TIME LIMITS AND MAINTENANCE CHECKS 1. GENERAL This chapter provides the recommended intervals for the overhaul and replacement of components, and the scheduled and unscheduled maintenance for the airplane. The recommended time limits and maintenance checks given in this chapter were created to meet the requirements of the Federal Aviation Regulations. Other Regulatory Authorities can have different requirements. Follow the requirements of the Regulatory Authority of the country where the airplane is registered. CAUTION: Recommended overhaul and replacement times are listed in Section 5-10, Time Limits. These maintenance items must be incorporated into the 100 Hour, Annual, or Progressive inspections as applicable. A. Scheduled Maintenance Programs and Requirements Note: It is important to note that Owners and Operators of non-commercially operated aircraft, for example private owners, require only an Annual inspection. Because the 100 Hour Inspection items are identical to the Annual Inspection items they are listed under the same column in Section 5-20, Scheduled Maintenance Report. However, 100 Hour Inspections are not required for non-commercially operated aircraft. It is the operator's responsibility to follow the requirements of the airworthiness authority of the country where the airplane is registered. civil airplanes of U.S. registry must undergo a complete inspection each 12 calendar months as required by 14 CFR 91.409. Compliance with the regulations is accomplished using one of three methods; Traditional Annual Inspection, Traditional 100 Hour Inspection, or Progressive Inspection. (1) Traditional Annual Inspection Program The Traditional Annual Inspection Program utilizes 14 CFR 43, Appendix D to inspect the airplane. Annual Inspection inspection items are listed under the Traditional Program column on the Scheduled Maintenance Report in Section 5-20. (Refer to 05-20) (2) Traditional 100 Hour Inspection Program The Traditional 100 Hour Inspection Program is required, in addition to a complete Annual Inspection, for civil airplanes of U.S. registry which are operated commercially (for hire). The 100 Hour inspection items are identical to the Annual Inspection items and are listed under the Traditional Program column on the Scheduled Maintenance Report in Section 5-20. (Refer to 05-20) (3) Progressive Inspection Program The Progressive Inspection Program allows the work load to be divided into smaller operations over a time period of 400 or 800 hours. At the completion of a Progressive Inspection Program the aircraft will have undergone a full Annual Inspection. The programs were developed to maximize inspection efficiency for aircraft with annual expected usage rates in excess of 400 hours. The Progressive Inspection Programs inspection items are identical to the Annual Inspection items and are broken into 5-cyclical phases listed under the Progressive Inspection Phase column on the Scheduled Maintenance Report in Section 5-20. (Refer to 05-20) Page 1
B. Traditional Inspection Program Intervals (1) Annual Inspection Time Intervals The inspection interval to the next Annual Inspection may not exceed twelve calendar months. For Example: If an inspection were signed off on 15 September 2005, the next Annual Inspection would be due and must be accomplished no later than 30 September 2006. subsequent Annual Inspections will be due in September unless the schedule is reset by performing an Annual Inspection early. (2) 100 Hour Inspection Time Intervals The interval between 100 Hour Inspections should never be exceeded by more than 10 hours, and then only if additional time is required to reach a place where the inspection can be satisfactorily accomplished. Additionally, the time the interval was exceeded must be included as flight hours in the next interval. For example: If a 100 Hour Inspection was due at 650 flight hours and was actually signed-off at 658 flight hours, the next 100 Hour Inspection is due at 750 flight hours, not 758 flight hours. Inspection tolerances cannot be accumulated. C. Progressive Inspection Program Intervals Progressive Inspection Program intervals should never be exceeded by more than 10 hours, and then only if additional time is required to reach a place where the inspection can be satisfactorily accomplished. At the completion of the 400 or 800 hour progressive inspection, the program will accomplish a full inspection of the aircraft, constituting an Annual Inspection. If all Phase Inspections are not completed within 12 calendar months, all remaining Phase Inspections must be completed to maintain airworthiness as required by 14 CFR 91.409. The Progressive Inspection Program uses Detailed and Routine inspections to accomplish the required maintenance. Routine Inspections are regular procedures generally consisting of a Visual or Operational Inspection of the airplane, component, or system. Detailed Inspections are comprehensive examinations or Functional Inspections of the airplane, component, or system. Disassembly is required as necessary to gain access for the inspection of assemblies and related sub-assemblies. (1) 400 Hour Progressive Inspection Program (See Figure 1) The 400 Hour Progressive Inspection Program provides for the complete inspection of the airplane utilizing a five-phase cyclic inspection program. A total of eight inspections are accomplished over the course of 400 flight hours, with an inspection occurring every 50 flight hours. (a) 400 Hour Progressive Inspection Program Intervals Phase I Inspection is accomplished at the 50 hour interval and covers: Detailed Inspection of the Wing Group Phase II Inspection is accomplished at the 100, 200, 300, and 400 hour intervals and covers: Detailed Inspection of the Engine Group Detailed Inspection of the Propeller Group Phase III Inspection is accomplished at the 150 hour interval and covers: Detailed Inspection of the Landing Gear Group Phase IV Inspection is accomplished at the 250 hour interval and covers: Detailed Inspection of the Fuselage and Empennage Page 2 15 Dec 2014
,, Routine Inspection of the Cabin Group. Detailed Inspection of the Ice Protection System Group. Phase V Inspection is accomplished at the 350 hour interval and covers: Detailed Inspection of the Cabin Group, Detailed Inspection of the Radio Group,,. (2) 800 Hour Progressive Inspection Program (See Figure 2) The 800 Hour Progressive Inspection Program uses the same five-phase cyclic inspection program as the 400 hour inspection with an alternating 50 hour oil service and general aircraft inspection. Additionally, supplemental inspections are currently required for Seats and Restraints, Control Surface Rigging, Wheel and Brakes, Landing Gear, Water Traps, and Transient Voltage Suppressors. These additional inspections are annotated with a bracketed 800 under the Phase Inspection columns of the Scheduled Maintenance Report. Service and reliability data will be collected on these systems with the intent of providing inspection relief upon future analysis. Operators enrolled in the 800 Hour Program are encouraged to provide Cirrus Design with maintenance feedback on these additional inspections using the online Publication Change Request form. http://servicecenters.cirrusdesign.com/techpubs/serviceloopform.asp A total of sixteen inspections are accomplished over the course of 800 flight hours, with an inspection occurring every 50 flight hours. (a) 800 Hour Progressive Inspection Program Intervals 50 Hour Inspection is accomplished at the 50, 150, 250, 350, 450, 550, 650, and 750 hour intervals and covers all inspection items as specified under the 50 Hour inspection column of the Traditional Program on the Scheduled Maintenance Report. Phase I Inspection is accomplished at the 100 hour interval and covers: Detailed Inspection of the Wing Group Phase II Inspection is accomplished at the 200, 400, 600, and 800 hour intervals and covers: Detailed Inspection of the Engine Group Detailed Inspection of the Propeller Group Phase III Inspection is accomplished at the 300 hour interval and covers: Detailed Inspection of the Landing Gear Group Supplemental Inspection of Seats and Restraints, Control Surface Rigging, Wheel and Brakes, Water Traps, and Transient Voltage Suppressors Page 3 19 Sep 2017
Phase IV Inspection is accomplished at the 500 hour interval and covers: Detailed Inspection of the Fuselage and Empennage Routine Inspection of the Cabin Group Detailed Inspection of the Ice Protection System Group Phase V Inspection is accomplished at the 700 hour interval and covers: Detailed Inspection of the Cabin Group Detailed Inspection of the Radio Group Supplemental Inspection of Wheel and Brakes and Landing Gear Page 4 19 Sep 2017
Hour Phase I Phase II Phase III Phase IV Phase V Complete 50 X 100 X 150 X 200 X 250 X 300 X 350 X 400 X O 450 X 500 X 550 X 600 X 650 X 700 X 750 X 800 X O 850 X 900 X 950 X 1000 X 1050 X 1100 X 1150 X 1200 X O 1250 X 1300 X 1350 X 1400 X 1450 X 1500 X 1550 X 1600 X O 1650 X 1700 X 1750 X 1800 X 1850 X 1900 X 1950 X 2000 X O Figure 1 400 Hour Progressive Inspection Program Phase Intervals Page 5
Hour 50 Hr Phase I Phase II Phase III Phase IV Phase V Complete 50 X 100 X 150 X 200 X 250 X 300 X* 350 X 400 X 450 X 500 X 550 X 600 X 650 X 700 X* 750 X 800 X O 850 X 900 X 950 X 1000 X 1050 X 1100 X* 1150 X 1200 X 1250 X 1300 X 1350 X 1400 X 1450 X 1500 X* 1550 X 1600 X O * Supplemental inspections are currently required for Seats, Control Surface Rigging, Wheel and Brakes, Landing Gear, Water Traps, and Transient Voltage Suppressors. These additional inspections are annotated with a bracketed 800 under the Phase Inspection columns of the Scheduled Maintenance Report. Page 6 Figure 2 800 Hour Progressive Inspection Program Phase Intervals
(3) Progressive Inspection Program Eligibility Cirrus Design SR22 airplanes with serial numbers 0002 and subsequent, and SR22T airplanes with serial numbers 0001 and subsequent are eligible for the Progressive Inspection Program. Eligible airplanes must meet one of the following conditions: (a) The airplane must have less than 50 hours total time in service, calendar time remaining within the Annual Inspection period, and comply with all applicable Airworthiness Directives, Special Inspection Requirements, and Mandatory Service Bulletins before initiating the Progressive Inspection Program. (b) Airplanes with more than 50 hours time in service must complete an Annual Inspection and comply with all applicable Airworthiness Directives, Special Inspection Requirements, and Mandatory Service Bulletins before initiating the Progressive Inspection Program. (4) Initiating the Progressive Inspection Program To initiate the Progressive Inspection Program, the owner or operator must: (a) United States: Submit a letter of request and a copy of the Progressive Inspection Program for approval to the Flight Standards District Office having jurisdiction over the area in which the applicant is located. (See Figure 3) A certified mechanic holding an Inspection Authorization or an appropriately certified Repair Station will be required to supervise or conduct the Progressive Inspection. Approval must be obtained before initiating this program. (b) International: Submit the appropriate applications and a copy of the Progressive Inspection Program for approval to the government agency having jurisdiction over the area in which the applicant is located. (c) Make an entry in the airplane maintenance records stating that airplane has been placed on the Progressive Inspection Program in accordance with 14 CFR 91.409 (d), noting the airplane total time in service and date. (5) Conducting the Progressive Inspection Program (a) Pre-Inspection: 1 Review airplane inspection records and maintenance history. 2 Determine which Phase Inspection is due. 3 Note any discrepancies indicated by owner or operator. 4 Determine and comply with any FAA Airworthiness Directives. Ensure required compliance will not become due prior to the next scheduled inspection and contrary to the instructions contained within the directive. 5 Inspect airplane records to determine hourly and calendar replacement times for components and expendable filters. (b) Complete the applicable Phase Inspection: Note: Inspection must be completed by a certified mechanic holding an Inspector Authorized (IA) or a Certified Repair Station. The Progressive Inspection Program provides a checklist for each Phase Inspection and is used in conjunction with the Cirrus Design Airplane Maintenance Manual, Illustrated Parts Catalog, and all other applicable manufacturer and vendor maintenance, service manuals, and bulletins. Each Phase Inspection outlines Routine and Detailed maintenance/inspection tasks. These tasks are numbered in sequence and must be performed in sequence. Each Phase Inspection form must be completed in full. 1 Each Phase Inspection begins with the Airplane Operational and Functional Check (Refer to 05-30). This check allows for the operational check of essential airplane systems. Any defects found during the operational check should be noted and addressed before returning the airplane to service. 2 Perform the specified Inspections. Check or initial each inspection item. Page 7 15 Dec 2014
3 Each Phase Inspection ends with a Airplane Operational and Functional Check and a Post Run-Up Inspection. These inspections allow for the operational check of essential airplane systems, leak checks, and status verification of Airworthiness Directives, Service Bulletins, and airplane documents. 4 In the airplane maintenance records: Enter date of inspection and airplane total time. Enter type of inspection accomplished. Enter the signature, certificate number, and kind of certificate held by the maintenance Facility/Inspector. Enter the following or similarly worded statement: I certify that in accordance with a Progressive Inspection Program a Routine Inspection of (identify whether airplane or components) and a Detailed Inspection of (identify components) were performed and the (airplane or components) are (approved/disapproved) for return to service. If disapproved, the entry will further state a list of discrepancies and un-airworthy items dated (date) has been provided to the owner/operator. Enter the hours when next inspection will be due. Example: Next Phase Inspection due at 526.25 time in service. 5 At the conclusion of the Phase-II 400 Hour or 800 Hour Inspection repeat the program. (c) Airplanes Away From Normal Base Of Operation If airplane is away from base of operation where inspections are normally conducted, a certified technician holding an Inspection Authorization or appropriately certified Repair Station may perform inspection. The inspection will be completed in appropriate sequence and in accordance with procedures and forms of technician who would normally perform the inspection. Electronic transmittal is acceptable means of communicating procedures and forms from normal base of operation to technician performing inspection. (6) Canceling the Progressive Inspection Program The owner or operator must notify the local Flight Standards District Office in writing before discontinuing the Progressive Inspection Program. After discontinuance, if enrolling in Annual Inspection the first Annual will be due within 12 calendar months after completion of the Phase-II 400 or 800 Hour Inspection. If enrolling in the 100 Hour inspection, the first 100 hour inspection will be due within 100 hours of the Phase-II 400 or 800 Hour Inspection. Page 8
Cirrus Design Progressive Inspection Program Letter of Request Submitted To: Federal Aviation Administration Flight Standards District Office Date: City, State, Zip: Contact Name: Phone: Fax: In accordance with FAR 91.409 (d), the undersigned desire to use and request acceptance of the Cirrus Design Progressive Inspection Program for use as an Approved Aircraft Inspection Program. The subject facility has appropriate housing, equipment, and technical information for the necessary disassembly and proper inspection of the aircraft. Certificated Mechanic with Inspection Authorization: Name: Certificate No.: Certificated Airframe Repair Station: Name: Certificate No.: The aircraft qualifies to begin the Progressive Inspection Program because: it is a new aircraft with less than 50 hours time in service. Date of Original Airworthiness Certificate Total Time in Service to Date an Annual Inspection was completed less than 50 hours ago. Date of Annual Total Time in Service at Annual Total Time in Service to Date Aircraft Registration Number: Aircraft Model: Aircraft Serial Number: Engine Model: Engine Serial Number: Propeller Model: Propeller Serial Number: Registered Owners Name: City, State, Zip: Contact Name: Phone: Fax: Operator Name: City, State, Zip: Contact Name: Phone: Fax: Service Facility Name: City, State, Zip: Contact Name: Phone: Fax: Signatures: Registered Owner Operator Service Facility Figure 3 Sample Letter of Request Page 9
D. Airplane Operational and Functional Checks Operational and Functional Checks must be performed before and after Scheduled Maintenance Inspections to detect any airplane abnormalities or malfunctions. These inspections are listed in Section 5-30, Airplane Operational and Functional Checks. (Refer to 05-30) E. Unscheduled Maintenance Checks Abnormal airplane operations require special maintenance checks. Definitions and inspection procedures for hard/overweight landings, overspeed, severe air turbulence, lightning strike, high drag/side loads due to ground handling, and ground gusts are listed in Section 5-50, Unscheduled Maintenance Checks. CAUTION: Airplanes operated for Air Taxi operation or other than normal operation and airplanes operated in humid tropics or cold and damp climates, etc., may need more frequent inspections for wear, corrosion, delamination, and/or lack of lubrication. For these conditions, periodic inspections should be performed until the operator can set his own inspection periods based on experience. For maintenance practices pertinent to operation in harsh environmental conditions, see Section 5-50, Unscheduled Maintenance Checks. (Refer to 05-50) For airplanes enrolled in the Progressive Inspection Program, owner/operators cannot exceed the 50 hour phase intervals (±10 hours) but may perform inspections more frequently. Page 10