AEROPRAKT-22LS Airplane Maintenance Manual

20.5 RESTORING OF DAMAGED PAINT/COATING ..................................................................................................... 66 21 Feedback Form .......................................................................................................... 67 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 4 1 General NOTE: Notifications, service bulletins and safety alerts are published at the official website of Aeroprakt company http://www.aeroprakt.kiev.ua. This manual describes the procedures of proper aircraft handling and servicing recommended by the aircraft manufacturer. It also contains certain inspection and maintenance requirements that must be met to maintain flight performance and safe operation of the aircraft. It is recommended to adhere to the scheduled periods of greasing/lubrication and preventive maintenance taking into account the climate and operating conditions. Each of the inspection or service/maintenance action outlined in this manual specifies: ̶ recommended special tools (if any) to accomplish the task, ̶ the parts needed to perform the task, ̶ type of maintenance, for example, line, heavy, or overhaul, ̶ the level of certification needed to accomplish the task, for example, owner, A&P, LSA repairman with inspection (or maintenance) rating, and repair station, ̶ detailed instructions and diagrams as needed to perform the task, ̶ method to test/inspect to verify the task was accomplished properly. The types of the maintenance (TM) tasks specified in this manual are marked with the following one-letter abbreviation and are defined as follows: Line maintenance (L) – any repair, maintenance, scheduled checks, servicing, inspections, or alterations not considered heavy maintenance that is approved by the manufacturer and is specified in this maintenance manual. Heavy maintenance (H) – any maintenance, inspection, repair, or alteration which manufacturer has designated that requires specialized training, equipment, or facilities. Overhaul (O) – maintenance, inspection, repair, or alterations that are only to be accomplished by the manufacturer or a facility approved by the original manufacturer of the product. The levels of certification (LC) needed to accomplish the maintenance tasks specified in this manual are marked with the following three-letter abbreviation and are defined as follows: OWN (owner) – items that can be expected to be completed by a responsible owner who holds a pilot certificate but who has not received any specific authorized training. LRI (LSA repairman inspection) – items that can be expected to be completed on an ELSA by a responsible owner, which holds an FAA repairman certificate (light sport aircraft), with an inspection rating or equivalent. LRM (LSA repairman maintenance) – items that can be expected to be completed on a SLSA by a responsible individual, which holds a FAA repairman certificate (light sport aircraft), with a maintenance rating or equivalent. A&P (airframe and powerplant mechanic) – items that can be expected to be completed by a responsible individual who holds a mechanic certificate with airframe or powerplant ratings, or both, or equivalent. TSP (task specific) – items that can be expected to be completed by a responsible individual who holds either a mechanic certificate or a repairman certificate and has received task specific training to perform the task. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 5 1.1 Sources to purchase parts For purchasing any parts or spares for this airplane contact your local dealer/distributor or address the aircraft Manufacturer: Aeroprakt Ltd., Polyova str. 24, 03056, Kyiv, UKRAINE, e-mail: air@prakt.kiev.ua or aeroprakt.kiev@gmail.com, web: www.aeroprakt.kiev.ua. 1.2 Equipment list This aircraft has the following equipment: Flight instruments: ̶ Airspeed indicator, ̶ Altimeter indicator, ̶ Vertical speed indicator, ̶ Compass, ̶ Slip ball. Engine instruments: ̶ Engine speed indicator, ̶ cylinder head temperature gauge, ̶ oil temperature gauge, ̶ oil pressure gauge, ̶ 2 fuel level indicators. Avionics: ̶ Transceiver, ̶ Intercom, ̶ Transponder. Miscellaneous equipment ̶ Landing light, ̶ Navigation and strobe lights. 1.3 List of disposable replacement parts The manual (see Sections 3 through to 16) contains the check lists with information about check periods, recommended change out (RCO) times as well as references to inspection and servicing/maintenance instructions for the airplane components and systems. Before expiration of the recommended change out time of separate airplane parts or when it is not specified their operation shall be performed on condition (OC). Such parts must be inspected and replaced, if necessary, before expiration of the RCO (if specified). If inspections and checks arouse any issues not covered in this manual contact the Manufacturer for additional information. Upon detecting corrosion on airplane structural elements contact the Manufacturer for the required technical support. In this case further operation of the airplane may be dangerous! AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 6 1.4 Engine specifications WARNING! On all issues of engine operation see Rotax engine Operator's Manual. Follow its instructions to ensure safe and efficient operation of the engine. Engine data and operational limitations are given in the table below: Engine manufacturer BRP-Rotax GmbH & Co KG (Austria) Engine model Rotax-912UL Rotax-912ULS Engine type Flat-four, four-stroke Take-off performance 59.6 kW (80 h.p.) 73.5 kW (100 h.p.) Max. continuous performance 58 kW (77.8 h.p.) 69 kW (92.5 h.p.) Take-off speed 5800 rpm (max. 5 minutes) Max. continuous speed 5500 rpm Idle speed min. 1400 rpm Oil pressure, maximum minimum normal 7 bar (102 psi) (for a short period at cold start) 0,8 bar (12 psi) (below 3500 RPM) 2,0 to 5,0 bar (29-73 psi) (above 3500 RPM) Oil temperature, maximum minimum normal 140 °C (285 °F) 50 °C (120 °F) 90-110 °C (190-230 °F) 130 °C (266 °F) 50 °C (120 °F) 90-110 °C (190-230 °F) Exhaust gas temperature max. 880 °C (1616 °F) Coolant temperature (coolant exit temperature) max. 120 °C (248 °F) Cylinder head temperature max. 150 °C (300 °F) max.135 °C (275 °F) Engine start, operating temperature max. 50 °C (120 °F) (ambient temperature) min. -25 °C (-13 °F) (oil temperature) Fuel pressure, maximum minimum 0.4 bar (5.8 psi) 0.15 bar (2.2 psi) Fuel antiknock properties min. RON 90 (min. AKI1 91) min. RON 95 (min. AKI 91) European standard of fuel EN 228 normal, EN 228 super, EN 228 super plus EN 228 super, EN 228 super plus Aviation Standard of fuel AVGAS 100 LL (ASTM D910) Oil specification Use only oil with Rotax norm RON 424 classification 1 Anti-Knock Index (RON+MON)/2 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 7 1.5 Weight and balance information The airplane CG position (𝑥𝐶𝐺) must be between 1.500 m [59.06 in] and 1.751 m [68.94 in] or between 19% and 37% of the wing MAC (mean aerodynamic chord) see Fig. 1. Fig. 1 CG location of the empty airplane, pilots, fuel and baggage Compute the airplane CG position using the example in the table below: Item Weight, kg/lbs × CG arm, m/inch = Moment, kg×m/lbs×inch Empty airplane Crew (2×xx.x kg) Baggage Fuel (2×xx l) Total: XCG = Total moment / Total weight = 1.6 Tire inflation pressure Normal inflation pressure: Main wheels – 1.6 bar (22.7 psi) for 6.00×6 wheels; – 1.3 bar (19.0 psi) for 8.00×6 wheels; Front wheel – 1.0 bar (14.5 psi) for both 6.00×6 and 8.00×6 wheels. 𝑥𝐶𝐺 𝑥𝐶𝐺 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 8 1.7 Approved fuel, oils and capacities WARNING! On all issues of engine operation see Rotax engine Operator's Manual. Follow its instructions to ensure safe and efficient operation of the engine. Fuel Approved grades: antiknock properties – min. RON 95 (min. AKI 912) European standard – EN 228 super, EN 228 super plus Aviation standard – AVGAS 100 LL (ASTM D910) Maximum capacity of the fuel tanks: standard tanks – 2 × 45 = 90 liters (23.8 US gal) optional tanks – 2 × 57 = 114 liters (30.1 US gal). “Fuel Low” warning light ignites at approximately 4.5 liters (1.2 US gal) of fuel left per tank. Unusable fuel: approximately 1 liter (0.3 US gal) per tank. Oil Approved grades: with RON 424 classification. Oil tank capacity: 3 liters (NOTE: check correct oil level in the tank using the oil probe.) Coolant Approved grade: TELKO Polar Premium Long Life Antifreeze. Quantity: 3 liters (NOTE: check the correct level using the overflow bottle marks.) Braking fluid Approved grade: Mobil ATF 220 Quantity: 0.2 liter (NOTE: check the correct level using the overflow bottle marks.) 1.8 Recommended fastener torque values In A-22LS all fasteners forward of the firewall and in the electrical system is metric, and rear of the firewall – inch. The bolts, screws and nuts (unless specified otherwise) must be tightened (using appropriate torque wrenches) to the following torque: 1. For the static joints with spacing inserts (spacers, spherical bearings, etc.) according to the table: Metric fasteners Inch fasteners Torque, N·m (lb·ft) М5 10-32 6 (4.4) М6 1/4 10 (7.4) М8 5/16 15 (11.0) М10 3/8 25 (18.4) 2. For the movable joints where bolts serve as hinge axle the nuts tightening must be done only to remove the axial play (gap) while preserving the rotational freedom in the joint. WARNING! All bolts, nuts (except for self-locking ones), pins, turnbuckles must be locked reliably. 2 Anti-Knock Index (RON+MON)/2 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 9 1.9 General safety information Aircraft owner/operator responsibilities: Each owner/operator of the Aeroprakt LSA must read and comply with the maintenance and continued airworthiness information and instructions provided by the Manufacturer. Each owner/operator of the Aeroprakt LSA is responsible for providing the Manufacturer with current contact information where the Manufacturer may send the owner/operator supplemental notification bulletins. The owner/operator of the Aeroprakt LSA is responsible for notifying the Manufacturer of any safety of flight issue or significant service difficulty upon discovery. The owner/operator of the Aeroprakt LSA is responsible for complying with all notices of corrective action issued by the Manufacturer and for complying with all applicable aviation authority regulations in regard to maintaining the airworthiness of the LSA. The owner/operator of the Aeroprakt LSA must ensure that any needed corrective action be completed as specified in a notice, or by the next scheduled annual inspection. Should the owner/operator of the Aeroprakt LSA not comply with any mandatory service requirement, the LSA shall be considered not in compliance with applicable ASTM standards and may be subject to regulatory action by the presiding aviation authority. 1.10 Reporting maintenance, service, and safety difficulties In case of encountering any maintenance or service or safety difficulties not covered by this Manual report about it to the aircraft Manufacturer by e-mail or by fax using the Feedback Form (see Appendix A). If necessary enclose sketches or photos showing the problem items in sufficient detail. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 10 2 Inspections This section contains the instructions and checklist for inspection and servicing for the completion of periodic and annual condition/100-h inspections with references to the sections containing detailed instructions for the inspection/servicing action.  Inspection/Servicing action and its interval in hours  100 200 500 1000 2000 Structures (section 3) Inspect fuselage for damage (fatigue cracks, loose rivets, etc.) X Inspect fuselage glazing for damage (silvering, cracks, etc.) X Inspect wings for damage (fatigue cracks, loose rivets, torn fabric covering, etc.) X Inspect wing attachment points for play X Remove the wings and inspect its spherical bearings for axial and radial play, and wing and strut attachment brackets for fatigue cracks X Inspect the wing struts for fatigue cracks, deformation and loose rivets X Inspect the sealing fabric tape of the wing strut fairings X Check the wing attachment bolts’ torque and locking X Inspect the stabilizer for fatigue cracks, deformation, loose rivets and play in joints X Check the stabilizer attachment bolts/nuts torque and locking X Inspect the tail wheel for damage and play X Check the tail wheel attachment bolt/nut torque and locking X Inspect engine cowlings for damage (cracks, ruptures, damaged paint, etc.) X Landing gear (section 4) Inspect the front leg for fatigue cracks, deformation and play X Check the front leg steering bellcrank bolt/nut torque and locking X Check the shock absorber condition and pressure X Inspect the MLG legs and attachment beam for fatigue cracks3, deformation and play X Check the MLG legs attachment bolts/nuts torque and locking X Remove the wheel fairings and inspect the wheel tires for cracks, cuts and wear X Inspect the wheel fairings for cracks, ruptures and damaged paint X Check the torque and locking of the fairing attachment bolts/nuts X Inspect the mud-screens for fatigue cracks and deformation4 X Check the torque and locking of the mud-screen attachment bolts/nuts4 X Inspect the skis for damage5 X Check the torque and locking of the ski attachment bolts/nuts5 X Braking system (section 5) Inspect expansion tank for leaks, cracks, secure attachment. Check the braking fluid level. X Inspect the master cylinder for leaks of braking fluid X Inspect the parking brake valve for leaks of the braking fluid X Inspect the brake unit for the leaks of the braking fluid X Check the form and amount of the brake disk wear X Inspect the braking system tubing and joints for leaks and damage X Engine and its control system (section 6) Inspect the engine mount for fatigue cracks and deformation X Check the torque of the engine mount attachment bolts X 3 After 5000 landings the MLG legs must be removed and inspected carefully for fatigue cracks 4 For an aircraft version on wheels with mud-screens 5 For an aircraft version on skis AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 11  Inspection/Servicing action and its interval in hours  100 200 500 1000 2000 Inspect the shock absorbers for damage (deep cracks, disintegration, etc.) X Inspect the engine attachment fitting for the fatigue cracks X Check the intake airbox function, condition and attachment6 X Check the throttle and choke cables and cable sheath for functioning, wear, damage, kinks X Check the torque of the throttle lever bolt (axle) X Cooling system (section 7) Check integrity and torque of the clamps attaching radiator to engine mount X Inspect the overflow bottle for leaks of coolant, cracks in cap and bottle; check coolant level X Inspect the coolant lines for leaks, damage (chaffing, cracks), check tightness of joints X Check torque of the water inlet elbow hose clamps, tighten if necessary X Lubrication system (section 8) Inspect the oil tank plug for oil leaks; verify vent line is intact and secured X Inspect oil lines for leaks and damage (chaffing, cracks), check tightness of joints X Fuel system (section 9) Remove fuel tanks and inspect them for fuel leaks and damage X Inspect the shut-off and drain fuel valves for leaks of fuel X Check condition and replace fuel filter (if necessary) X Inspect fuel lines for leaks, damage (chaffing, cracks), loose joints X Check condition and replace fuel lines (if necessary) X Exhaust system (section 10) Inspect exhaust pipes and muffler for cracks X Verify attachment springs are intact and secured X Propeller (section 11) Inspect propeller hub for fatigue cracks; check pitch angles of the blades X Check torque and locking of the propeller attachment bolts/nuts X Check torque of the spinner attachment bolts X Airplane control system (section 12) Inspect control surfaces for fatigue cracks, deformation, loose rivets, damaged fabric skin X Check the play in the hinges of control surfaces/linkages X Check tightness/locking of the nuts of control surfaces/linkages X Check tightness/locking of the nuts and play in hinges of control rods/shafts X Extend flaps and inspect flap extension mechanism (play in hinges, bolt/nut tightness/locking) X Grease the sliding bearings of all control surfaces/linkages (where necessary) X Inspect rudder control cables for wear, check cable tension X Inspect rudder pedals for fatigue cracks and deformation X Check tightness/locking of the nuts of the front leg control rods X Check condition of the control cable pulleys and fairleads X Check trim tab attachment bolts/nuts for corrosion. Replace corroded fasteners X Inspect the trim tab control cables and sheath for damage (wear, kinks, etc.) X Take out and inspect the aft elevator control rod for wear. Replace if necessary. X Check control surfaces' deflection angles X 6 For all aircraft variants equipped with intake airbox AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 12  Inspection/Servicing action and its interval in hours  100 200 500 1000 2000 Electrical system (section 13) Verify battery charges/discharges properly, otherwise replace X Inspect starter terminals and starter relay connector, remove corrosion from contacts, if any X Verify starter relay and cables are connected and attached reliably X Verify power cables have good contact with battery, starter and ground X Clean rectifier-regulator and condenser terminals/connectors of corrosion, if any X Check condition of electric switches and warning lights X Clean fuse block terminals of corrosion, if any. Check fuses X Verify correct function of the fuel level sensors/indicators (check readings) X Check landing light function and attaching nut torque X Clean engine sensors' terminals and connectors of corrosion, if any X Inspect electrical harness for damage (chaffing, broken wires, bad insulation) X Cockpit heating system (section 14) Inspect warm air scoop for damage. Repair or replace if necessary X Inspect warm air shutter and its housing for damage. Repair or replace if necessary X Inspect warm air duct for damage. Replace if necessary X Check condition and operation of the warm air shutter actuator. Replace if necessary X Instruments, avionics, full and static pressure system (section 15) Check condition of the switches and lights. Replace defective ones, if any X Check operation of the instruments and avionics. Replace defective ones, if any X Check condition of the full and static pressure system X Pilot seats and harness belts (section 16) Inspect the seats framework for the fatigue cracks and loose rivets X Inspect the seat cushions upholstery for damage X Verify harness belts’ locks function properly X Cockpit doors (section 17) Inspect door glass, framework, hinges and fasteners for fatigue cracks, mechanical damage X Verify the gas struts function properly X Recovery system (section 18) Check attachment of the suspension cables to fuselage structure and to parachute lanyard X Glider and banner towing system (section 19) Inspect the tow release control cable for damage/corrosion. Replace if necessary. X Clean, lubricate and check the tow release for operation. Replace if necessary.7 X 7 Tow release must be returned to the manufacturer for complete reconditioning after 10000 operations (approx. 2000 starts). The manufacturer recommends general overhaul after 4 years. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 13 3 Structures The airframe of A-22LS airplane includes the following parts: fuselage with glazing and cockpit doors, wings, wing struts, horizontal and vertical tail units, wing root and strut fairings and engine cowling. Fuselage with fin, wing struts and stabilizer are made of aluminum alloys. Wing framework including leading edge section and top skin are all-metal and bottom skin is fabric. Flaperons, elevator and rudder have metal framework and fabric skin aft of spar. Rear fuselage panels (on top and on both sides) depending upon customer-selected options may be made of transparent plastic glass, all-metal or combined. Wing root /tip fairings, wheel fairings and engine cowling are made of glass fiber composites. Wing strut fairings are made of transparent plastic using vacuum forming. When servicing the airplane a special care shall be taken to keeping the paint coating intact which prevents the airframe from corrosion. Care of the fabric skin consists mainly of care of its paint coating. Correct care of the paint coating is one of the conditions of preserving the airplane strength and aerodynamic characteristics. To keep the paint coating of the airplane in good condition the dust and moisture must be removed in time, scratches, spilling oil products, solvents, alkalis and acids on paint must be avoided. INSPECTION CHART Description Interval RCO Instr. No. TM LC Fuselage 500 h OC 3.1 L LRI Windscreen glass 100 h OC 3.2 L OWN Rear fuselage skin panel, top 100 h OC Rear fuselage skin panel, right 100 h OC Rear fuselage skin panel, left 100 h OC Wing, right 500 h OC 3.3 L OWN Wing, left 500 h OC 3.3 L OWN Spherical bearings, 4 pcs. 2000 h OC 3.4 L LRI Wing strut, right 500 h OC 3.5 L LRI Wing strut, left 500 h OC Wings strut fairing, top, right 200 h OC 3.6 L LRI Wings strut fairing, top, left 200 h OC Wings strut fairing, bottom, right 200 h OC Wings strut fairing, bottom, left 200 h OC Wing attachment bolts, 4 pcs. 100 h OC 1.8 L OWN Wing strut attachment bolts, 4 pcs. 100 h OC Stabilizer 100 h OC 3.7 L LRI Stabilizer attachment bolts, 2 pcs. 100 h OC 1.8 L OWN Stabilizer attachment nut 100 h OC Tail wheel 100 h OC 3.8 L LRI Tail wheel bolt 100 h OC 1.8 L OWN Engine cowling panel, top 100 h OC 3.9 L LRI Engine cowling panel, bottom 100 h OC AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 14 Instructions: 3.1 Remove the engine cowling, doors, lower wing strut fairings (undo the screws fixing the fairings and 'slide' them along the strut), pilot seats, and rugs. Inspect the fuselage for cracks and deformation, paying special attention to primary structural elements, areas of their connection and rivet joints. Inspection for fatigue cracks: Use torch or any other suitable source of light. When detecting very thin cracks remove the paint in the area of the suspected crack for a closer flaw detection. If possible apply load in this area in a manner that will 'open up' the crack. If the closer inspection confirmed the presence of crack contact the manufacturer for required technical support. If the suspected crack was not detected repaint this area. Inspection for loose rivets: When inspecting rivet joints look at the area around river heads. The paint around the rivet heads must have no cracks or black stains that indicate a loose and corroded rivet joint. When detecting such flaws contact the manufacturer for the required technical support. If no flaws were detected, reinstall everything in reverse order. Apply Loctite 222 on the thread of the attachment screws of the wing strut fairings before reinstalling them. Recommended special tools: magnifying glass, electric torch. Necessary parts/materials: paint, Loctite 222. 3.2 Inspect the glass inside and outside for cracks. If any crack protruding from under the glass attachment strips is detected the glass must be replaced. Contact the local dealer for glass replacement instructions. WARNING! The glazing material is not resistant to fuels, oils and solvents. Spilling those liquids on glazing may cause its dimness and cracking. Washing the glass with any agents that may damage PET-G glass is strictly forbidden! Recommended special tools: none. Necessary parts/materials: none. 3.3 Drain fuel from the fuel tanks. Remove the upper wing strut fairings and fuel tanks. Inspect the outer surface and, as much as possible, internal structure of the wing for fatigue cracks, deformation and loose rivets as described in 3.1 (2nd and 3rd paragraph). Pay special attention to the strut-to-wing attachment points, rivet joints of the wing leading edge section and top skin. Inspect the fabric skin for damage and detachment from the wing framework. It is allowed to repair small cuts/ruptures (shorter 50 mm or 2 in) covering them with ORACAL permanent sticking film. Upon detecting bigger damages and detachment of the fabric skin from the framework contact manufacturer for the required technical support. Verify that there is no play in attachment points of the wing and strut by holding the wingtip gently and moving it up and down with an amplitude of 300 mm (1 ft). No movement in the attachment points due to loose joint (play) is allowed. When detecting insignificant radial play (less than 0.2 mm or 0.01 in) in the strut attachment points it must be eliminated by tightening its attachment bolt. In case if the play is more than 0.2 mm (0.01 in) contact the manufacturer for the required technical support. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 15 In case if no defects are found re-assemble everything in reverse order. Before re- installing the screws attaching the fuel tanks and strut fairings apply Loctite 222 on the thread. Recommended special tools: magnifying glass, electric torch. Necessary parts/materials: ORACAL permanent sticking film, Loctite 222. 3.4 To detach the wings do the following: - detach the doors; - drain fuel from the fuel tanks; - disconnect the fuel lines from the fuel valves, close the valves, plug the fuel lines and pull them out of cockpit through the rubber sealing rings in fuselage beams; CAUTION! Be careful while working with the fuel system, the fuel remaining in the fuel lines is highly fire-hazardous and when spilled on the cockpit glass may cause glass dimness and cracking. - disconnect the electric connectors of the navigation lights and fuel level probes at wing root and take the cables out of fuselage; - detach the strut fairings (undo the screws attaching the fairings and slide fairings along the struts); - detach the Cardan rings of the flaperon shafts by removing the vertical bolts; - remove the locking pins and undo the nuts from wing and strut attachment points; - while holding the wing by the tip and strut carefully take out the strut attachment bolts and remove the struts; - while holding the wing by the tip and at the root take out the wing attachment bolts and slowly move the wing away from fuselage carefully pulling the navigation light cables from the wing fillets. Inspect the wing and strut attachment fittings for fatigue cracks. Check the spherical bearings of the wing attachment fittings for axial and radial play. When detecting play in the bearings, as well as corrosion and fatigue cracks in the attachment fittings contact the manufacturer for the required technical support. If no defects were detected re-assemble everything in reverse order. Before reinstalling the screws attaching the fuel tanks and strut fairings apply Loctite 222 on the thread. Recommended special tools: magnifying glass, electric torch. Necessary parts/materials: screw clamps, Loctite 222. 3.5 Remove the strut fairings (undo the screws attaching the fairings and slide fairing along the strut). Inspect the struts for fatigue cracks, deformation (bend) and loose rivets as described in 3.1 (2nd and 3rd paragraph). If no defects were found re-install the fairing applying Loctite 222 on the thread of the attaching screws. Recommended special tools: none. Necessary parts/materials: none. 3.6 Undo the screws attaching the fairings and slide the fairings along the strut. Inspect outer and inner surface of the fairings for cracks. If the crack length does not exceed 20 mm drill the crack end with 3 mm drill bit. The fairing with longer cracks must be replaced. Upon inspection re-install the fairings applying Loctite 222 on the thread of the attaching screws. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 16 3.7 Inspect the stabilizer for fatigue cracks, deformation and loose rivets as described in 3.1 (2nd and 3rd paragraph). Pay special attention to the areas near the stabilizer attachment fittings and leading edge near the hole for elevator trim tab cable. Verify that there is no play in the stabilizer attachment joints by gently moving the stabilizer by its tip up and down with an amplitude not more than 50 mm (2 in). CAUTION! The applied load may not exceed 30 N (7 lb). There must be no movement due to the play in the attachment joints. When detecting insignificant play (less than 0.2 mm or 0.01 in) it must be eliminated by tightening the relevant bolted joint. In case if the play exceeds 0.2 mm (0.01 in) contact the manufacturer for the required technical support. Recommended special tools: magnifying glass, electric torch. Necessary parts/materials: none. 3.8 Inspect the tail wheel for integrity and play. When detecting a serious damage replace the wheel. When detecting an axial play below 0.5 mm (0.02 in), tighten the tail wheel axle nut. If the play exceeds 0.5 mm (0.02 in), remove the wheel and install back inserting a washer of appropriate thickness between the wheel hub and fuselage. Tighten the tail wheel axle nut to ensure that the wheel can be rotated with an effort. Recommended special tools: none. Necessary parts/materials: none. 3.9 Remove the top and bottom engine cowling and inspect for cracks, ruptures, as well as damaged paint coating. When detecting damaged paint coating sand the damaged area with sandpaper and re-paint. When detecting cracks and ruptures sand the damaged area from inside with sandpaper and cover it with a patch of fiberglass cloth with epoxy resin. After the resin solidifies properly, sand the damaged area outside with sandpaper and re-paint. Recommended special tools: rubber gloves. Necessary parts/materials: fiberglass cloth, epoxy adhesive, paint. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 17 4 Landing gear A-22LS may have the landing gear (LG) of one of the following three types: wheels, skis or floats. This manual contains the information for servicing the wheel and ski LG. The float type LG is not included in this manual. For obtaining additional information contact the manufacturer. When put on wheels the airplane is equipped with wheels of Matco mfg. NOTE! When installing wheels tighten the axle nut as follows: first tighten the nut to remove the axial play, then turn it back until its slots aligns with the hole for the split pin in the axle. Then lock the nut using the split pin. The front LG leg is steerable, of the trailing link type with spring shock absorber. The leg structure consists of a strut, steering bellcrank, trailing link with wheel fork, spring shock absorber, axle, spacing sleeves, wheel/ski and fairing/mud-screen (if installed). The steering is achieved using the rudder pedals via the rods connected to the steering bellcrank on the strut. The leg is attached to the firewall at two points – lower and upper supports. The upper support is made of aluminum alloy plate, the lower support is an assembly. The supports contain bronze bushings. The main landing gear (MLG) is of cantilever spring type. The MLG consists of 2 flexible legs each with wheel axle, wheel (or ski), brake unit with supporting plate, and wheel fairing (or mud-screen). The MLG leg is made of aluminum alloy. It is attached with bolts at two points to the lower beam of the frame No.2. Maintenance of the brake unit with supporting plate is described in "Ошибка! Источник сылки не найден." section. INSPECTION CHART Description Interval RCO Instruction TM LC Front LG leg strut 100 h OC 4.1 L LRI Steering bellcrank bolt 100 h OC 1.8 L OWN ROCK SHOX shock absorber 100 h OC 4.2 L LRM Main LG leg, right 100 h OC 4.3 H LRM Main LG leg, left 100 h OC Leg attachment bolts, upper, 2 pcs. 100 h OC 1.8 L OWN Leg attachment bolts, lower, 2 pcs. 100 h OC Front wheel assembly 200 h OC 4.4 L LRI Right wheel assembly 200 h OC Left wheel assembly 200 h OC Front wheel fairing* 100 h OC 4.5 L LRI Right wheel fairing* 100 h OC Left wheel fairing* 100 h OC Front wheel mud-screen** 100 h OC 4.6 L LRI Right wheel mud-screen** 100 h OC Left wheel mud-screen** 100 h OC Front ski*** 100 h OC 4.7 L LRI Right ski*** 100 h OC Left ski*** 100 h OC * for wheel LG version with fairings; ** for wheel LG version with mud-screens AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 18 *** for ski LG version. Instructions: 4.1 To inspect the front LG leg put the airplane on the tail wheel and secure it in this position. The parking brake must be switched to ON. Check the front LG leg supports for play. The radial play in the supports may not exceed 1 mm (0.04 in). No axial play is allowed. If the radial play in the upper support exceeds the above specified value then the bronze bearing in the support must be replaced. If the radial play in the lower support exceeds the above specified value then the support with bearing must be replaced. Contact manufacturer to obtain the instructions on replacement of the bearing and support. Upon detecting any axial play in the supports tighten the upper support nut until the play is eliminated, if necessary, insert a washer of an appropriate thickness. WARNING! Tightening the nut must eliminate the play while ensuring free rotation of the leg in the supports. Do not over-tighten the nut! Check for play the joint of the wheel fork to the strut and the shock absorber joints to the strut and to the wheel fork. If the play exceeds 0.5 mm replace the bronze bearings in the joints. Inspect the strut for deformation and fatigue cracks paying special attention to the welded seams. To remove the front LG leg (if necessary) do the following - disconnect the control rods from the front leg steering bellcrank; - remove the split pin and undo the nut of the upper support of the front leg; - undo the nut and take out the bellcrank bolt; - carefully take out the front LG leg from the supports simultaneously removing the bellcrank from it. CAUTION! Do not put the fuselage nose down while the front leg is removed! This may cause damage to the airframe and propeller. To inspect the wheel fork remove the wheel fairing (if installed) by doing the following: - take out the bolts attaching the wheel fork and shock absorber to the strut; - remove the wheel fork together with wheel fairing; - detach the wheel fairing from the wheel fork by removing three attachment bolts. Inspect the wheel fork for cracks. Make sure there is no axial play in the joint of the wheel fork and the wheel axle and the wheel rotates freely. Inspect the wheel tire for cracks and cuts. Estimate degree and uniformness of the tire wear. In case of normal operation the tire wear must be uniform over entire contact surface of the wheel. It is allowed to use the tires until the first wheel cords become visible. If the cords are visible, or there are any deep cuts or cracks in the tire, the tire must be replaced. If the front wheel must be repaired or its tire must be replaced see instruction 4.4. In case if the shock absorber must be repaired or replaced see instruction 4.2. Before applying fresh grease on the friction surfaces of the front LG leg remove the old grease. Any grease for bearings may be used for the strut. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 19 To assemble the front LG leg perform the above operations in reverse order, ensuring free motion and absence of axial play in the movable joints. CAUTION! Tightening of the nut on the wheel axle must be done as follows: first tighten the nut to remove the axial play, then rotate it a little back to align the hole in the axle for the split pin with the nearest groove in the nut. Recommended special tools: none. Necessary parts/materials: grease gun, grease. 4.2 If the spring shock absorber is seriously damaged, then it must be removed for repair or replacement. To remove the shock absorber do the following: - set the parking brake valve to CLOSE; - remove the front wheel fairing; - remove the split pins and undo the nuts of the shock absorber attachment; - carefully push down the airplane tail near the stabilizer attachment points till the airplane sets on the tail wheel and remove the shock absorber (this operation must be done by two persons); - secure the airplane in this position with a wooden support under its fuselage as close to the frame No. 1 (firewall) as possible (the support width must be equal or bigger than the fuselage width). To re-install the spring shock absorber perform the above actions in reverse order. Before installation of the spring shock absorber lubricate its attachment bolts with bearing grease. WARNING! When installing the shock absorber tighten the nuts as follows: first tighten to remove the axial play, then rotate a little back to align the nearest slot of the castle nut with the hole for the split pin and secure it with a split pin. The shock absorber must rotate freely on the attaching bolts. Recommended special tools: none. Necessary parts/materials: grease gun, grease. 4.3 Remove the pilot seat and wheel fairing. Inspect the MLG attachment beam and spring for fatigue cracks, deformation and play following the instructions of 3.1 (2nd and 3rd paragraph) of "Structures" section. Pay special attention to the areas of the spring attachment to the beam and wheel axle attachment to the spring. If axial play is detected in the MLG attachment, check the attachment bolts' torque. If radial play is detected, contact the manufacturer to obtain the required technical support. After 5000 landings careful inspection of the MLG leg is required. The MLG leg must be removed for that. To remove the MLG leg do the following: - put the wheel chokes under the front and main wheel on the other side; - remove the pilot seats; - remove the wheel fairing (if installed); - remove the plastic cable ties fixing the braking system tube to the MLG leg; - lift the airplane using a jack placed under a special plate near the opening in the fuselage bottom skin for the MLG leg; - remove the safety wire and undo the brake disk screws and wheel axle nut; AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 20 - remove the wheel and brake disk; - leaving the braking system tube connected, disconnect the braking unit from the supporting plate (undo two bolts and three screws of the braking unit and move the brake unit with the tube aside); WARNING! When handling the brake pads and disk avoid smearing their working surfaces with any lubricating materials. Do not move the brake actuation lever in the cockpit when the braking disk is removed! - remove the split pins and undo the nuts of the upper and lower bolts of the MLG leg attachment and take out the bolts; - remove the spring. Inspect carefully the spring and fittings of the MLG attachment beam for fatigue cracks. Pay special attention to the areas around the attachment holes in the beam and leg. Upon detecting fatigue cracks in the MLG leg or MLG attachment beam contact the manufacturer to obtain the required technical support. If no defects were detected, install the MLG leg back by doing the above actions in reverse order. Before re-installing the attachment screws of the brake disk and pilot seats apply Loctite 222 on their thread. Recommended special tools: none. Necessary parts/materials: plastic cable ties. 4.4 Remove the wheel fairing. Inspect the tire for cracks and cuts. Estimate the uniformness and degree of the tire wear. In case of normal operation the wear will be uniform over entire operating surface of the tire. Tire operation is allowed until exposure of its cord. In case if exposed cord or deep cuts are detected the tire must be replaced. To replace the front wheel tire do the following: - set the parking brake valve to CLOSED; - remove the front wheel fairing; - remove the split pin of the front wheel axle nut and undo it; - carefully push down the airplane tail near the stabilizer attachment points till the airplane sets on the tail wheel and remove the front wheel (this operation must be done by two persons); - put the airplane’s nose down placing a wooden support under the front wheel fork; - replace the tire; - inflate the wheel (1.0 bar) and install it back on the airplane making the above actions in reverse order. To replace a main wheel tire do the following: - undo the nuts of the three bolts joining the aluminum wheel halves and bearing hub; - replace the tire and assemble the wheel; - inflate the wheel (1.6 bar) and install it back on the axle in reverse order. For more detailed information regarding the servicing (repairing) the wheels visit the wheel manufacturer’s web site http://www.matcomfg.com. Recommended special tools: none. Necessary parts/materials: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 21 4.5 Inspect the fairing for cracks, ruptures and paintwork damage. If the paintwork is damaged, remove the fairing, clean the damaged area with sand paper and repaint. If cracks and ruptures are detected, remove the fairing, clean the damaged area with sand paper from inside, and apply a patch of fiberglass cloth with epoxy resin. After the resin solidifies properly, sand the damaged area outside with sandpaper and re- paint. Check the torque of the fairing attachment bolts/nuts. Recommended special tools: torque wrench, rubber gloves. Necessary parts/materials: fiberglass cloth, epoxy adhesive, paint. 4.6 Inspect the mud-screens for fatigue cracks and deformation. Pay special attention to the areas around the bolt joints and mud-screen framework weld seams. If any cracks are detected in the mud-screen it must be replaced. If cracks are detected in the mud-screen framework it must be replaced too. Check the torque of the mud-screen attachment bolts/nuts. Recommended special tools: torque wrench. Necessary parts/materials: none. 4.7 Inspect the ski for mechanical damage. If damage of the paintwork is detected, clean the damaged area with the sand paper and re-paint. In case of serious damage of the ski contact the manufacturer for the required technical support. Inspect the rubber cord and cable braces of the ski for wear and damage. If the surface of the rubber cord brace is damaged or any cracks are detected in its metal end fittings the brace must be replaced. If any threads of the cable are broken it must be replaced. Check the torque of the ski brace attachment bolts/nuts. CAUTION! When installing the ski on the wheel axle tightening of the nut on the axle must be done as follows: first tighten the nut to remove the axial play, then rotate it a little back to align the hole in the axle for the split pin with the nearest groove in the nut. Recommended special tools: torque wrench. Necessary parts/materials: paint. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 22 5 Braking system The main wheels are equipped with Matco mfg hydraulic disk brakes. The braking system includes: expansion tank, master cylinder with lever, parking brake valve, brake units with supporting plates, brake disks, copper tubes, fittings and reinforced rubber hose. The braking system is filled with automotive transmission fluid ATF, application of which is approved by Matco mfg. MIL-H-5606, recommended by Matco mfg, is compatible with ATF and those fluids may be mixed without negative effect on sealing components of the braking system. The amount of the fluid in the system can be checked by its level in the expansion tank and must be not less than half of the tank. When servicing the braking system it may be necessary to disconnect its tubes. After such disconnection air gets into its cavities which is not permissible. To fill the braking system with braking fluid and remove air from it in the airplane version with yokes, do the following: - check the level of the braking fluid in the expansion tank and refill if necessary; - remove the cover set the parking brake valve to "OPEN"; - remove protecting cap from the brake unit nipple and put on it a transparent PVC tube with the inner diameter of 3 mm (1/8 in) and minimum length of 300 mm (1 ft), put the other end of the tube into a container with the braking fluid so that it is completely submerged into the fluid; - while holding the tube, loosen the nipple by ½ turn; - pump the braking fluid through the system with the braking lever till air bubbles stop appearing completely in the transparent tube (they may start appearing after some time of such pumping); while doing it do not forget to add braking fluid into the expansion tank to avoid air inflow into the system; - after air bubbles disappear, tighten the braking unit nipple, remove the PVC tube and put on the protecting cap; - repeat above actions for the other wheel. To fill the braking system with braking fluid and remove air from it in the airplane version with central stick, do the following: - remove the stick cover; - disconnect the stick from the roll torque tube and elevator pushrod; - remove the parking brake; - remove the plastic clamps holding the braking system tubes; - put the stick on the longitudinal beams of fuselage with the braking cylinder nipples facing up and pump the braking system through as described above for the airplane version with yokes; - re-assemble everything in reverse order. WARNING! When filling the braking system it is necessary to pump through it braking fluid in the amount of 1 to 2 volumes of the expansion tank. For more detailed information about maintenance (repair) of the braking system components visit its manufacturer web site: http://www.matcomfg.com. Recommended special tools: none. Necessary parts/materials: 300 mm of Ø3.0 mm PVC tubing, brake fluid. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 23 INSPECTION CHART Description Interval RCO Instruction TM LC Expansion tank 100 h OC 5.1 L LRM Master cylinder 200 h OC 5.2 L LRM Parking brake valve 200 h OC 5.3 L LRM Brake unit assembly, right 200 h OC 5.4 L LRM Brake unit assembly, left 200 h OC Brake disk, right 200 h OC 5.5 L LRM Brake disk, left 200 h OC Copper tubes 200 h OC 5.6 L LRM Reinforced rubber hose 200 h OC Instructions: 5.1 Remove the top engine cowling. Inspect the expansion tank for leaks of braking fluid, cracks in its housing and cap. If the tank is damaged it must be replaced, then the braking system must be filled with braking fluid, following the instructions described in the beginning of this section. Check the fluid level in the tank and refill if necessary. The required level is at least half of the tank. Make sure the tank attachment to the firewall is secure. Replace the plastic cable ties if necessary. Recommended special tools: none. Necessary parts/materials: none. 5.2 Remove handles from the control levers of the throttle, trim tab, brake and choke. Remove the horizontal panel. Inspect the master cylinders for leaks of braking fluid. If no defects of the master cylinder are detected re-assemble everything in reverse order. If leaks are detected, it must be removed for repair or replacement. In order to remove the master cylinder, do the following: - remove the left seat; - remove the panel between the pilot seats; - disconnect the control cables of the engine and elevator trim tab (first from the engine and trim tab ends, and then from the control levers); - undo the screws of the control lever unit attachment to fuselage beams (9 pcs.); - disconnect the reinforced rubber hose from the master cylinders after squeezing it with a clamp near the disconnection point; - disconnect the copper tube connecting the parking brake valve with brake units on the wheels; WARNING! When disconnecting the braking system tubes some amount of braking fluid may spill out. - remove the control lever unit assembled with the master cylinder; - detach the master cylinder from the control lever unit; To install the master cylinder perform the above actions in reverse order. After re- assembling fill the braking system following the instructions given in the beginning of this section. Then adjust the control systems of the engine and elevator trim tab as described in the corresponding sections of this manual. Recommended special tools: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 24 Necessary parts/materials: none. 5.3 Remove the handles from the control levers of the throttle, elevator trim tab, brakes and choke. Remove horizontal panel. Inspect the parking brake valve for leaks of the braking fluid. If any leak is detected the valve must be removed for repair or replacement. In order to remove the parking brake valve do the following: - block the reinforced rubber hose connecting the expansion tank with the master cylinder by squeezing the hose with a clamp; - cut the plastic cable ties fixing the valve; - undo the screws attaching the valve; - disconnect the copper tubes from the valve. To install the parking brake valve back perform the above actions in reverse order. After assembling fill the braking system with the braking fluid following the instructions described in the beginning of this section. If no defects are detected in the parking brake valve, re-assemble everything in reverse order. Recommended special tools: none. Necessary parts/materials: none. 5.4 Remove the wheel fairing (if installed). Inspect the brake unit for leaks of the braking fluid. If any leak is detected the brake unit must be removed for repair or replacement. To remove the brake unit, do the following: - put the wheel chokes under the front and opposite main wheel; - lift the airplane using a jack placed under a special plate near the opening in the fuselage bottom skin for the MLG leg; - unlock and undo the brake disk screws and wheel axle nut; - remove the wheel and brake disk; - disconnect the copper tube from the brake unit; - disconnect the brake unit from the supporting plate (undo two bolts and three screws of the brake unit) and remove the braking pads from it. To re-install the brake unit perform the above actions in reverse order. After assembling fill the braking system following the instructions described in the beginning of this section. Check the brake pads for integrity and wear. The minimum thickness of the pad is 2.54 mm (0.1 in). The wear may be checked using a special depression in the butt of the braking pad. In case of significant wear or loss of integrity the pads must be replaced. In order to do that, detach the brake unit as described above and replace the brake pads (the braking system tubes need not to be disconnected from the brake unit). For more detailed instructions on servicing and replacement of the brake pads contact the manufacturer (Matco mfg). If the wear is within the permissible limits, re-assemble everything in reverse order. Before re-installing the attachment screws of the brake disk apply Loctite 222 on their thread. Recommended special tools: none. Necessary parts/materials: Loctite 222. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 25 5.5 Define the character and degree of the brake disk wear. For that remove the brake disk as described in 0. Measure the brake disk thickness at its working surface. It must be at least 3.3 mm (0.13 in). If the disk thickness is less than that, the brake disk must be replaced. For more detailed instructions on servicing and replacement of the brake disk contact the manufacturer (Matco mfg). If the brake pads wear is within the permissible limits, re-assemble everything in reverse order. Before re-installing the attachment screws of the brake disk apply Loctite 222 on their thread. Recommended special tools: none. Necessary parts/materials: Loctite 222. 5.6 Remove the handles from the control levers of the throttle, elevator trim tab, brakes and choke. Remove the horizontal panel, main wheel fairings and pilot seats. Inspect the tubing of the braking system for leaks and mechanical damage. Pay special attention to the joints. If any leak or damage is detected replace the corresponding portion of the tubing. To obtain additional technical support contact the manufacturer. After re-assembly fill the braking system following the instructions described in the beginning of this section. After inspection (repair) re-assemble everything in reverse order. Before re-installing the pilot seats apply Loctite 222 on the thread of the attaching bolts. Recommended special tools: none. Necessary parts/materials: Loctite 222. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 26 6 Engine and its control system A-22LS is equipped with 100 hp Rotax-912ULS or 80 hp Rotax-912UL four-cylinder four- stroke carburetor engine with combined cooling system manufactured by BRP-Rotax GmbH&Co KG (Austria). WARNING! Maintenance of the engine must be performed according to the current documentation of BRP-Rotax company on operation and maintenance of Rotax 912 engine. For more detailed information visit the engine manufacturer’s web site: www.flyrotax.com. Arrangement and design of the engine systems (fuel, electric, oil, cooling, control, exhaust) complies with the requirements of the “Installation Manual for Rotax® Engine Type 912 series”. The engine is installed on a mount and is retained on top with a rod. The engine mount consists of upper and lower parts. The lower mount (truss) is attached to fuselage structure (firewall), and the upper mount (frame) is attached to the engine. To damp the vibrations and shock loads produced by the running engine the upper and lower mounts are connected via rubber shock absorbers. The shock absorbers are installed on the upper mount. The rod connects a bracket installed on the engine with fuselage structure. The rod is connected to fuselage structure via a shock absorber as well. The throttle lever is located between the pilot seats. In the airplane equipped with a central stick the throttle levers are located outboard of the pilot seats. Two cables run from the throttle lever(s) to the left and right carburetors. The engine control system also includes engine start mixture control. The mixture control lever is located near the throttle lever on the horizontal panel. It is connected to the carburetors’ chokes with cables. The engine may be equipped with an intake air box of Aeroprakt design that improves the engine operating conditions, prevents carburetor icing and increases the engine power output in hot climate. INSPECTION CHART Description Interval RCO Instr. No. TM LC Engine * OC 6.1 H TSP Engine mount, upper 200 h OC 6.2 L LRI Engine mount, lower 200 h OC Engine retaining rod 200 h OC Shock absorbers, 6 pcs. 500 h OC 6.3 H LRM Engine attachment fitting 2000 h OC 6.4 H LRM Intake airbox assembly** 200 h OC 6.5 H LRM Throttle cables (central stick) 100 h OC 6.6 H TSP Throttle cables (yokes) 100 h OC Choke cables (central stick) 100 h OC Choke cables (yokes) 100 h OC Throttle cables sheath (central stick) 100 h OC 6.7 H TSP Throttle cables sheath (yokes) 100 h OC Choke cables sheath (central stick) 100 h OC Choke cables sheath (yokes) 100 h OC Throttle lever (central stick) 100 h OC 6.8 L OWN Throttle lever (yokes) 100 h OC 6.9 L OWN * – see "Maintenance Manual for Rotax® Engine Type 912 series" ** – in aircraft version equipped with intake airbox. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 27 Instructions: 6.1 The engine servicing must be performed according to the "Maintenance Manual for Rotax® Engine Type 912 series". When servicing and repairing the engine it may be necessary to dismantle it. The plastic cable ties securing the engine system components must be cut. When disconnecting the tubes and hoses it is recommended to plug the holes and fittings. When installing the engine back secure the cables and tubes of the engine systems with the plastic cable ties. To dismantle the engine, do the following: - set the fuel valves to CLOSED; - switch OFF the battery using the battery switch or (if it is not available) disconnect one of the power lines from the battery; - remove the top and bottom engine cowlings; - disconnect the fuel line at its joint behind the firewall; WARNING! Be careful when working with the fuel system, as remains of fuel in the fuel lines are highly fire hazardous. - remove the muffler and exhaust pipes (see “Exhaust system” section); - disconnect the throttle and choke control cables from the carburetors; - remove the intake airbox (see instruction 6.5 of this section); - drain the coolant from the cooling system (see “Cooling system” section); - disconnect the cooling system hose from the coolant pump; - disconnect the cooling system hoses from the expansion tank outlet and overflow sleeve; - disconnect the oil system hose from the oil outlet on the bottom of the crankcase and drain the remaining oil from the crankcase; - disconnect the oil system hose from the oil pump inlet and drain the remaining oil from the system; - drain oil from the oil tank, if necessary; - disconnect the oil system hose from the oil tank outlet; - detach the oil radiator by unfastening the metal clamps attaching the radiator; - take out the senders of oil temperature and cylinder head temperature (or disconnect the cables from them if possible) and detach the cables from the engine; - disconnect the cables from the oil pressure sender and untie the cables; - disconnect the cables from the starter; - take out the shielded cables of the ignition switches from the ignition system connector and untie the cables; - take out the shielded cable of generator from the rectifier-regulator connector and untie the cable; - disconnect the tachometer connector from the engine and untie he cable; - disconnect the engine retaining rod from fuselage; - remove the engine by undoing 4 bolts attaching engine to the upper engine mount. Engine installation is performed in reverse order following the instructions of the “Installation Manual for Rotax® Engine Type 912 series”. After engine installation the cooling and oil system must be refilled and engine control system must be re-adjusted. WARNING! When adjusting the throttle cables ensure 1 mm clearance between the throttle valve control arm in IDLE position and the idle RPM stop (special feature of A-22LS). When installing the vent tubes of the carburetors do not let them protrude out of the engine cowling as this may cause unstable operation of the engine in flight. Recommended special tools: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 28 Necessary parts/materials: fuel line plugs. 6.2 Remove the top and bottom engine cowling. Check the torque of the engine mount attachment bolts and tighten if necessary. Inspect the engine mount for fatigue cracks and deformation. Pay special attention to the weld seams. If any defects were detected contact the manufacturer for the required technical support. Recommended special tools: magnifying glass, electric torch, torque wrench. Necessary parts/materials: none. 6.3 Remove the top and bottom engine cowling. Inspect the shock absorbers for deep cracks and disintegration. If such defects are detected the shock absorbers must be replaced. To replace the shock absorbers do the following: - remove the safety pin and undo the nut of the rod attaching engine to fuselage; - remove the bolt while holding the engine; - remove the shock absorbers of the rod; - install new shock absorbers; WARNING! The shock absorbers are asymmetric about their attachment plate. They must be installed with their bigger halves towards each other in order to ensure 3-5 mm (0.1-0.2 in) clearance between their bushings. - put a support of an appropriate size under the tail wheel (with the engine removed the airplane will tend to lower the tail); - remove the safety pins and undo 2 nuts of the bolts attaching the upper engine mount to the lower one; - remove the bolts and carefully lift the engine using a hoist; - remove the shock absorbers; - install new shock absorbers; WARNING! The shock absorbers are asymmetric about the plane of their attachment plate. They must be installed with their bigger side towards each other to ensure the dimension along the bushing axes equal to 51 mm (2 in). - re-assemble everything in reverse order. Recommended special tools: magnifying glass, electric torch, hoist, torque wrench. Necessary parts/materials: none. 6.4 Remove the top cowling. Disconnect the rod from the fitting. Inspect the fitting for the fatigue cracks. Check the spherical bearing for play. Permissible radial play is 0.25 mm (0.1 in), axial – 0.5 mm (0.2 in). If fatigue cracks or play more than permissible are detected the fitting must be replaced. Contact manufacturer for the required technical support. Recommended special tools: magnifying glass, electric torch, torque wrench. Necessary parts/materials: none. 6.5 Remove top and bottom cowling. Check if the shutter actuator functions properly and the shutter fits tight at its extreme position, adjust if necessary. To adjust the shutter actuator, do the following: AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 29 - set the shutter to ON; - loosen the screws fixing the cable sheath in the nylon block on the bottom side of the airbox; - push the shutter to the extreme position with the cable sheath and tighten the screws. If the cable sheath travel is insufficient for the adjustment, the shutter must be re- installed. Remove the top half of the airbox for that (see installation of the airbox below). Check the torque of the airbox screws and tighten them if necessary applying Loctite 222 on the thread. Check the attachment of the shutter actuator, vent tube and corrugated hose and replace the plastic clamps if necessary. Check the integrity and reliable attachment of the sealing ring of the intake manifold. Install new ring, if necessary, using any suitable glue. It may be necessary to remove the airbox when servicing and repairing the engine. To remove the airbox do the following: - remove the carburetor vent tubes; - undo the screws connecting the airbox halves; - undo and remove the bolt joining the upper rod attaching engine to fuselage; - remove the top half of the airbox by moving the engine forward; - set the airbox shutter to ON; - unfix and remove the shutter; - remove the carburetor air filters; - cut the plastic clamps fixing the corrugated hose and airbox vent tube; - loosen the cable sheath clamp screws and take it out from the airbox; - remove the bottom half of the airbox. Airbox installation shall be performed in reverse order. Then while installing the shutter, set the carburetor heating knob to ON and ensure 33 mm (1.3 in) clearance between the lower flange and the shutter. After assembling the airbox the shutter can be adjusted by loosening the cable sheath clamp. When assembling the airbox apply Loctite 222 on the thread of its fixing screws. Recommended special tools: torque wrench. Necessary parts/materials: Loctite 222. 6.6 Remove the top cowling. Remove the handles from the control levers of throttle, elevator trim tab and horizontal panel. Inspect the cables for wear. In case of significant wear the cables must be replaced. Use 1x19 Ø1.5 mm (0.075 in) cable cut to the length of the old one. Tin the cable ends before its installation. WARNING! Using the cable with broken wires is not allowed. After replacement or disconnection of the cables the engine control system must be re-adjusted (see “Installation Manual for Rotax® Engine Type 912 series”). Recommended special tools: soldering iron. Necessary parts/materials: none. 6.7 Remove the top cowling. Inspect the control cables for kinks and damage of their sheath, paying special attention to the areas where it goes through the firewall. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 30 A damaged portion of the cable sheath may be repaired by setting over it a piece of thermoshrinkable tube. If significant kinks in cable sheath were detected that hamper the cable motion, the sheath must be replaced. After replacement or repair of the cable sheath the engine control system must be re-adjusted. (see Installation Manual for Rotax-912 aircraft engine). WARNING! When adjusting the throttle cables ensure 1 mm clearance between the throttle valve control arm in IDLE position and the idle RPM stop (special feature of A-22LS). Recommended special tools: heat gun. Necessary parts/materials: thermoshrinkable tube. 6.8 Check the torque of the bolt serving as the axle of the throttle lever and adjust if necessary. The adjustment must ensure that the lever remains at IDLE when engine is running and the force to move the throttle is not too high. Recommended special tools: torque wrench. Necessary parts/materials: none. 6.9 Remove the left pilot seat. Check the torque of the throttle lever friction stop, located on the left side behind the seat beam, and adjust it if necessary. The adjustment must ensure the throttle lever is retained in IDLE position with engine running and the force to move the lever is low. Recommended special tools: torque wrench. Necessary parts/materials: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 31 7 Cooling system Rotax-912 has cooling system of a combined type. The cylinders are air-cooled and the cylinder heads are liquid-cooled. The liquid cooling system consists of a water pump, expansion tank, radiator, overflow tank and hoses. Its servicing consists of systematic inspection of its components, timely replacement of the coolant and system cleaning, as well as replacement of its parts with expired service life (hoses, sealing, etc.). WARNING! Servicing of the cooling system must be performed in accordance with the latest documentation of BRP-Rotax company on operation and maintenance of Rotax 912 engine. Cooling system capacity is about 3 l (0.8 US gal). Amount of the coolant in the system must be checked by the coolant level in the expansion and overflow tanks. WARNING! When the cooling system is filled with coolant, air lock may be formed within the top portion of the radiator. To remove it from the system, loosen the clamp of the upper left inlet of the radiator and let the air out by carefully inserting a flat-end screwdriver between the upper surface of the radiator inlet and inner surface of the hose. To drain coolant from the system remove the top and bottom cowlings, disconnect the lower hose from the lower right outlet of the radiator and let the coolant out. INSPECTION CHART Description Interval RCO Instruction TM LC Radiator clamps, 2 pcs. 100 h OC 7.1 L LRI Overflow tank 100 h OC 7.2 L LRI Hoses 100 h OC 7.3 L LRM Coolant inlet elbow hose clamp First – 25 h; next – 100 h OC 7.4 L LRM Instructions: 7.1 Check for integrity the clamps attaching the radiator to the engine mount. If any clamp is damaged it must be replaced. Check the clamp torque and tighten if necessary. Recommended special tools: torque wrench. Necessary parts/materials: none. 7.2 Remove the top and bottom cowlings. Inspect the tank for leaks of coolant, cracks in its housing and cap. If any damage is detected the tank must be replaced. Check the level of coolant in the tank and refill if necessary. Check the required level using the marks on the tank. Make sure the tank is attached reliably to the firewall. Replace the plastic cable ties if necessary. Recommended special tools: none. Necessary parts/materials: coolant. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 32 7.3 Remove the top and bottom cowlings. Inspect the hoses for leaks and any damage (chaffing, cracks). Pay special attention to the areas of hose attachment and passing close to structural elements of engine and its mount. Damaged hoses must be replaced. Drain coolant before replacing the hoses and re- fill the cooling system with coolant as described in the beginning of this section. Check torque of the clamps on joints and tighten if necessary. Pay special attention to tightness of the joints before beginning operation in cold season. Check the torque of the clamps (except for the screw clamp attaching the water hose to the inlet fitting of the water pump) which must be 2-3 Nm (1.5 – 2.2 lb·ft) and tighten if necessary. Pay special attention to tightness of the joints before beginning operation in cold season. Recommended special tools: torque wrench. Necessary parts/materials: none. 7.4 Remove the top and (if needed) bottom cowlings. Inspect the hose attachment to water outlet elbow. Check the torque of the screw clamp attaching the water hose to the inlet fitting of the water pump, that must be equal to 4 N·m (3 lb·ft). Recommended special tools: screwdriver. Necessary parts/materials: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 33 8 Lubrication system The engine lubrication system is of closed type with dry crankcase and forced circulation of oil. The lubrication system consists of oil pump, oil tank, radiator, filter and connecting lines. Servicing of the lubrication system consists of systematic inspection of its components, timely replacement of oil and oil filter, as well as replacement of the parts with expired service life (connecting lines, sealing, etc.). WARNING! Servicing of the lubrication system must be performed in accordance with the latest documentation of BRP-Rotax company on operation and maintenance of Rotax 912 engine. The lubrication system must be filled with high quality oil for gasoline four-stroke engines, recommended by BRP-Rotax company. Lubrication system capacity is 3 l (0.8 US gal). INSPECTION CHART Description Interval RCO Instruction TM LC Oil tank 100 h OC 8.1 L LRI Connecting lines 100 h 1000 h/OC 8.2 H TSP Instructions: 8.1 Remove top and bottom cowling. Inspect the oil tank bottom plug for oil leaks. If leaks are detected, tighten and lock the plug with safety wire. Make sure that the vent line has no kinks, is intact and secured reliably. If the line is damaged it must be replaced. Recommended special tools: none. Necessary parts/materials: safety wire. 8.2 Remove top and bottom cowling. Inspect the connecting lines for leaks of oil and damage (chaffing, cracks). Pay special attention to the areas of connecting lines binding and passing close to engine, its mount and cowling. If damaged connecting lines are detected, they must be replaced. WARNING! When disconnecting the lines some oil may be spilled out. Check the torque of the clamps on joints and tighten if necessary. Pay special attention to tightness of the joints before beginning operation in cold season. Recommended special tools: torque wrench. Necessary parts/materials: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 34 9 Fuel system The fuel system (see Fig. 2) includes: – two wing fuel tanks (1,2) with filler inlets (3,4); – fuel lines d8 (5,6,9,10,12,14,16); – two fuel valves (7,8); – sediment collector (13); – fuel drain line d12 (26); – drain valve (27); – fuel filter (15); – T-connector (11) and bulkhead fitting (17); – genuine ROTAX hoses (18,20,22,23); – engine fuel pump (19); – two carburetors (21,24); – return line d6 (25); – fuel pressure sensor (28) – optionally; – fuel flow transducer (29) – optionally. Fig. 2 Fuel system schematic AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 35 Servicing of the fuel system consists of systematic inspection of its components, timely replacement of the fuel filter, as well as replacement of the parts with expired service life (connecting lines, sealing, etc.). WARNING! Be careful when working with the fuel system, as the remains of fuel are highly fire hazardous and when spilled on glass may cause its dimness and cracking. INSPECTION CHART Description Interval RCO Instruction TM LC Fuel tank, right 500 h OC 9.1 L LRM Fuel tank, left 500 h OC Fuel valves, 2 pcs. 100 h OC 9.2 L LRM Drain fuel valve 100 h OC Fuel filter 100 h 200 h/OC - L LRM Connecting lines 100 h 1000 h/OC 9.3 L LRM Instructions: 9.1 Drain fuel from the tanks. Remove the tank and inspect it for leaks of fuel. In case of suspected damage of the tank a more thorough check is necessary. Contact manufacturer for the required technical support. Inspect the inner surface of the tank through the fuel inlet. If the tank bottom is contaminated rinse it with gasoline. If no defects were detected, re-install the tank, applying Loctite 222 on the tread of the attaching screws. Recommended special tools: magnifying glass, electric torch. Necessary parts/materials: Loctite 222. 9.2 Remove the rear plastic panel of the cockpit (if installed). Inspect the fuel valve for leaks of fuel. If leaks of fuel are detected in the areas of valve connection to its fittings, the valve must be replaced. Recommended special tools: none. Necessary parts/materials: none. 9.3 Remove the top cowling, upper and lower rear plastic panels of the cockpit (if installed) and the right pilot seat. Inspect the fuel lines for leaks of fuel and damage (chaffing, cracks). Pay special attention to the areas of fuel line binding and passing through the fuselage structure. If damaged fuel lines are found, they must be replaced. For replacement of fuel lines use reinforced rubber hoses resistant to fuels and oils with inside diameter Ø8 mm and Ø12 mm (drain). Check torque of the clamps on joints and tighten if necessary. Pay special attention to tightness of the joints before beginning operation in cold season. Make sure the fuel lines are fixed to fuselage structure reliably and replace the plastic cable ties if necessary. Recommended special tools: none. Necessary parts/materials: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 36 10 Exhaust system The exhaust system of A-22LS airplane is arranged and installed in accordance with the recommendations of "Installation manual for Rotax-912 aircraft engine". The system comprises of the exhaust pipes and muffler. Depending on configuration the exhaust pipes may be fitted with exhaust gas temperature (EGT) sensors. Each exhaust pipe is fixed to the engine with two studs and secured with M8 self-locking nuts. The exhaust muffler is attached to the exhaust pipes via spherical joints and secured with springs. WARNING! Servicing of the exhaust system must be performed in accordance with the current documentation of BRP-Rotax company on operation and maintenance of Rotax-912 engine. INSPECTION CHART Description Inspection interval RCO Instruction TM LC Muffler 100 h OC 10.1 L OWN Exhaust pipe of cylinder 1 100 h OC Exhaust pipe of cylinder 2 100 h OC Exhaust pipe of cylinder 3 100 h OC Exhaust pipe of cylinder 4 100 h OC Springs, 8 pcs. 100 h OC 10.2 L OWN Instructions: 10.1 Remove the top and bottom cowling. Inspect the exhaust system for fatigue cracks. Pay special attention to the weld seams and the areas around them. Use electric torch any other suitable source of light for the inspection. In case of suspicion for fatigue crack the exhaust system must be dismantled for more thorough flaw detection. In case of a confirmed crack, contact the aircraft manufacturer for the required technical support. To dismantle the exhaust system, do the following: - remove the springs retaining the muffler; - undo the nuts securing the exhaust pipes; - carefully take out the exhaust pipes and the EGT sensors (if the latter are fitted); - remove the old heat-resistant grease from the spherical joint of exhaust pipes and muffler. To install the exhaust system, do the following: - put in place the EGT sensors (if fitted); - apply a heat-resistant grease (e.g. LOCTITE ANTISEIZE) on the surfaces of the spherical joint of exhaust pipes and muffler; - put in place the exhaust pipes and nuts attaching them; - attach the exhaust muffler and tighten the exhaust pipe nuts. WARNING! When installing the exhaust pipes follow the requirements of "Installation manual for Rotax-912 aircraft engine". Recommended special tools: magnifying glass, electric torch. Necessary parts/materials: heat-resistant grease. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 37 10.2 Remove the top and bottom cowling. Inspect the springs for integrity. Broken or missing springs must be replaced. Recommended special tools: magnifying glass, electric torch. Necessary parts/materials: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 38 11 Propeller A-22LS airplane may be fitted with any propeller, approved by Aeroprakt Ltd. Propeller and its spinner servicing comprises of their systematic inspection and timely repair (or replacement) of the parts with expired service life in accordance with the requirements of their manufacturer. INSPECTION CHART* Description Interval RCO Instruction TM LC Propeller hub 200 h **/OC 11.1 L LRM Bolts, 6 pcs. 200 h **/OC 1.8 L OWN Spinner 200 h OC 11.2 L LRI * for propeller manufactured by KievProp company (e-mail: kievprop@i.ua, web: http://www.kievprop.com) and spinner produced by Aeroprakt ** in accordance with the requirements of KievProp company. Notes: 11.1 Remove the propeller spinner. Inspect the propeller hub for fatigue cracks. If any cracks are detected contact propeller manufacturer (KievProp, Ukraine, Kyiv, 04128, Tupolev str. 19, tel./fax: +38 (044) 443-79-91, e-mail: kievprop@i.ua) for necessary technical support. Check the pitch angles of the blades and re-adjust the propeller if necessary. If no defects are detected install the spinner in place applying Loctite 222 on the thread of the attachment screws. Recommended special tools: propeller blade angle gauge, torque wrench. Necessary parts/materials: Loctite 222. 11.2 Check the torque of the screws attaching the spinner. Tighten if necessary using Loctite 222. Recommended special tools: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 39 12 Airplane control system The airplane control system consists of control systems of ailerons, elevator, elevator trim tab, and aileron drooping mechanism. Control systems of ailerons and elevator may be with either yokes or central stick. The control system of elevator trim tab may be either mechanical or electrical. Control system linkage for ailerons and elevator is rigid, and for the elevator and its trim tab it is made of cables. Servicing of the airplane control system comprises of its systematic inspection, lubrication, detection of worn components, repair and timely replacement of the parts with the expired service life. The control system must operate smoothly without jamming and significant play (see below). The clearances between the movable parts of the control system and fixed structural elements must be at least 5 mm (0.2 in). Main components of the system to be checked are: - fabric covering of the control surfaces; - spherical bearings; - sliding bearing; - fairleads; - cables; - pulleys; - fasteners. The fabric covering must be inspected for damage and delamination from the framework of the control surfaces. Minor ruptures (less than 50 mm or 2 in) may be repaired by covering them with ORACAL permanent sticking film. In case of significant damage and delamination of the fabric covering from the framework contact aircraft manufacturer for the required technical support. The spherical bearings are installed in hinge brackets of the control surfaces, in control rods and control system supports. The used hinges do not require any servicing. Their wear must be checked by their radial and axial play. Maximum radial play is 0.25 mm (0.01 in) maximum axial play – 0.5 mm (0.02 in). If the play is exceeding the above specified values contact the manufacturer for the required technical support. Sliding bearings are used in hinge brackets of the control surfaces and in control system supports. They consist of a sleeve and an axle. The sleeves used in this airplane are made either of bronze or steel. In the hinge brackets the sleeve is press-fitted into the bracket, fixed to the airframe structure, and the axle is component of the movable control surface. In the Cardan joints and in the control system supports the sleeves are installed both in fixed and movable parts, and bolts (or pins) are used as axles. Sliding bearing wear must be checked by the radial play. The maximum radial play is 0.5 mm (0.02 in). If the play exceeds the specified value contact the manufacturer for the required technical support. Sliding bearings require periodic lubrication. They may be lubricated by any grease for bearings every 200 hours or on condition. The fairleads are used in the control systems of rudder and elevator trim tab and serve to retain the cables. The fairleads are made of composite epoxy material (CEM). The fairleads wear must be checked by the depth of the slot created due to cable friction against them. The slot depth must not exceed double diameter of the cable. If the wear is exceeding the specified value contact the manufacturer for the required technical support. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 40 The cables are used in the control systems of the rudder and elevator trim tab. The cables must be inspected for broken wires. Special attention must be paid to the areas where cables pass through the fairleads, pulleys and to the cable terminations. If broken cable wires are found than the cable must be replaced. Contact the manufacturer for the required technical support. Pulleys are used in the control system of rudder. The pulley supports do not require any servicing. The pulleys rotate on a sliding bearing which require periodic lubrication. The sliding bearings must be lubricated with any bearing grease every 200 hours or on condition. After re-installation of a pulley after its servicing the joining bolt shall be tightened with a torque corresponding to its size as the inner sleeve of the sliding bearing must be static. The pulleys must rotate freely without jamming or play. If jamming or play appears the pulleys must be replaced. WARNING! When servicing the control system avoid over-tightening the bolts serving as sliding bearing axles. The tightening must eliminate the axial play however it must allow unrestricted motion of the movable part of the joint. All bolts, nuts (except for self-locking ones), pins, turnbuckles must be locked reliably. Adjustment of the aileron control system is achieved by changing the length of the vertical and diagonal control rods. Adjustment of the elevator control system is achieved by changing the length of the aft control rod. WARNING! To increase the length of a control rod, loosen the locking nut and screw the rod end OUT (all treads are right-hand!), to reduce the length – screw it IN. After adjusting the rod length tighten the locking nut applying the Loctite 222 on the thread. Adjustment of the rudder control system is achieved using the turnbuckles of the rudder control cables. Adjustment of the elevator trim tab control system is achieved by fixing the control cable of the trim tab with a screw in the control arm of the tab at a proper setting. WARNING! Do not cut the excessive length of the cable beyond the control arm of the tab. This portion is required for passing the cable through its sheath in the elevator when re-attaching the elevator to the stabilizer. After adjusting the cable length coil its free end carefully and secure it to the trim tab control arm with a plastic cable tie but in a manner that does not hamper the tab deflection while it is being controlled. Adjustment of the control system must ensure the following deflection angles of the control surfaces: - Flaperon deflection angles (as ailerons): up – 19±1°, down – 13±1°. - Flaperon deflection angles (as flaps): 1st setting – 10±1°, 2nd setting – 19±1° - Elevator deflection angles: up – 25±1°, down – 15±1°. - Elevator trim tab deflection angles: up – 21±1°, down – 22±1°. - Rudder deflection angles: neutral – 2±0.5°, right/left from neutral – 25±1°. The deflection angles of the control surfaces must be checked every 500 hours of aircraft operation.