TYPE: Gemini Flash 2 Alpha (1) MANUFACTURER: Mainair Sports Ltd now supported by P & M Aviation Ltd., Unit B, Crawford Street Rochdale, Lancashire, OL16 5NU. (2) UK IMPORTER: N/A (3) CERTIFICATION: BCAR Section S, Advance Issue March 1983 BCAR Section S, Paper, 11 October 1988 (4) DEFINITION OF BASIC STANDARD: 440 Dual Master List of Drawings, Issue 7 Flash Wing Master Drawing List, Issue 5 (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) (g) ZFW + 172 kg crew + 1 hr fuel (litres / kg) 370 kg 23.78 kg/m² 24 kts (25 mph) 55 90 kg per seat. (Alpha 503) 149kg (Alpha 462) 149kg (Alpha 503-2V) 151kg (Alpha 582) 157kg (503) 336kg (426) 340 kg (503-2V) 338 kg (582) 347 kg TADS BM23 Issue 14 Page 1 of 15
(h) ZFW + 86 kg pilot + full fuel ( litres / kg) (i) Max ZFW at initial permit issue (503) 267 Kg [290 kg with mod99] (462) 267 kg [292 kg with mod99] (503-2V) 269 kg [292 kg with mod99] (582) 275 kg [298 kg with mod99] (503) 183 kg (462) 179 kg (503-2V) 183 kg (582) 180 Kg TADS BM23 Issue 14 Page 2 of 15
(6) POWER PLANTS Designation Gemini Flash 2 Alpha 503 Gemini Flash 2 Alpha 503 Gemini Flash 2 Alpha 503 Gemini Flash 2 Alpha 462 Gemini Flash 2 Alpha 462 Gemini Flash 2 Alpha 462 Gemini Flash 2 Alpha 462 Engine Type Rotax 503 Rotax 503 Rotax 503 Rotax 462 Upright Rotax 462 Upright Rotax 462 Upright Rotax 462 Upright Upright Upright Upright Single Points Ign or Twin Electronic Ign. Single Points Ign or Twin Electronic Ign. Single Points Ign or Twin Electronic Ign. Reduction Gear 2.58:1 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 Mount with After Muffler Rotax Side Mount with After Muffler Rotax Side Mount with After Muffler Rotax Side Mount with After Muffler Intake System Rotax Intake Silencer Rotax Intake Silencer Rotax Intake Silencer Rotax Intake Silencer Rotax Intake Silencer Rotax Intake Silencer Rotax Intake Silencer Propeller Type Mainair Mainair Grd Adjustable Mainair WD Grd Adj Mainair Round Tip Mainair Square Tip Mainair Ground Adjustable Mainair WD Grd. Adjustable Propeller Dia x Pitch 62 x 40 3 Blade 62 107deg at 12 3 Blade 62 113deg at 12 62 x 44 or 62 x 46 62 x 46 3 Blade 62 107deg at 12 3 Blade 62 113deg at 12 Noise Type Cert No. 26M 50M 50M 35m 35m 35m 35m AAN approving configuration 20331 20375 22913 20331 20331 20375 22913 TADS BM23 Issue 14 Page 3 of 15
Designation Gemini Flash 2 Alpha 503-2V Gemini Flash 2 Alpha 503-2V Gemini Flash 2 Alpha 503-2V Gemini Flash 2 Alpha 582 Gemini Flash 2 Alpha 582 Engine Type Rotax 503-2V Upright Twin Electronic Ign. Rotax 503-2V Upright Twin Electronic Ign. Rotax 503-2V Upright Twin Electronic Ign. Rotax 582-2V Upright 40k Version Rotax 582-2V Upright 40k Version Reduction Gear 2.58:1 2.58:1 2.58:1 3.00:1 3.00:1 Exhaust System Rotax Side Mounted with After Muffler Rotax Side Mounted with After Muffler Rotax Side Mounted with After Muffler Rotax Side Mount with After Muffler Rotax Side Mount with After Muffler Intake System Rotax Intake Silencer or K & N Filter Rotax Intake Silencer or K & N Filter Rotax Intake Silencer or K & N Filter K & N Filter K & N Filter Propeller Type Mainair Mainair Grd Adjustable Mainair WD Grd Adj Mainair WD Grd Adjustable Mainair WD Grd Adjustable Propeller Dia x Pitch 62 x 40 3 Blade 62 110deg at 12 3 Blade 62 112 114deg at 12 4 Blade 62 Dia 119deg at 12 r 4 Blade 62 Dia 125deg at 12 r Noise Type Cert No. 133M 133M 133M 134m 134m AAN approving configuration 22707 Ad1 22707 Ad 1 22707 Ad 1 22708 Ad 1 22708 Ad 2 TADS BM23 Issue 14 Page 4 of 15
(7) MANDATORY LIMITATIONS: (A) Max Take-Off Weight 370 Kg (B) CG Limits (C) CG datum N/A N/A (D) Cockpit Loadings Front Rear Total Min 55kg 15 kg 70 kg Max 90kg 90 kg 180 kg (E) Never Exceed Speed (F) Manoeuvring Speed (G) Permitted Manoeuvres (H) Fuel Contents (Max Useable) 77 knots (89 mph) 38 knots (44 mph) 30 Nose up / 30 nose down 60deg Max Bank Angle Non Aerobatic Normal acceleration limits, +4 / -2g 44 litres (22 Optional) 65 litres (Mod99) TADS BM23 Issue 14 Page 5 of 15
(I) Power Plant See Table Engine Rotax 503 Upright Rotax 462 Upright Rotax 503-2V Upright Rotax 582-2V Upright (40kw) Max RPM 6800 6800 6800 6400 MAX CHT 250 degc 150 degc 250 degc 150 degc MAX EGT 650 degc 650 degc 650 degc 650 degc Fuel Spec Engine Oil Spec Gearbox oil 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. Two Stroke Oil ASTM/CEC Standards, API- TC Classification API-GL5 or GL6, SAE 140 EP Two Stroke Oil ASTM/CEC Standards, API- TC Classification API-GL5 or GL6, SAE 140 EP Two Stroke Oil ASTM/CEC Standards, API- TC Classification API-GL5 or GL6, SAE 140 EP Two Stroke Oil ASTM/CEC Standards, API- TC Classification API-GL5 or GL6, SAE 140 EP Fuel/Oil Mix 50/1 50/1 50/1 50/1 Coolant Temperature N/A 80 DegC N/A 80 DegC Oil Pressure N/A N/A N/A N/A Oil Temperature N/A N/A N/A N/A Fuel Pressure N/A N/A N/A N/A (8) INSTRUMENTS REQUIRED: ASI Altimeter RPM CHT / Compass Coolant Fuel VSI Slip ball EGT temp Pressure Required (to 90 mph min.) Required Required (Twin Ign Only) N/A N/A N/A N/A N/A N/A TADS BM23 Issue 14 Page 6 of 15
(9) CONTROL DEFLECTIONS: N/A Elevator UP: ± Tailplane trim UP: ± Elevator DOWN: ± Tailplane trim DOWN ± Ailerons* UP: ± Rudder LEFT: ± Ailerons* Down: ± Rudder RIGHT: ± (10) PILOT'S NOTES, MAINTENANCE MANUALS REFERENCES: 10.1 Manuals approved for use with this aircraft. (a) Flash 2A Microlight Manual Doc Ref GF Manual (at appropriate issue) 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). If MTOW can be exceeded with full fuel and maximum cockpit weight, the fuel loads at MTOW for cockpit weights. An example is shown at Annex D. (d) Switches See Annex D. TADS BM23 Issue 14 Page 7 of 15
(11) MANDATORY MODIFICATIONS / SERVICE BULLETINS / AIRWORTHINESS DIRECTIVES ETC: CAA MPD 1995-021 Flight limitations CAA MPD 2000-003 Inspection of wing rigging CAA MPD 2001-004 Upper torso restraint Annual Bettsometer test is to be carried out to 1050 grammes with wing sails fitted and tensioned to flight. Test must be to both upper and lower surfaces. (12) MINIMUM PERFORMANCE AT MAX TAKE-OFF WEIGHT Rate of Climb: Stall or Minimum Flying Speed: 490 fpm at 47 IAS. Alpha 582 660 fpm at 47 mph 24kts (25mph) IAS at MTOW / idle. TADS BM23 Issue 14 Page 8 of 15
Issue History Issue No. Reason and signatory 1 03/07/87 J D WATKINS 2 25/09/87 J D WATKINS 3 07/03/91 K D RUSSELL 4 18/03/91 Correction of prop pitch range and editorial changes. K D RUSSELL 5 08/05/91 Introduction of Rotax 582 engine (Mod No. 56) including Appendix 1 and further editorial changes. K D RUSSELL 6 01/07/91 Introduction of implications of modified front suspension (Mod 57) and optional 3.47:1 gearbox (Mod 63) K D RUSSELL 7 23/10/91 Introduction of Mainair 3 blade ground adjustable propeller and complete optional mods listing (Appendix 2). Introduction of Mainair WD propeller on Rotax 503-IV and Rotax 462 engines (Mod 62). K D RUSSELL 8 18/02/92 Approval of Mainair Modification No. 66 to incorporate duel electronic ignition on Upright Rotax 503 single carburetor engines. K D RUSSELL 9 01/02/93 Approval of Mainair Modification No. 70 (Electronic Starter Option). K D RUSSELL 10 10/12/93 Re-instatement of 60 bank angle limitations (SB No. 41 refers) K D RUSSELL 11 08/07/02 Update using new format J BARRATT 12 06/07/05 New company name J BARRATT 13 08/03/06 Correction to gearbox ratio for Rotax 582 J BARRATT TADS BM23 Issue 14 Page 9 of 15
Issue No. Reason and signatory 14 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 BM23 Issue 14 Page 10 of 15
Illustration of Aircraft - 3 View TADS BM23 Issue 14 Page 11 of 15
ANNEX A MANDATORY MODIFICATIONS Modification 98 Shoulder Straps (MPD 2001-004 refers) 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. Mainair Modification Number Description 7 Rear Seat Steering 11 503 Rotax Engine 12 462 Rotax Engine 12a 462 Fuel Heating 12b 462 Rotax engine/62 x 42 Square Tip propeller 12c 462 Rotax engine/62 x 44 Round Tip propeller 12d 462 Rotax engine/62 x 46 Round Tip propeller 16 Back-up wires on front strut 18 Transit Yoke 32 3-blade propeller on Gemini Flash, Flash 2, 2A and Scorcher 33 Short Reach Foot Steering Bar Gemini Flash 2A Dwg. 99-00-263 34 Aerofoil Side Strut Inner Grid Sleeve Dwg 44-305 35 Suspension Spring Rate Change 38 Rear Dip Pipe Locator Spring Dwg 99-00-303 39 Negative Load Wing Warning Sticker 00-02 40 Fibreglass exhaust shield Dwg 99-44-204 41 Q.D. Rear Steering, Alpha Trikes Dwg 44-141 42 Gas Damper Front Suspension, Alpha Trike Dwg 99-41-261 44 Additional monobolt fixing on Aerofoil Axles and additional sleeve on Drag Link 45 Boss Ballast Bag System Dwg 99-44-500 49 Alpha rear wheels ball race and axie 50 Flash Wing Over-rider Instructor Bars 51 Ear Bracket (Modified) 52 22 degree Steering 53 Nose Cone Warning Label 54 Rotax 503 Engine with Twin Carburettors and twin ignition 55 Radiator Top Mounting TADS BM23 Issue 14 Page 12 of 15
Mainair Modification Number Description 56 Rotax 582 (40 Kw) Engine with Twin Carburettors and twin electronic ignition 57 Trailing Arm forks and suspension 60 Hand Throttle Lever 61 Fuel Tank Level graduations 62 Mainair WD ground adjustable propeller (Rotax 503 and 462) 63 3.47:1 Gearbox on Rotax 582 66 Dual Electronic ignition on Rotax 503 single carburetor engines 69 Wiring change to Rotax points ignition 70 Electronic starter options 71 Base Bar Moved Forwards 2 inches 72 Sealed Nose Wheel Bearings 90 Clear Fuel Filter 92 Sleeve in Drag Link 99 65 Litre Fuel Tank 187 Increase Seat Load Limit to 110kg ANNEX C WEIGHING INFORMATION 1. CG Datum: N/A 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). 8. Aft CG Limit: N/A (units) (direction) of datum 9. Fwd CG Limit: N/A (units) (direction) of datum TADS BM23 Issue 14 Page 13 of 15
ANNEX D EXAMPLE PLACARDS (a) Flight & Engine Limitations Placard (to be visible to pilot) [Typical Examples] GEMINI FLASH2A MAX. ALL UP WEIGHT MIN. ALL UP WEIGHT EMPTY WEIGHT STALL SPEED NEVER EXCEED (V.N.E.) MIN LANDING APPROACH MAX CROSS WIND REC. ENGINE EGT REC ENGINE CHT REC. WATER TEMP REC. ENGINE MAX 370KG 240KG 149KG 28MPH 89MPH 42MPH 10MPH 650 DEGC 150 DEGC 80DEGC 6800RPM WARNING THIS AIRCRAFT IS NON-AEROBATIC MAXIMUM NOSE UP 30DEG MAXIMUM NOSE DOWN 30DEG MAXIMUM BANK ANGLE 60DEG SPINNING ATTEMPTS PROHIBITED NO WHIPSTALLS LOOPS TAILSLIDES OR AEROBATIC MANOEUVRES DO NOT EXCEED MAX LOAD (b) Fuel Limitations Placard (to be visible to pilot) Empty Wt Date Fuel Load (litres) 65 55 45 35 25 15 5 Kg Max Cockpit Wt (kg) TADS BM23 Issue 14 Page 14 of 15
(c) Fuel Capacity and Type (to be located near to filler cap) FUEL - 22 LITRES EN228 UNLEADED or AVGAS 100LL INSPECT INTERNAL AND EXTERNAL FILTERS FREQUENTLY 2 STROKE OIL MIX AT RATIO 50:1 FUEL - 65 LITRES EN228 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 BM23 Issue 14 Page 15 of 15
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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