AEROPRAKT-22LS Airplane Maintenance Manual

18.4 RESTORING OF DAMAGED PAINT/COATING ...................................................................................................... 64 21 Feedback Form .......................................................................................................... 65 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 4 1 General NOTE: This manual is subject to change by the notifications or safety bulletins 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 specifies the requirements to inspection and maintenance that are required for keeping the flight performance and reliability at a level of a new airplane. 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: o BK-3 airspeed indicator o BG-3E altimeter o BC-2A vertical speed indicator o slip indicator o compass Engine instruments: o analog engine instruments o two VAZ-2104 fuel level indicators Radio equipment: o FILSER ATR833 radio transceiver Miscellaneous equipment o Strobe & navigation lights 1.3 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: BOMBARDIER-Rotax-GmbH (Austria) Engine model: Rotax-912UL Rotax-912ULS Engine type: Flat-four, four-stroke Maximum takeoff power: 80 h.p. 100 h.p. Time limit at full power: 5 min (5800 rpm) Max. revolutions (no time limit) 5500 rpm Min. revolutions at idle 1400 rpm Maximum coolant temperature at pick-up point: 120 ºC (248 ºF) Oil temperature, normal minimum maximum 90-110 ºC (190-250 ºF) 50 ºC (120 ºF) 140 ºC (285 ºF) 90-110 ºC (190-250 ºF) 50 ºC (120 ºF) 130 ºC (266 ºF) Exhaust gas temperature: - maximum at takeoff - maximum - normal 880 ºC (1620 ºF) 850 ºC (1560 ºF) 800 ºC (1470 ºF) Oil pressure, normal minimum maximum 2,0-5,0 bar (29-73 psi) (above 3500 RPM) 0,8 bar (12 psi) (below 3500 RPM) 7 bar (100 psi) (at cold start, allowed for a short time) Fuel pressure, normal maximum 0,15-0,4 bar (2,2-5,8 psi) 0,4 bar (5,8 psi) Ambient air temperature range from -25 ºC to +50 ºC AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 7 1.5 Weight and balance information The airplane CG position must be between 1.47 m and 1.78 m 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 × Arm, m = Moment, kg·m Empty aircraft 309.3 × 1.499 = 463.8 Pilot(s) 180 × 1.6 = 288 Baggage 20 × 2.3 = 46.0 Fuel (0.72 kg/l) 82.1 × 2.0 = 164.2 Total 591.4 1.627 962.0 Airplane CG: Total moment / Total weight = 973.8 / 599.7 = 1.624 (m) 1.6 Tire inflation pressure Normal inflation pressure for both main and nose wheels is 1.6 kg/cm2 (22.8 psi). 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 grade: unleaded MOGAS min. RON 95 or AVGAS 100LL Maximum capacity of the fuel tanks: 2 × 57 = 114 liters AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 8 “Fuel Low” warning light at: approx. 6 liters per tank Unusable fuel: approx. 0.5 liter Oil Approved grade: any automotive oil of API classification “SF” or “SG” Oil tank capacity: 3 liters (NOTE: check correct oil level in the tank using the oil probe.) Coolant Approved grade: Mobil Antifreeze Advanced Concentrate 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 in front 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: Metric fasteners Inch fasteners Torque, N·m (lb·ft) М5 10-32 6 (0.9) М6 1/4 10 (1.5) М8 5/16 15 (2.3) М10 3/8 25 (3.8) WARNING! All bolts, nuts (except for self-locking ones), pins, turnbuckles must be locked reliably. 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. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 9 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 " 25 50 100 200 500 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 play and hinge brackets for 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 nose leg for fatigue cracks, deformation and play X Check the nose leg bellcrank bolt/nut torque and locking X Check the shock absorber condition and pressure X Inspect the MLG springs and attachment beam for fatigue cracks1, deformation and play X Check the MLG spring 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 deformation2 X Check the torque and locking of the mud-screen attachment bolts/nuts2 X Inspect the skis for damage3 X Check the torque and locking of the ski attachment bolts/nuts3 X Brake system (section 5) Inspect expansion tank for leaks, cracks, secure attachment. Check 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 Measure the brake disks' wear X Inspect the brake 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 1 After 5000 landings the MLG springs must be removed and inspected carefully for fatigue cracks 2 For an aircraft version on wheels with mud-screens 3 For an aircraft version on skis AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 11 Inspection/Servicing action ! and its interval in hours " 25 50 100 200 500 1000 2000 Check the torque of the engine mount attachment bolts X Inspect the shock absorbers for damage (deep cracks, etc.) X Inspect the engine attachment fitting for the fatigue cracks X Check the intake airbox function, condition and attachment4 X Inspect the throttle and choke cables and cable sheath for wear, damage, kinks X Check the torque of the throttle lever bolt (axle) X Cooling system (section 7) Check the radiator clamps integrity and torque X Inspect the overflow tank for leaks of coolant, cracks; check coolant level X Inspect lines for leaks, damage (chaffing, cracks), loose joints X Lubrication system (section 8) Inspect the oil tank plug for oil leaks; verify vent line is intact and secured X Inspect lines for leaks and damage (chaffing, cracks), loose 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 X Propeller (section 11) Inspect propeller hub for fatigue cracks; check pitch angles X Check torque and locking of the propeller bolts/nuts X Check torque of the spinner bolts X Airplane control system (section 12) Inspect control surfaces for fatigue cracks, deformation, loose rivets, torn fabric 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 (play in hinges, nuts tightness/locking) X Grease the slide 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 condition of the control cable pulleys and fairleads X Check trim tab attachment bolts/nuts for corrosion, replace if necessary X Inspect the trim tab control cables and sheath for damage (wear, kinks, etc.) X Electrical system (section 13) Verify battery charges/discharges properly, otherwise replace X Clean starter terminals and starter relay connector of corrosion, 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 4 For an aircraft version equipped with intake airbox AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 12 Inspection/Servicing action ! and its interval in hours " 25 50 100 200 500 1000 2000 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 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 and Avionics (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 and sealing for damage X Verify the gas struts function properly X Recovery system (section 19) Check attachment of the suspension cables to fuselage and parachute lanyard X AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 13 3 Structures The airframe of A-22LS airplane includes the following parts: fuselage with polycarbonate glass windscreen and rear skin panels, wings, wing struts, horizontal and vertical tail units (HTU and VTU), wing fillets, 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. Framework of flaperons, elevator and rudder is all-metal, their rear skin (aft of spar) is fabric. The rear fuselage skin panels (top and two side ones) depending on airplane configuration may be made of PVC glass, all-metal or combined. The fairings and engine cowling are made of fiberglass. When servicing the airplane a special care shall be taken to protect the airframe from corrosion and to protection of the paint coating. Protection of the airframe parts from corrosion consists mainly of keeping the protective coatings intact. 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, the paint must be protected from scratches, and spilling oil products, solvents, alkalis and acids on paint must be avoided. INSPECTION CHART Part No. Description Interval RCO Instr. No. TM LC A22LS-0-0100-00 Fuselage 100 h OC 3.1 L LRI A22L-0-1300-00 Windscreen glass 100 h OC 3.2 L OWN A22L-0-1320-00 Rear fuselage skin panel, top 100 h OC A22L-0-1330-01 Rear fuselage skin panel, right 100 h OC A22L-0-1330-02 Rear fuselage skin panel, left 100 h OC A22LS-0-2000-00 Wing 100 h OC 3.3 L OWN COM-5 Spherical bearings, 4 pcs. 2000 h OC 3.4 L LRI A22LS-1-2920-01 Wing strut, right 100 h OC 3.5 L LRI A22LS-1-2920-02 Wing strut, left 100 h OC A22LS-0-2950-01 Wings strut fairing, top, right 200 h OC 3.6 L LRI A22LS-0-2950-02 Wings strut fairing, top, left 200 h OC A22LS-0-2940-01 Wings strut fairing, bottom, right 200 h OC A22LS-0-2940-02 Wings strut fairing, bottom, left 200 h OC AN 175-11 Wing attachment bolts, 4 pcs. 100 h OC 1.8 L OWN AN 175-12 Wing attachment bolts, 4 pcs. 100 h OC A22LS-0-3100-00 Stabilizer 100 h OC 3.7 L LRI AN 174-6 Stabilizer attachment bolts, 2 pcs. 100 h OC 1.8 L OWN AN 310-5 Stabilizer attachment nut 100 h OC - Tail wheel 100 h OC 3.8 L LRI AN 5-32 Tail wheel bolt 100 h OC 1.8 L OWN A22L-2-6920-00 Engine cowling panel, top 100 h OC 3.9 L LRI A22L-2-6910-00 Engine cowling panel, bottom 100 h OC AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 14 Instructions: 3.1 Remove the engine cowling, doors, 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 (frames No. 1, 4, 5, 6, longitudinal, transverse and vertical beams of the cockpit, undercarriage beam, fuselage tubes, tail boom and fin skin). 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 crack existence 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 on 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 the reversed 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 for 'silvering' (micro cracks) and cracks in the attachment areas. When detecting a crack shorter than 50 mm (2 in) carefully cut a hole at its end with a Ø3 mm (0.12 in) drill to stop the crack propagation. If the crack is longer than 50 mm (2 in) the glass must be replaced. Contact the manufacturer 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. Recommended special tools: electric drill, 3 mm drill. Necessary parts/materials: none. 3.3 Drain fuel from the fuel tanks. Remove the wing strut fairings and fuel tanks. Inspect 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 delaminating 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). The movement in the attachment points due to loose joint (play) is not 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 bolt joint. 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 the reversed 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 Detach the wings by doing 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 from the flaperon shafts by removing the vertical bolts; - remove the split 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 from the wing fillets; Inspect the wing and strut attachment fittings for fatigue cracks. Check the spherical bearing for axial and radial play. When detecting play in 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 the reversed 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 the sealing fabric tape in the inner side. If necessary use double-sided sticking tape to fix the tape. 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 damage and play. When detecting a serious damage replace the wheel. When detecting play below 0.5 mm (0.02 in), tighten its axle nut. If the play exceeds 0.5 mm (0.02 in), insert a washer of appropriate thickness between the wheel hub and fuselage. Tighten the axle nut until it stops the free rotation of the wheel. 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 alight with the hole for the split pin in the axle. Then lock the nut using the split pin. The nose LG leg is steerable, of trailing link type with spring shock absorber. The leg structure consists of the strut, trailing link, bellcrank, wheel fork, spring shock absorber, axle, spacing sleeves, wheel/ski and fairing/mud-screen. The steering is achieved using the rudder pedals via the rods connected to the 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 bearings. Main landing gear (MLG) is of cantilever spring type. The MLG leg consists of the spring, axle, wheel (or ski), brake unit with supporting plate, and fairing (or mud-screen). The MLG spring is made of aluminum alloy. It is bolted at two points to the lower beam of the frame No.2. Maintenance of the brake unit with supporting plate is described in "Brake system" section. INSPECTION CHART Part No. Description Interval RCO Instr. No. TM LC A22LS-0-4310-00 Nose leg 100 h OC 4.1 L LRI AN 4-22A Bellcrank bolt 100 h OC 1.8 L OWN 165x40 mm Spring shock absorber 100 h OC 4.2 L LRM A22LS-3-4110-00 Main leg, right 100 h OC 4.3 H LRM A22LS-3-4110-00 Main leg, left 100 h OC 4.3 AN 6-37 Spring bolts, upper, 2 pcs. 100 h OC 1.8 L OWN AN 7-41 Spring bolts, lower, 2 pcs. 100 h OC See Matco P/N Nose wheel assembly 200 h OC 4.4 L LRI See Matco P/N Right wheel assembly 200 h OC 4.4 See Matco P/N Left wheel assembly 200 h OC 4.4 A22LS-0-4410-00 Nose wheel fairing 25 h OC 4.5 L LRI A22LS-0-4420-01 Right wheel fairing 25 h OC 4.5 A22LS-0-4420-02 Left wheel fairing 25 h OC 4.5 A22LS-0-4510-00 Nose wheel mud-screen* 50 h OC 4.6 L LRI A22LS-0-4520-01 Right wheel mud-screen* 50 h OC 4.6 A22LS-0-4520-02 Left wheel mud-screen* 50 h OC 4.6 A22LS-0-4710-00 Nose ski** 100 h OC 4.7 L LRI A22LS-0-4610-01 Right ski** 100 h OC 4.7 A22LS-0-4610-02 Left ski** 100 h OC 4.7 * – for wheel version with mud-screens; ** – for ski version. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 18 Instructions: 4.1 Remove the nose wheel fairing. Inspect the nose leg for fatigue cracks, deformation and play. When inspecting follow the instructions of 3.1 (2 and 3 paragraph) of “Structures” section. Pay special attention to the areas of the nose leg attachment near its upper and lower supports as well as weld seams of the nose leg. Check the nose 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 axial play in the supports tighten the upper support nut until 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 the torque of all bolted joints with self-locking nuts. Lubricate all surfaces of the nose leg trailing link subjected to friction depending on their condition as follows: - set parking brake to ON; - disconnect the control rods from the nose leg bellcrank; - remove the split pin and undo the nut of the upper support of the nose leg; - undo the nut and take out the bellcrank bolt; - while holding the nose leg carefully push down the airplane tail near the stabilizer attachment points till the airplane sets on the tail wheel and hold it in this position till the nose leg is re-installed back (this operation must be done by two persons); - carefully take out the nose leg from the supports simultaneously removing the bellcrank from it; CAUTION! Do not lower the fuselage nose while the nose leg is removed! This may cause damage to the airframe and propeller. - remove the old grease from the surfaces of the nose leg trailing link subjected to friction; - apply thin layer of new grease; - re-install the leg in the reversed order; - squirt grease into the nose leg hinge till grease comes out; - remove the excessive grease with rags. Any lubricating grease for bearings may be used for the nose leg. After servicing the nose leg re-install the nose wheel fairing. Recommended special tools: none. Necessary parts/materials: grease gun, grease. 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: AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 19 - set the parking brake to ON; - remove the nose 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); - set the airplane level on a wooden support under its bottom 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 the reversed 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 alight the nearest slot of the castle nut with the hole for the split pin and secure it with a split pin. Tightening of the shock absorber bolts must not restrict its free motion. Recommended special tools: none. Necessary parts/materials: none. 4.2 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 spring is required. The MLG leg must be removed for that. To remove the MLG leg do the following: - put the wheel chokes under the nose and opposite main wheel; - remove the pilot seats; - remove the wheel fairing; - cut the plastic cable ties fixing the brake system tube to the MLG spring; - lift the airplane using a jack placed under a special plate near the opening in the fuselage bottom skin for the MLG spring; - remove the safety wire and undo the brake disk screws and wheel axle nut; - remove the wheel and brake disk; - leaving the braking system tube assembled, 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 use braking system with a braking disk removed. - remove the split pins and undo the nuts of the upper and lower bolts of the MLG spring attachment and carefully force the bolts out of the holes; - 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 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 20 and spring. Upon detecting fatigue cracks in the MLG spring 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 the reversed 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. 4.3 Remove the wheel fairing. Inspect the tire for cracks and cuts. Determine the nature 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 nose wheel tire do the following: - set the parking brake to ON; - remove the split pin of the nose 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 nose wheel (this operation must be done by two persons); - put the airplane’s nose down placing a wooden support under the nose wheel fork; - replace the tire; - inflate the wheel (1.6 bar) and install it back on the airplane making the above actions in the reversed order. To replace a main wheel tire do the following: - put wheel chokes under the opposite main wheel and nose wheel; - remove the split pin of the main wheel axle nut and undo it; - lift the airplane using a jack placed under a special plate near the opening in the fuselage bottom skin for the MLG spring; - remove the safety wire and undo the brake disk screws and wheel axle nut; - remove the wheel; - replace the tire; - inflate the wheel (1.6 bar) and install it back on the airplane making the above actions in the reversed order. Before re-installing the attachment screws of the brake disk apply Loctite 222 on their thread. If no defects were found, check the wheel pressure and inflate if necessary. The pressure must be equal to 1.6 bar. Install the wheel fairing after servicing. For more detailed information regarding the servicing (repairing) the wheels visit the manufacturer’s web site http://www.matcomfg .com. Recommended special tools: none. Necessary parts/materials: none. 4.4 Inspect the fairing for cracks, ruptures and paintwork damage. If damaged paint is detected, remove the fairing, clean the damaged area with sand paper and repaint. If cracks and ruptures were 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. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 21 Check the torque of the fairing attachment bolts/nuts. Recommended special tools: torque wrench, rubber gloves. Necessary parts/materials: fiberglass cloth, epoxy adhesive, paint. 4.5 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 they must be welded using argon-arc welding or the framework must be replaced. Check the torque of the mud-screen attachment bolts/nuts. Recommended special tools: torque wrench. Necessary parts/materials: none. 4.6 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. Check the torque of the ski attachment bolts/nuts. Recommended special tools: torque wrench. Necessary parts/materials: paint. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 22 5 Brake system The main wheels are equipped with Matco mfg hydraulic disk brakes. The brake 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 brake system is filled with transmission fluid ATF, one of the fluids recommended by Matco mfg. The amount of the fluid in the system can be checked by its level in the expansion tank that must be not less than half of the tank. When servicing the brake system it may be necessary to disconnect its tubes. After such disconnection air gets into its cavities which is inadmissible. After such action it is necessary to fill the brake system with fluid to force all air out. To fill the brake system with braking fluid in the airplane version with yokes, do the following: - check the level of the braking fluid in the expansion tank and refill if necessary; WARNING! Use only the fluid that is recommended by Matco mfg. Do not mix up the fluids of different grade. This may cause damage to the components and failure of the brake system. - remove the cover set the parking brake valve to "OFF"; - 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). The other end of the tube put 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 brake system with braking fluid in the airplane version with central stick, do the following: - remove the stick cover; - remove the stick from the roll torque tube; - remove the parking brake; - remove the clamps holding the brake system tubes; - put the stick on the longitudinal beams of fuselage with the braking cylinder nipples up and pump the brake system through as described above for the airplane version with yokes; - re-assemble everything in the reversed order. WARNING! When filling the brake 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 brake 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 Part No. Description Interval RCO Instr. No. TM LC - Expansion tank 100 h OC 5.1 L LRM See Matco P/N Master cylinder 200 h OC 5.2 L LRM See Matco P/N Parking brake valve 200 h OC 5.3 L LRM See Matco P/N Brake unit assembly, right 200 h OC 5.4 L LRM See Matco P/N Brake unit assembly, left 200 h OC 5.4 See Matco P/N Brake disk, right 200 h OC 5.5 L LRM See Matco P/N Brake disk, left 200 h OC 5.5 - Copper tubes 200 h OC 5.6 L LRM - Reinforced rubber hose 200 h OC 5.6 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 brake 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 remove the horizontal panel. Inspect the master cylinders for leaks of braking fluid. If leaks are detected, it must be removed for repair or replacement. In order to remove the master cylinders, do the following: - remove the left seat; - remove the panel between 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 (9 pcs.); - block the reinforced rubber hose near the master cylinders by squeezing it with a clamp and disconnect it from the master cylinders; - disconnect the copper tube connecting the parking brake valve with brake units; WARNING! When disconnecting the brake 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 the reversed order. After re-assembling fill the brake 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. If no defects were detected in the master cylinder re-assemble everything in the reversed order. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 24 Recommended special tools: none. Necessary parts/materials: none. 5.3 Remove the handles from the control levers of the throttle, elevator trim tab, brakes and the 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 the reversed order. After assembling fill the brake 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 the reversed order. Recommended special tools: none. Necessary parts/materials: none. 5.4 Remove the wheel fairing. Inspect the brake unit for the 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 nose 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 spring; - 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 the reversed order. After assembling fill the brake 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 serious 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 the reversed 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 nature 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 wear is within the permissible limits, re-assemble everything in the reversed 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 and brakes, horizontal panel, main wheel fairings and pilot seats. Inspect the tubing of the brake system for leaks and damage. Pay special attention to the joints. If leaks and damage is detected replace the corresponding portion of the tubing. To obtain additional technical support contact the manufacturer. After re-assembly fill the brake system following the instructions described in the beginning of this section. After inspection (repair) re-assemble everything in the reversed 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 a 100 hp Rotax-912ULS four-cylinder four-stroke engine with combined cooling system manufactured by Rotax GmbH (Austria). WARNING! Maintenance of the engine must be performed according to the current documentation of ROTAX company on operation and maintenance of Rotax 912 engine. For more detailed information visit the engine manufacturer’s web site: http://www.rotax-aircraft-engines.com. Arrangement and design of the engine systems (fuel, electric, oil, cooling, control, exhaust) complies with the requirements of the “Installation Manual for Rotax-912 aircraft engine”. 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 produced by the 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 between the pilot seats. 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 Part No. Description Interval RCO Instr. No. TM LC Rotax 912 ULS Engine * OC 6.1 H TSP A22L-3-6402-00 Engine mount, upper 200 h OC 6.2 L LRI A22L-2-6401-00 Engine mount, lower 200 h OC 6.2 A22L-0-6404-00 Engine retaining rod 200 h OC 6.2 See Gumokov P/N Shock absorbers, 6 psc. 500 h OC 6.3 H LRM A22-1-6405-00 Engine attachment fitting 2000 h OC 6.4 H LRM A22L-0-6570-00 Intake airbox assembly** 200 h OC 6.5 H LRM A22LS-0-6023-01*** Throttle cable right 100 h OC 6.6 H TSP A22LS-0-6023-02*** Throttle cable left 100 h OC 6.6 A22LS-0-6013-01 Throttle cable right 100 h OC 6.6 A22LS-0-6013-02 Throttle cable left 100 h OC 6.6 A22LS-0-6056-01*** Choke cables right 100 h OC 6.6 A22LS-0-6056-02*** Choke cables left 100 h OC 6.6 A22LS-1-6056-01 Choke cables right 100 h OC 6.6 A22LS-1-6056-02 Choke cables left 100 h OC 6.6 A22LS-0-6021-01*** Throttle cable sheath right 100 h OC 6.7 H TSP A22LS-0-6021-02*** Throttle cable sheath left 100 h OC 6.7 A22LS-1-6011-01 Throttle cable sheath right 100 h OC 6.7 A22LS-1-6011-02 Throttle cable sheath left 100 h OC 6.7 A22LS-0-6054-01*** Choke cable sheath right 100 h OC 6.7 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 27 Part No. Description Interval RCO Instr. No. TM LC A22LS-0-6054-02*** Choke cable sheath left 100 h OC 6.7 H TSP A22LS-1-6054-01 Choke cable sheath right 100 h OC 6.7 A22LS-1-6054-02 Choke cable sheath left 100 h OC 6.7 A22LS-0-6007-00 Throttle lever 100 h OC 6.8 L OWN * - see "Maintenance Manual for Rotax Engines. Rotax-912 Serie" ** - in aircraft version equipped with intake airbox. *** – for the airplane version with central control stick. Instructions: 6.1 The engine servicing must be performed according to "Maintenance Manual for Rotax Engines. Rotax-912 Serie". 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 air box (see 0 of this section); - drain the coolant from the cooling system (see “Cooling system” section); - disconnect the cooling system hose from the water pump; - disconnect the cooling system hoses from the expansion tank outlet and overflow sleeve; - disconnect the oil system hose from the oil outlet and drain the remaining oil from the crank case; - disconnect the oil system hose from the oil 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 undoing the attachment fittings’ bolts (4 pcs.); - 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; AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 28 - remove the engine by undoing the bolts of engine attachment to the engine mount (4 pcs.), use engine hoist for that. Engine installation is performed in the reversed order following the instructions of the “Installation Manual for Rotax-912 Aircraft Engine”. 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 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. 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 other damage. If any such defects were 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 the nuts of the bolts attaching the upper engine mount to the lower one (2 pcs.); - remove the bolts and carefully lift the engine using the 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 the reversed order. Recommended special tools: magnifying glass, electric torch, hoist, torque wrench. Necessary parts/materials: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 29 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: - set the shutter to ON; - loosen the cable sheath fixing screws; - 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 cable ties 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 attaching the engine rod to fuselage; - remove the top half of the airbox pushing the engine forward if necessary; - set the airbox shutter to ON; - unfix and remove the shutter; - remove the carburetor air filters; - cut the plastic cable ties 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 the reversed 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. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 30 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 912 aircraft engine). 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. 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 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. 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 – accumulator, 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 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 hose and carefully let air out. To drain coolant from the system remove the top and bottom cowlings, disconnect the lower hose from the radiator and let coolant out. INSPECTION CHART Part No. Description Interval RCO Instr. No. TM LC Norma 30-40 Radiator clamps, 2 pcs. 100 h OC 7.1 L LRI See Rotax P/N Overflow tank 100 h OC 7.2 L LRI - Hoses 100 h OC 7.3 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. 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. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 32 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. Recommended special tools: torque wrench. 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 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 Rotax company. Lubrication system capacity is 3 l (0.8 US gal). INSPECTION CHART Part No. Description Interval RCO Instr. No. TM LC See Rotax P/N 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 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 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 (each 45 l capacity, 57 I fuel tanks are optional) with filler inlets 2 and fuel lines 9 connecting the tanks to each other and to the engine fuel pump 6 (that is feeding fuel to the engine carburetors 10) via two fuel valves 3, mud box 11 and fuel filter 5. Fuel can be drained from the tanks using the drain valve 4. The fuel tanks are connected with the atmosphere via the vent lines 8 in inlet covers 2. 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 Part No. Description Interval RCO Instr. No. TM LC A22LS-1-6120-01 Fuel tank, right 500 h OC 9.1 L LRM A22LS-1-6120-02 Fuel tank, left 500 h OC 9.1 A22LS-6-6120-01* Fuel tank, right 500 h OC 9.1 A22LS-6-6120-02* Fuel tank, left 500 h OC 9.1 Fuel valve х2 100 h OC 9.2 L LRM Drain fuel valve 100 h OC 9.2 Fuel filter 100 h 200 h/OC - L LRM Connecting lines 100 h 1000 h/OC 9.3 L LRM * – larger fuel tank (55L) 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. 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 Inspect the fuel valve for leaks of fuel. If fuel leaks under fuel valve fittings, do the following: - drain fuel from the fuel tanks; - remove the valve after disconnecting handle and fuel lines from it; - take out the fittings from the valve and clean their thread from old sealing material; - put the fitting back after applying Loctite 55 sealing material on their thread; - install the fuel valve back using Loctite 222. If any other defect, causing leaks of fuel, was detected, the valves must be replaced. Recommended special tools: none. Necessary parts/materials: Loctite 55, Loctite 222. 9.3 Remove the top cowling. 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). AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 36 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 37 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 Rotax company on operation and maintenance of Rotax-912 engine. INSPECTION CHART Part No. Description Interval RCO Instr. No. TM LC А22-0-6475-04 Muffler 100 h OC 10.1 L LRM A22-1-6471-04 Exhaust pipe of cylinder 1 100 h OC 10.1 A22-1-6473-04 Exhaust pipe of cylinder 2 100 h OC 10.1 A22-1.6472-04 Exhaust pipe of cylinder 3 100 h OC 10.1 A22-1-6474-04 Exhaust pipe of cylinder 4 100 h OC 10.1 A22-1-6471-03* Exhaust pipe of cylinder 1 100 h OC 10.1 A22-1-6473-03* Exhaust pipe of cylinder 2 100 h OC 10.1 A22-1.6472-03* Exhaust pipe of cylinder 3 100 h OC 10.1 A22-1-6474-03* Exhaust pipe of cylinder 4 100 h OC 10.1 A22-2-6471-03** Exhaust pipe of cylinder 1 100 h OC 10.1 A22-2-6473-03** Exhaust pipe of cylinder 2 100 h OC 10.1 A22-2.6472-03** Exhaust pipe of cylinder 3 100 h OC 10.1 A22-2-6474-03** Exhaust pipe of cylinder 4 100 h OC 10.1 See Rotax P/N Springs, 8 pcs. 100 h OC 10.2 L OWN * – with nut for egt. temp. probe ** – with hole for egt. temp. probe. 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). To install the exhaust system, do the following: - put in place the EGT sensors (if fitted); AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 38 - 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: none. 10.2 Remove the top and bottom cowling. Inspect the springs for integrity. Broken springs must be replaced. Recommended special tools: magnifying glass, electric torch. Necessary parts/materials: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 39 11 Propeller A-22LS airplane may be fitted with three-blade on-ground adjustable propeller of 1.71 m (67 in) diameter manufactured by KievProp company (e-mail: kievprop@i.ua, web: http://www.kievprop.com). Propeller servicing comprises of its systematic inspection and timely repair (or replacement) of the parts with expired service life in accordance with the requirements of its manufacturer. INSPECTION CHART Part No. Description Interval RCO Instr. No. TM LC - Propeller hub 200 h 4 years/OC 11.1 L LRM - Bolts, 6 pcs. 200 h 4 years/OC 1.8 L OWN А22-4-6481-00 Spinner 200 h OC 11.3 L LRI Instructions: 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. Necessary parts/materials: none. AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-02 40 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 one. 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. 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; - slide 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. Slide 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 either off bronze or off 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. Slide 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. Slide 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 textolite. 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.