 9 08/07/02 Editorial corrections. J BARRATT 10 06/07/05 New company name J BARRATT 11 18/11/09 To record Modification Number 187, which increases seat load limit to 110kg but still with a total cockpit load of 180g. D S CORTIZO TADS BM47 Issue 11 Page 6 of 10
TADS BM47 Issue 11 Page 7 of 10
ANNEX A MANDATORY MODIFICATIONS Description Modification Number Shoulder Straps 98 ANNEX B APPROVED OPTIONAL MODIFICATIONS The installation of all optional modifications is to be inspected by a BMAA inspector and an entry made in the appropriate logbook(s). Note that other approved modifications may exist which are not listed here. Description Modification Number Front Strut back-up 16 Rear seat steering 41 Boss Ballast Bag 45 Overrider Instructor Bar 50 Electric Start 70 Adjustable Index Tips 89 Clear Fuel Filter 90 Sleeve Indrag Link 92 Intake Silencer 93 Rotax 582 (99 model) 97 65 litre Single Tank 99 Increase Seat Load Limit to 110kg 187 ANNEX C WEIGHING INFORMATION 1. CG Datum: N/A (flexwing microlight) 2. Weighing attitude: N/A 3. Mainwheel moment arm: N/A 4. Nosewheel moment arm: N/A (units) (direction) of datum 5. Fuel moment arm: N/A (units) (direction) of datum 6. Crew moment arm: N/A (units) (direction) of datum 7. Crew weights: Minimum 55 kg / maximum 90 kg (maximum reducible, not below 86 kg, if required). TADS BM47 Issue 11 Page 8 of 10
8. Aft CG Limit: N/A (units) (direction) of datum 9. Fwd CG Limit: N/A (units) (direction) of datum ANNEX D EXAMPLE PLACARDS (a) Flight Limitations and Engine Limitations Placard (to be visible to pilot) MAINAIR BLADE MAX ALL UP WEIGHT MAX COCKPIT LOAD MIN ALL UP WEIGHT EMPTY WEIGHT 390KG 180KG 250KG 174KG STALL SPEED MANOUVRE SPEED NEVER EXCEED Vne MIN LANDING APP MAX CROSS WIND 30MPH 60MPH 101MPH 50MPH 10MPH MAX EGT 1200 F MAX CHT (Rotax 503) 480 F MAX WATER TEMP 80 C MAX RPM 6800 WARNING THIS AIRCRAFT IS NON-AEROBATIC MAXIMUM NOSE UP 30 MAXIMUM NOSE DOWN 30 MAXIMUM BANK ANGLE 60 SPINNING ATTEMPS PROHIBITED NO WHIPSTALLS LOOPS TAILSLIDES OR AEROBATIC MANOEUVRES DO NOT EXCEED MAX. LOAD MAINAIR SPORTS ROCHDALE ENGLAND (b) Fuel Limitations Vs Max Cockpit Load Placard (to be visible to the pilot) Empty Wt Date Fuel Load (litres) 65 55 45 35 25 15 Kg Max Cockpit Wt (kg) TADS BM47 Issue 11 Page 9 of 10
5 (c) Fuel Capacity and Type (to be located near to filler cap) FUEL - 22 LITRES EN 228 UNLEADED or AVGAS 100LL INSPECT INTERNAL AND EXTERNAL FILTERS FREQUENTLY 2 STROKE OIL MIX AT RATIO 50:1 FUEL - 65 LITRES EN 228 UNLEADED or AVGAS 100LL INSPECT INTERNAL AND EXTERNAL FILTERS FREQUENTLY 2 STROKE OIL MIX AT RATIO 50:1 (d) Switches All switches are to be marked with function and sense (up=on, down=off). TADS BM47 Issue 11 Page 10 of 10
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Civil Aviation Authority EMERGENCY MANDATORY PERMIT DIRECTIVE Number: 2016-008-E Issue date: 3 October 2016 In accordance with Article 41(1) of The Air Navigation Order 2016, as amended, the following action required by this Mandatory Permit Directive (MPD) is mandatory for applicable aircraft registered in the United Kingdom operating on a UK CAA Permit to Fly. Type Approval Holder s Name: P&M Aviation Ltd Title: Type/Model Designation(s): Pegasus XL-Q variants, Pegasus Quasar variants, Pegasus Quantum variants, Pegasus Quik, Quik, Quik GT450, Quik Lite, Gemini Flash IIA, Mainair Blade variants Wing Luff Line Attachment Webbing Inspection Manufacturer: Applicability: Reason: P&M Aviation Ltd Pegasus XL-Q variants, Pegasus Quasar variants, Pegasus Quantum variants, Pegasus Quik, Quik, Quik GT450, Quik Lite, Gemini Flash IIA, Mainair Blade variants. The port inner luff line attachment webbing failed on a GT450 wing with 620 hours airtime during taxiing. The polyester webbing loop had chafed against the chrome plated brass eyelet. The webbing wear was visible from the top side, but not from the underside of the sail. A detached luff line is hazardous as it may go into the propeller. Pitch stability in a steep dive or in turbulence would also be compromised. It appears that the eyeleting process has been forming a ridge inside it capable of damaging the webbing. New tooling has been introduced at the Factory to prevent recurrence of the problem. Effective Date: 3 October 2016 Compliance/Action: Compliance is required as follows, unless previously accomplished: 1. Before further flight, inspect the luff line attachment webbings in accordance with paragraph 2.1 of P & M Aviation Ltd Service Bulletin 142. If there is no sign of damage to the webbing, the aircraft may continue in service. 2. Before further flight, inspect the luff line attachment webbings in accordance with paragraph 2.1 of P & M Aviation Ltd Service Bulletin 142. If there is no sign of damage to the webbing, the aircraft may continue in service. Mandatory Permit Directive 2016-008-E Page 1 of 2
Civil Aviation Authority Mandatory Permit Directive SARG Airworthiness Compliance/Action Cont: 3. If the inspection in paragraph 1 reveals damage to the webbing, it must be replaced or a back up load path installed in accordance with paragraph 2.3 of P & M Aviation Ltd Service Bulletin 142 before further flight. 4. Record the inspection from paragraph 1 and any necessary rectification action from paragraph 2 in the aircraft technical log in accordance with paragraph 3 of P & M Aviation Ltd Service Bulletin 142. 5. Repeat the actions in paragraphs 1 and 2 at 50 flight hour intervals. ENSURE COMPLIANCE WITH THIS MPD IS RECORDED IN THE AIRCRAFT LOGBOOK Reference Publications: P & M Aviation Ltd Service Bulletin Number 142 Issue 4 dated 23 September 2016 Remarks: 1. This MPD was not posted for consultation because of the urgency of the requirement. 2. Enquiries regarding this Mandatory Permit Directive should be referred to: GA Unit, Civil Aviation Authority, Safety and Airspace Regulation Group, Aviation House, Gatwick Airport South, West Sussex, RH6 0YR. Tel: +44 (0)1293 573988 E-mail: ga@caa.co.uk Mandatory Permit Directive 2016-008-E Page 2 of 2
Civil Aviation Authority EMERGENCY MANDATORY PERMIT DIRECTIVE Number: 2016-011-E Issue date: 23 November 2016 In accordance with Article 41(1) of The Air Navigation Order 2016, as amended, the following action required by this Mandatory Permit Directive (MPD) is mandatory for applicable aircraft registered in the United Kingdom operating on a UK CAA Permit to Fly. Type Approval Holder s Name: P&M Aviation Ltd Type/Model Designation(s): Various, see below Title: Manufacturer: Applicability: Clevis Pin / Split Ring Installations Inspection / Replacement P&M Aviation Ltd All Microlights where P & M Aviation Ltd is the Type Approval Holder: TADS No. Aircraft Type TADS No. Aircraft Type BM2 Gemini Sprint BM43 Mainair Mercury BM3 Tri-Flyer Sprint BM44 Pegasus Quasar 2 TC BM4 Gemini Flash BM45 Cyclone AX3//503 BM5 Panther XL-S BM46 Pegasus Quantum 15 (Rotax 2-stroke engines) BM9 Pegasus XL-R BM47 Mainair Blade BM10 Pegasus Flash BM50 Pegasus Quantum 15-912 BM17 Pegasus Flash 2 BM51 Mainair Blade 912 BM14 Gemini Flash 2 BM53 Cyclone AX2000 BM16 Scorcher BM54 Mainair Rapier BM17 Pegasus Flash 2 BM56 Pegasus Quantum 15-HKS BM23 Gemini Flash 2 Alpha BM60 Mainair Blade 912S BM25 Pegasus XL-Q BM65 Flight Design CT2K (rudder control) BM27 Chaser S BM66 Pegasus Quik BM28 Pegasus Photon BM70 Quik GT450 BM31 Chaser S 1000 BM72 Flight Design CTSW (rudder control) BM33 Chaser S 508 BM77 QuikR BM37 Chaser S 447 BM80 Quik GTR BM38 Pegasus Quasar BM81 PulsR BM42 Pegasus Quasar TC BM83 Flight Design CTSL (rudder control) Mandatory Permit Directive 2016-011 Page 1 of 2
Civil Aviation Authority Mandatory Permit Directive SARG Reason: Following maintenance, a clevis pin came out of the RP-4 roll trim system pulley on a QuikR causing a left turn. The split ring securing the clevis pin had come out. It is not known if the ring was disturbed during the maintenance. The split ring which came out was the same spiral start pattern as that which has caused trouble before (see Service Bulletin 139). This pattern of ring has no positive stop, so that simple rotation of the ring (e.g. caused by it getting caught on something) will cause it to disengage. Disengagement of the split ring and subsequent clevis pin departure could affect the control of the aircraft. Effective Date: 24 November 2016 Compliance/Action: Compliance is required as follows, unless previously accomplished: 1. Before further flight, from the effective date of this MPD, inspect all clevis pin / split ring installations on the aircraft in accordance with paragraph 2 of P & M Aviation Ltd Service Bulletin 144. 2. If the inspection in paragraph 1 reveals any spiral start pattern split rings they must be replaced in accordance with paragraph 2 of P & M Aviation Ltd Service Bulletin 144 before further flight. 3. Record the inspection from paragraph 1 and any necessary rectification action from paragraph 2 in the aircraft technical log in accordance with paragraph 3 of P & M Aviation Ltd Service Bulletin 144. 4. Repeat the actions in paragraphs 1, 2 and 3 at each Permit to Fly revalidation. ENSURE COMPLIANCE WITH THIS MPD IS RECORDED IN THE AIRCRAFT LOGBOOK Reference Publications: Remarks: P & M Aviation Ltd Service Bulletin Number 144, Issue 3, dated 27 October 2016. 1. This MPD was not posted for consultation because of the urgency of the requirement. 2. Enquiries regarding this Mandatory Permit Directive should be referred to: GA Unit, Civil Aviation Authority, Safety and Airspace Regulation Group, Aviation House, Gatwick Airport South, West Sussex, RH6 0YR. Tel: +44 (0)1293 573988 E-mail: ga@caa.co.uk Mandatory Permit Directive 2016-011 Page 2 of 2
Civil Aviation Authority EMERGENCY MANDATORY PERMIT DIRECTIVE Number: 2017-004-E Issue date: 15 May 2017 In accordance with Article 41(1) of The Air Navigation Order 2016, as amended, the following action required by this Mandatory Permit Directive (MPD) is mandatory for applicable aircraft registered in the United Kingdom operating on a UK CAA Permit to Fly. Type Approval Holder s Name: P&M Aviation Ltd Type/Model Designation(s): Various, see below Title: Rigging Cables with Roll Swaged End Terminals Inspection / Replacement Manufacturer: Applicability: P&M Aviation Ltd All Microlights of the following types where P & M Aviation Ltd are the Type Approval Holder: TADS No. Aircraft Type BM4 BM10 BM14 BM16 BM17 BM23 BM43 BM47 Gemini Flash Pegasus Flash Gemini Flash 2 Scorcher Pegasus Flash 2 Gemini Flash 2 Alpha Mainair Mercury Mainair Blade BM51 Mainair Blade 912 BM54 Mainair Rapier BM60 Mainair Blade 912S BM70 Quik GT450 BM77 QuikR BM80 Quik GTR BM81 PulsR Mandatory Permit Directive 2017-004-E Page 1 of 3
Civil Aviation Authority Mandatory Permit Directive Safety and Airspace Regulation Group Reason: A P&M Quik GT450 in a flying school had a partial failure of a lower side rigging cable (Part No. YQD-045) when recovering from a spiral manoeuvre, within the limits of the flight envelope. These cables are arranged in pairs, to give a backup load path. The second cable carried the load and the aircraft landed safely. This is the only recorded lower side cable failure since 1984. The partial failure was at the edge of the roll swaged terminal end. The alternative cable terminations using Nicopress sleeves and thimbles allow more progressive flexing of the cable. The incident Quik GT450 lower side rigging cables had been in use for 1050 hours and 9 years. The aircraft had been subject to an accident and rebuilt once in its life. It was also operated quite near the coast where it is probable that sea air chlorides could have affected the material. There were corrosion pits in the S316 stainless steel material which accelerate fatigue failures. CLSCC (Chloride Stress Corrosion Cracking) is known to affect stainless steel. The cable fitting was at the bottom end of the cable, where solutions can wick down it and collect. The strand failures were caused by bending and tensile fatigue because of cracks propagating from scratches and corrosion pits on the surface. All the remaining cables had broken strands at the edge of the roll swaged terminals. Some of these strands had been failed for some time, as shown by discolouration of the failure surfaces. The cable is 7 cores of 7 strands construction. Failure of a lower rigging cable would potentially reduce the integrity of the wing and hazard the aircraft. Effective Date: 15 May 2017 Mandatory Permit Directive 2017-004-E Page 2 of 3
Civil Aviation Authority Mandatory Permit Directive Safety and Airspace Regulation Group Compliance/Action: Compliance is required as follows, unless previously accomplished: 1. Before further flight, for lower side, front and rear rigging cables with roll swaged terminal ends with more than 750 flying hours or 7 years of service, whichever comes first, visually inspect at the edge of the roll-swaged terminal(s) using a magnifying glass with a power of at least 3x. Inspect closely for damage i.e. broken strands, corrosion, mechanical damage or slippage. If any damage is found, replace the affected cable before further flight. If no damage is found, replace the cable within 25 flying hours. See paragraphs 1 and 2 of P & M Aviation Ltd Service Bulletin 147 including the warning in paragraph 2. 2. Within 25 flying hours, for lower side, front and rear rigging cables with roll swaged terminal ends with less than 750 flying hours and less than 7 years of service, visually inspect at the edge of the rollswaged terminal(s) using a magnifying glass with a power of at least 3x. Inspect closely for damage i.e. broken strands, corrosion, mechanical damage or slippage. If any damage is found, replace the affected cable before further flight. If no damage is found, replace the cable at 750 flying hours or 7 years of service, whichever comes first. See paragraphs 1 and 2 of P & M Aviation Ltd Service Bulletin 147 including the warning in paragraph 2. 3. Removal and replacement of any airframe structural cable requires a duplicate inspection - see paragraph 3 of P & M Aviation Ltd Service Bulletin 147. 4. Record the inspection from paragraph 1 or paragraph 2 and any necessary rectification action in the aircraft technical log in accordance with paragraph 3 of P & M Aviation Ltd Service Bulletin 147. 5. Repeat the inspection in paragraph 2 at each Permit to Fly revalidation and replace damaged cables as necessary. Replace the cables at 750 flying hours or 7 years of service, whichever comes first. ENSURE COMPLIANCE WITH THIS MPD IS RECORDED IN THE AIRCRAFT LOGBOOK Reference Publications: Remarks: P & M Aviation Ltd Service Bulletin Number 147 Issue 1 dated 10 May 2017 1. This MPD was not posted for consultation because of the urgency of the requirement. 2. Enquiries regarding this Mandatory Permit Directive should be referred to: GA Unit, Civil Aviation Authority, Safety and Airspace Regulation Group, Aviation House, Gatwick Airport South, West Sussex, RH6 0YR. Tel: +44 (0)1293 573988 E-mail: ga@caa.co.uk Mandatory Permit Directive 2017-004-E Page 3 of 3