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AEROPRAKT A22LS Maintenance Manual

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Aeroprakt Ltd.
24, Polevaya str., Kiev, Ukraine
Tel: 0038 044 496-77-21
Fax: 0038 044 496-77-31
e-mail:
air@prakt.kiev.ua
www.aeroprakt.kiev.ua
AEROPRAKT-22LS
Airplane Maintenance Manual
A22LS-AMM-01

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Summary of Contents for AEROPRAKT A22LS

  • Page 1 Aeroprakt Ltd. 24, Polevaya str., Kiev, Ukraine Tel: 0038 044 496-77-21 Fax: 0038 044 496-77-31 e-mail: air@prakt.kiev.ua www.aeroprakt.kiev.ua AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01...
  • Page 2 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 Model: AEROPRAKT-22LS (A-22LS) Serial No: Registration: Document No: A22LS-AMM-01 Date of issue: Approved by: Signature: Position: Stamp: Date of approval: This airplane is to be serviced and maintained in compliance with information and instructions contained herein.
  • Page 3 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 RECORD OF REVISIONS No part of this manual may be reproduced or changed in any manner without a written consent of the Manufacturer. Any revision of the present manual, except actual weighing data, must be recorded in the following table according to information from the Manufacturer.
  • Page 4 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 LIST OF EFFECTIVE PAGES Section Page Date Section Page Date 6/40 08/2009 24/40 08/2009 7/40 08/2009 8/40 08/2009 25/40 08/2009 9/40 08/2009 10/40 08/2009 26/40 08/2009 27/40 08/2009 11/40 08/2009 28/40 08/2009 12/40 08/2009 13/40...

  • Page 5: Table Of Contents

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 Contents GENERAL ..............................6 AIRFRAME ...............................7 LANDING GEAR ............................11 BRAKE SYSTEM ...........................16 ENGINE AND ITS CONTROL SYSTEM ....................20 COOLING SYSTEM ..........................24 LUBRICATION SYSTEM ........................25 FUEL SYSTEM............................26 EXHAUST SYSTEM ..........................27 PROPELLER ............................28 AIRPLANE CONTROL SYSTEM ......................29 ELECTRICAL SYSTEM .........................34 PILOT SEATS AND HARNESS BELTS ....................37...

  • Page 6: General

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 1 General WARNING! The safety bulletins 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 specifies the requirements to inspection and maintenance that are required for keeping the flight performance and reliability at a level of a new airplane.

  • Page 7: Airframe

    Spherical bearing ×4 2000 h A22LS-0-2920-01 Wing strut, right 100 h A22LS-0-2920-02 Wing strut, left 100 h A22LS-0-2950-01 Wings strut fairing, top, right 200 h A22LS-0-2950-02 Wings strut fairing, top, left 200 h A22LS-0-2940-01 Wings strut fairing, bottom, right 200 h...
  • Page 8 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 Notes: 2.1 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.
  • Page 9 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 2.4 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;...
  • Page 10 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 2.8 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.

  • Page 11: Landing Gear

    A22LS-0-4310-00 Nose leg 100 h AN 4-22A Bellcrank bolt 100 h Torque Bar2.1 190x50 mm ROCK SHOX shock absorber 100 h A22LS-0-4110-01 Main leg, right 100 h A22LS-0-4110-02 Main leg, left 100 h AN 6-37 Spring bolt, upper х2 100 h Torque AN 7-41 Spring bolt, lower х2...
  • Page 12 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 Notes: 3.1 Remove the nose wheel fairing. Inspect the nose leg for fatigue cracks, deformation and play. When inspecting follow the instructions of 2.1 (2 and 3 paragraph) of "Airframe" 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.
  • Page 13 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 If the required shock absorber pressure is not maintained or if the 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 to ON;...
  • Page 14 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 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 spring. Upon detecting fatigue cracks in the MLG spring or MLG attachment beam contact the manufacturer to obtain the required technical support.
  • Page 15 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 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.

  • Page 16: Brake System

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 4 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.
  • Page 17 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 INSPECTION CHART Inspection Service Part No. Description R.C.O interval reference Expansion tank 100 h See Matco P/N Master cylinder 200 h See Matco P/N Parking brake valve 200 h See Matco P/N Brake unit assembly, right...
  • Page 18 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 4.3 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.
  • Page 19 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 4.6 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.

  • Page 20: Engine And Its Control System

    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.
  • Page 21 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 Notes: 5.1 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 binders securing the engine system components must be cut.
  • Page 22 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 5.2 Remove the tom 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.
  • Page 23 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 Check the attachment of the shutter actuator, vent tube and corrugated hose and replace the plastic binders 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.

  • Page 24: Cooling System

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 6 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.

  • Page 25: Lubrication System

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 7 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.).

  • Page 26: Fuel System

    INSPECTION CHART Part No. Description Inspection interval Service reference A22LS-0-6120-01 Fuel tank, right 500 h A22LS-0-6120-02 Fuel tank, left 500 h Fuel valve х2 100 h...

  • Page 27: Exhaust System

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 9 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.

  • Page 28: Propeller

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 10 Propeller A-22LS airplane may be fitted with any suitable propeller compatible with Rotax-912 engine power output and the airplane speed range. One of the most widely used ones is the three-blade on-ground adjustable propeller of 1.8 m (71 in) diameter manufactured by KievProp company.

  • Page 29: Airplane Control System

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 11 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.
  • Page 30 Aileron control system A22LS-0-3700-01 Aileron, right 100 h 11.1 A22LS-0-3700-02 Aileron, left 100 h 11.1 A22LS-0-5165-00 Cardan ring x2 100 h 11.2 A22LS-0-5160-01 Aileron shaft, right 100 h 11.2 A22LS-0-5160-02 Aileron shaft, left 100 h 11.2 A22LS-0-5175-00 Rod, vertical х2 100 h 11.3...
  • Page 31 A22LS-0-5210-00 Pedals 100 h 11.8 A22LS-0-5214-00 Rods х2 100 h 11.9 Pulley, front х2 500 h A22LS-0-5216-00 Pulley unit, aft х2 500 h A22LS-0-5224-00 Fairleads, front 500 h A22LS-0-5204-00 Fairleads, aft 500 h Elevator trim tab control system A22LS-0-4000-00 Trim tab 200 h 11.10...
  • Page 32 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 11.2 Check tightness and locking of the nuts and play in hinged joints. Grease the slide bearings if necessary. 11.3 Check tightness and locking of the nuts and play in hinged joints. Inspect the riveted joints for loose rivets as described in 2.1. If loose rivets are detected contact the manufacturer for the required technical support.
  • Page 33 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 In airplane version with electromechanical control system of the elevator trim tab inspect the cable in the areas where it passes fairleads, sheath and near its attachment to the control arm of the trim tab.

  • Page 34: Electrical System

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 12 Electrical system The major components of the electrical system of A-22LS airplane are: battery (12 V, minimum 16 Ah), starter relay, rectifier-regulator, condenser (22000 µF, 25 V), warning light (12 V, 2 W), master switch, ignition and consumer switches, fuse block, electric harness, fuel level senders and indicators and analog engine instruments.
  • Page 35 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 Inspection Service Part No. Description interval reference Fuel level sensor х2 200 h 12.6 Fuel level indicator х2 200 h 12.6 Landing light 100 h 12.7 Engine instruments 100 h 12.8 Main harness 100 h 12.9...
  • Page 36 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 If at «4/4» and «1/2» readings the remaining fuel differs from the reading for more than 5 l (1.3 US gal) and the fuel remaining at ignition of “reserve fuel remains” light differs for more than 2 l (0.5 US gal), contact the manufacturer for the required technical support.

  • Page 37: Pilot Seats And Harness Belts

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 13 Pilot seats and harness belts The pilot seats of A-22LS airplane are adjustable (they have 2 fixed settings) and consist of an aluminum framework and a cushion. The harness system is of four-point type. It consists of two sets of harness belts.

  • Page 38: Cockpit Doors

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 14 Cockpit doors The cockpit doors are made in form of a PVC glass on a riveted metal framework. The doors may be fitted optionally with locks. The doors are retained in their open position with a gas strut.

  • Page 39: Recovery System

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 15 Recovery system A-22LS airplane can optionally be equipped with a parachute recovery system for the maximum take-off weight of 600 kg (1320 lb). The recovery system is installed on the right side behind the luggage container. The system actuation handle is installed on the panel between the pilot seats.

  • Page 40: Inspection Schedule For A-22Ls Aeroplane

    AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 16 Inspection Schedule for A-22LS aeroplane Inspection/Servicing action  and its interval in hours  Airframe Inspect fuselage for damage (fatigue cracks, loose rivets, etc.) Inspect fuselage glazing for damage (silvering, cracks, etc.) Inspect wings for damage (fatigue cracks, loose rivets, torn fabric covering, etc.)
  • Page 41 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 Inspection/Servicing action  and its interval in hours  Inspect the engine attachment fitting for the fatigue cracks Check the intake airbox function, condition and attachment Inspect the throttle and choke cables and cable sheath for wear, damage, kinks...
  • Page 42 AEROPRAKT-22LS Airplane Maintenance Manual A22LS-AMM-01 Inspection/Servicing action  and its interval in hours  Clean fuse block terminals of corrosion, if any. Check fuses Verify correct function of the fuel level sensors/indicators (check readings) Check landing light function and attaching nut torque...

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