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JS1 Jet Maintenance Manual – Issue1 JS1 JET SUSTAINER MAINTENANCE MANUAL Model: JS1-B, JS1C-18m, JS1C-21m Serial number: Registration Number: Document part number: 1A-5.04.80 Title: JS1 Jet Sustainer Maintenance Manual Date of issue: 26 May 2016 Prepared by: A.P. Kotze Signature: Name: Approved by: J.S.U.
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JS1 Jet Maintenance Manual – Issue1 0. General This Maintenance Manual has been prepared to provide maintenance personnel with the necessary information to maintain the JS1 Revelation Jet Sustainer System. All the data required to be furnished to the pilot and the maintenance personnel, by the Airworthiness Requirement CS-22, is contained in this manual.
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JS1 Jet Maintenance Manual – Issue1 Rev. Affected Date of Change Description Pages Issue First Issue 26.05.2016 Date of issue: 26 May 2016 Page 0 - 2 SACAA Accepted section...
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JS1 Jet Maintenance Manual – Issue1 0.2. List of effective pages Affected Date of Affected Date of Affected Date of Affected Date of Pages Issue Pages Issue Pages Issue Pages Issue 2-21 6-16 11-3 26.05.2016 26.05.2016 26.05.2016 26.05.2016 2-22 6-17 12-1 26.05.2016 26.05.2016...
JS1 Jet Maintenance Manual – Issue1 TABLE OF CONTENTS General Section 1 Description of Systems and Equipment Section 2 Control Deflection and Play Section 3 Airworthiness limitations and inspections Section 4 Control surfaces masses and moments Section 5 Maintenance Schedule Section 6 Lubrication Section 7...
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JS1 Jet Maintenance Manual – Issue1 ABBREVIATIONS Approved Maintenance Organisation Leading Edge National Aviation Authority Original Equipment Manufacturer TCDS Type Certificate Data Sheet Trailing Edge Jet Display Unit Electronic Computer Unit LiFePo Lithium Ferrite Polymer Jet Sustainer System Exhaust Gas Temperature Date of issue: 26 May 2016 Page 0 - 5 SACAA Accepted section...
JS1 Jet Maintenance Manual – Issue1 1. General 1.1 Descriptive Data The JS1 JET SUSTAINER SYSTEM is a propulsion system used to sustain flight when soaring conditions become unfavourable. Propulsion is made possible by means of a jet turbine mounted on a retractable pylon in the rear section of the fuselage. Normal performance of the sailplane continues when the turbine is retracted.
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JS1 Jet Maintenance Manual – Issue1 1.2 Technical data Engine technical data M&D TJ-42 Engine M&D Flugzeugbau GmbH, Friedeburg Manufacturer 35 daN (ISA conditions) Max thrust 97 000 RPM Max Engine RPM 80 000 RPM Max Continuous RPM 790 °C Max continuous EGT Diesel mixed with 2% 2-stroke oil Fuel...
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JS1 Jet Maintenance Manual – Issue1 1.3 Three-view drawing Illustrated in Fig 1.3-1 is a three view drawing of the Jet Box System. Figure 1.3-1: Jet Box Layout Date of issue: 26 May 2016 Page 1 - 3 SACAA Accepted section...
JS1 Jet Maintenance Manual – Issue1 2. Description of Systems and Equipment 2.1 Introduction The JET SUSTAINER SYSTEM comprises of the following systems: Control System Kinematics Fuel system Electrical system 2.2 Control System The pilot controls the system by using a Jet Display Unit (JDU) installed on the instrument panel.
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JS1 Jet Maintenance Manual – Issue1 2.3.1 Engine Assembly The pylon for the JET SUSTAINER SYSTEM was developed to accommodate the MD TJ 42 Turbine engine. The turbine is held in place by two 127 -152mm Heavy Duty Hose Clamps. Bolts on the hose clamps are secured by locking wire to ensure that they are not loosened by vibration during operation.
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JS1 Jet Maintenance Manual – Issue1 Two fuel lines run from the bottom of the pylon to the top of the jet engine. The left hand line, the Fuel Line Assembly, is connected to a fuel manifold that distributes the fuel through the turbine.
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JS1 Jet Maintenance Manual – Issue1 2.3.2 Jet Pylon Assembly The Jet Pylon Assembly, illustrated in Fig 2.3.2-1, contains the cam system that allows the doors to be opened when the actuator is extended. Description Description Jet Pylon Fuel Line Attachment Bracket Jet Pylon Cam Nut: Nylock: M6 Jet Pylon Bearing (SKF 61804)
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JS1 Jet Maintenance Manual – Issue1 2.3.3 Main Door Bell Crank The main door bell-crank assembly, illustrated in Fig 2.3.3-1, is installed in the Jet Box and connects the main doors to the pylon. Description Description Main Door Bell Crank M4FCSF12 Main Door Bell Crank Bearing Cap M4H11/18 –...
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JS1 Jet Maintenance Manual – Issue1 2.3.4 Engine Box Assembly Kinematics to extend and retract the engine is contained inside the engine box. The engine box, as illustrated in Fig 2.3.4-1, is secured to the fuselage with 6 x M5FCSF25 screws and Tinnerman washers to distribute the load on the composite lip.
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JS1 Jet Maintenance Manual – Issue1 2.3.5 Engine Bay Doors The engine bay doors consist of the following main components: Main doors Front cover plate Front door The main doors are connected by means of a single pushrod and control horn to a bell- crank.
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JS1 Jet Maintenance Manual – Issue1 2.3.6 Main Door Assembly The main doors are attached to the main door bell crank with 2 pushrods as illustrated in Fig 2.3.6-1. Two hinges per door connects the doors to the fuselage. DESCRIPTION DESCRIPTION Ball Link Nut Main Door Pushrod Assembly...
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JS1 Jet Maintenance Manual – Issue1 2.3.7 Front Cover plate Assembly The Front Cover plate assembly is installed over the front area of the jet box. The rear of the plate is held in place with 2 x 2.9mm countersink screws and the front with an attachment bracket.
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JS1 Jet Maintenance Manual – Issue1 2.4 Fuel System Fuel is contained in three interconnected composite tanks situated inside the fuselage. The tanks are connected in such a way that switching between the tanks is not possible. Fuel management is provided by the fuel panel situated on the left hand side of the engine box. All tubing is manufactured from aluminium pipes except for the tubing installed inside the engine box.
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JS1 Jet Maintenance Manual – Issue1 Left tank assembly A refuelling tube runs down to the bottom of the tank as illustrated in Fig 2.4-2. This allows fuel to be pumped in and out of the system with a single revisable pump. Remaining fuel (approx.
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JS1 Jet Maintenance Manual – Issue1 2.4.1 Right Tank Assembly The right tank assembly holds the capacitance probe as illustrated in Fig 2.4.1-1. The capacitance probe is necessary for measuring the fuel quantity in the bottom tanks. The two main tanks are connected at their lowest point with an 8D aluminium tube that also serves as the connecting tube for the fuel drain.
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JS1 Jet Maintenance Manual – Issue1 2.4.2 Top Tank Assembly The top tank is located between bulkheads B8 and B6/7. Illustration of the assembly can be seen in Fig 2.4.2-1. DESCRIPTION DESCRIPTION Top Tank Rear 4D Bulkhead and Universal Top Tank Front Top Tank Inner Vent Tube Assembly 4D AN 924 Nut Fig 2.4.2-1: Top Tank Assembly...
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JS1 Jet Maintenance Manual – Issue1 2.4.3 Fuel Panel Assembly The fuel panel is situated on the left side of the fuselage above the left tank. Illustration of the assembly can be seen in Fig 2.4.3-1. DESCRIPTION DESCRIPTION Fuel Panel Mounting Bracket Fuel Flow Meter Assembly Fuel Pump Assembly Fuel Pump Bracket...
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JS1 Jet Maintenance Manual – Issue1 The following components are installed on the fuel panel: Fuel Pump Fuel sensor Start Solenoid Main Solenoid The fuel pump is a geared, high flow, intrinsically safe pump specifically developed for this operation.
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JS1 Jet Maintenance Manual – Issue1 2.4.4 Emergency Fuel Shut-off Assembly Emergency fuel shutoff consists of two assemblies: Emergency Fuel Valve Emergency Fuel Lever Emergency Fuel Valve Assembly An emergency fuel valve is installed behind the left tank. The entire assembly is bonded to the rear surface of the tank and can be removed by unscrewing two M3 Nylocks and disconnecting the tubing.
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JS1 Jet Maintenance Manual – Issue1 Emergency Fuel Lever Assembly The Emergency Fuel Lever assembly is installed on the left side of the cockpit under the left hand side channel. The assembly is illustrated in Fig xxx. DESCRIPTION DESCRIPTION M4 Rivnut 9mm External CIR clip Fuel Lever Bracket Cable Housing...
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JS1 Jet Maintenance Manual – Issue1 2.4.5 Fuel Tubing Assembly All tubing used in the JET SUSTAINER SYSTEM is aluminium tubing with the exception of the rubber hoses in the jet box. The tubing assembly is illustrated in Fig 2.4.5-1. DESCRIPTION DESCRIPTION Left Tank Assembly...
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JS1 Jet Maintenance Manual – Issue1 2.5 Electrical System The JET SUSTAINER SYSTEM is powered by a battery connected through a bulkhead fitting in the centre section table. Note: The jet system has the ability to charge the battery and external charging is required after use.
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JS1 Jet Maintenance Manual – Issue1 2.5.2 ECU Assembly The ECU is bonded to the rear of the wheel box in the centre section. All the wiring for the entire system runs through to the ECU with the exception of the MOP box wire that runs directly to the instrument in the front.
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JS1 Jet Maintenance Manual – Issue1 2.5.3 Wiring Looms Six wiring looms connect the ECU to the individual systems. Main loom The main loom contains the cables for the following components and is routed from the ECU to the Right Jet Support: ...
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JS1 Jet Maintenance Manual – Issue1 Fuel Panel Loom The wiring loom routed from the bulkhead connector in the Jet Side Support to the fuel panel and contains the wires for the following components: Fuel flow sensor Fuel pump ...
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JS1 Jet Maintenance Manual – Issue1 Date of issue: 26 May 2016 Page 2 - 23 SACAA Accepted section...
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JS1 Jet Maintenance Manual – Issue1 Date of issue: 26 May 2016 Page 2 - 24 SACAA Accepted section...
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JS1 Jet Maintenance Manual – Issue1 Date of issue: 26 May 2016 Page 2 - 25 SACAA Accepted section...
JS1 Jet Maintenance Manual – Issue1 3. Control Deflection and Play Controls not affected by the JET SUSTAINER SYSTEM. Date of issue: 26 May 2016 Page 3 - 1 SACAA Accepted section...
JS1 Jet Maintenance Manual – Issue1 4. Airworthiness limitations and inspections 4.1 Airworthiness Limitations Table 4.1-1 lists the life limits that should not be exceeded. When these limits have been reached, the affected component must be returned to the manufacturer or to an approved maintenance organisation so that the required maintenance activities or inspections can be performed.
JS1 Jet Maintenance Manual – Issue1 5. Control Surfaces Masses and moments Controls surfaces are not affected by the JET SUSTAINER System. Date of issue: 26 May 2016 Page 5 - 1 SACAA Accepted section...
JS1 Jet Maintenance Manual – Issue1 6. Maintenance Schedule 6.1 Annual inspection A mandatory annual or 250 hours* inspection is required for issuing the Certificate of Airworthiness. Note: Some regulating authorities require a one year or 100 hour-interval inspection. General inspection guidelines ...
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JS1 Jet Maintenance Manual – Issue1 Table 6.1-1: Maintenance Requirements Schedule Who may Maintenance interval perform the Maintenance Every 6 years Every 449 starts Every 50 hr. Every 8 years 10 hours engine operation) Maintenance requirements Engine Service Turbine Compressor Fuel Pump Starter Motor ECU Diagnostics Test...
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JS1 Jet Maintenance Manual – Issue1 6.3 Procedure to remove the Engine To remove the engine for maintenance purposes 1. Turn the system on by switching the main switch on the JDU to “On” 2. Extend the Engine 3. Turn off the system and disconnect the battery Caution: A small voltage is still being drawn by the ECU even when the JDU is turned off.
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JS1 Jet Maintenance Manual – Issue1 6.4 Procedure to install the Engine Figure 6.4-1 To install the engine on the pylon 1. Connect the jet battery 2. Turn the system on and extend the engine 3. Disconnect the jet battery 4.
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JS1 Jet Maintenance Manual – Issue1 9. Connect the fuel lines 10. Connect the battery 11. Turn on the system and select “extend” Caution: The default for the system is to retract when turned on for the first time after being turned off.
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JS1 Jet Maintenance Manual – Issue1 6.5 Procedure to remove main doors To remove the doors 1. Activate the “Maintenance Mode” using the JDU. This extends the jet to the halfway extended position and allows access to the pushrod and countersink screws located at the rear of the cover plate.
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JS1 Jet Maintenance Manual – Issue1 6.6 Procedure to remove the Front Door Assembly To remove the front door assembly 1. Extend the engine to the halfway position by using “Maintenance Mode” 2. Unclip the ball joints from the main door bellcrank 3.
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JS1 Jet Maintenance Manual – Issue1 6. Remove the two countersink screws on the rear of the door. Slide the front door backwards and lift clear of the fuselage (The door is still attached to the pushrod). 7. Unscrew the pushrod from the ball link attached to the front door 8.
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JS1 Jet Maintenance Manual – Issue1 6.7 Procedure to remove the Engine Box To remove the box 1. Remove the main doors and front cover plate 2. Retract the engine and cover the intake 3. Remove the 3 canon plugs on the right side of the box 4.
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JS1 Jet Maintenance Manual – Issue1 6.8 Procedure to remove the Fuel System Before uninstalling the tanks the box and doors need to be removed. To remove the Top Tank the glider must be de-rigged. After removing the box and de-rigging 1.
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JS1 Jet Maintenance Manual – Issue1 8. Unscrew the bolt holding the rear tank bracket in place 9. Remove the Right tank through the jet bay 10. Disconnect all tubing from the fuel panel except the tubing connecting the fuel panel to the Fuel Line Attachment Bracket.
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JS1 Jet Maintenance Manual – Issue1 6.9.1 Manual Calibration For manual calibration go the following screen, illustrated in Fig 6.9.1-1, on the JDU. Figure 6.9.1-1 The probe can be calibrated manually with the following process: 1. Position the glider in the attitude used for weight and balance 2.
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JS1 Jet Maintenance Manual – Issue1 6.9.2 Input values from factory During the production process the values for each probe is captured and stored at the factory. These values can be manually inserted into the JDU to provide accurate fuel level readings.
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JS1 Jet Maintenance Manual – Issue1 6.10 Priming of the system The system can be primed, by performing a number of ground starts, until both the main fuel line and start fuel lines are primed. Alternatively a manual priming process can be used as follows: Note: When installing the engine after maintenance the manual priming process should be followed to ensure all contaminants have been removed from the...
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JS1 Jet Maintenance Manual – Issue1 6. Follow the steps described in section 8 (Firmware/Software Upgrades) to activate the fuel pump 7. Allow fuel to run through the lines until all air is removed and no bubbles can be seen passing through the line 8.
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JS1 Jet Maintenance Manual – Issue1 6.11 Electrical loads Electrical loads experienced in the system are illustrated in Table 6.11-1 and correspond to the fuses that need to be used. Table 6.11-1: Electrical Loads Peak Current Component Starter Glow Plug Solenoid Pump Actuator...
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JS1 Jet Maintenance Manual – Issue1 USB Communication Cable Figure 6.12-1: ECU Layout 6.12.1 Fuses Blade type fuses are installed on the ECU. They are accessible through the rear inspection panel in the wheel well. Note: Take care when exchanging fuses to ensure that they are installed in the correct position Run Valve (3A) Pump (7.5A)
JS1 Jet Maintenance Manual – Issue1 7. Lubrication 7.1 Introduction Hinge points and metal to metal contact points in the Jet Sustainer System must be lubricated according to the lubrication schedule. All these points are initially lubricated in the factory but will need additional lubrication during the lifespan of the sailplane. This section describes the lubrication requirements of the Jet Sustainer System 7.2 Lubricants The bearing surfaces must be lubricated with good quality grease.
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JS1 Jet Maintenance Manual – Issue1 Figure 7.3-1 Figure 3.3-2 Date of issue: 26 May 2016 Page 7 - 2 SACAA Accepted section...
JS1 Jet Maintenance Manual – Issue1 8. Software/Firmware Upgrade The jet system allows for 3 types of upgrades to be made using 3 different types of cables. The types of changes and the cables required for each are given in Table 8-1. Table 8-1: Software upgrades Upgrade Type JS Part Number...
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JS1 Jet Maintenance Manual – Issue1 8.1.1 Starting and installing the driver software Turbine Tool will be located within a folder on your computer. The file used to open the application will vary according to the OS on your computer. When the turbine tool folder is opened the following should be displayed on your screen: Once Turbine Tool is opened the following screen will appear: Date of issue: 26 May 2016...
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JS1 Jet Maintenance Manual – Issue1 8.1.2 Connecting to the ECU To transfer data between the computer and the ECU a connection must be made: Steps to connect to the ECU: 1. Plug the USB cable into a USB port on your computer and into the port located in the cockpit.
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JS1 Jet Maintenance Manual – Issue1 4. Right Click on the new port and install the driver software for Turbine Tool by following the steps below. a. Right Click on the new port and select Update Driver Software b. Select “Browse my computer for driver software” Date of issue: 26 May 2016 Page 8 - 4 SACAA Accepted section...
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JS1 Jet Maintenance Manual – Issue1 c. Input the address where Turbine Tool is located on your hard drive and click next. d. The driver for Turbine Tool is now installed on your computer. e. Open Turbine Tool With the engine in the extended position select, Settings>>>>Establish Connection Date of issue: 26 May 2016 Page 8 - 5...
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JS1 Jet Maintenance Manual – Issue1 g. Choose the com port previously selected h. Once connected a stream of data will show on the screen. 8.1.3 Uploading a new settings file Once connected to the ECU a new settings file can be uploaded from your hard drive without having to change individual settings on the ECU.
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JS1 Jet Maintenance Manual – Issue1 5. Select Settings >>>> Configuration >>>> Load from file. The following screens will be displayed: Date of issue: 26 May 2016 Page 8 - 7 SACAA Accepted section...
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JS1 Jet Maintenance Manual – Issue1 6. In the browser window displayed, load the new settings file. 7. Select OK and close the configuration window. The new settings are now loaded on the ECU. 8.1.4 Priming the system Priming of the system will be required after maintenance or long periods of not using the engine.
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JS1 Jet Maintenance Manual – Issue1 4. Input the following values in the fields available. 5. Check the Start valve box. A loud clicking noise should be heard as the electromagnetic valve engages. f a sound is not heard the connection was not successful.
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JS1 Jet Maintenance Manual – Issue1 8. Check the Pump box. The pump will start running. Allow the pump run until enough fuel has run through the lines to remove all air. (Do not allow the fuel run into the engine!!!) Connect the start line to the engine.
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JS1 Jet Maintenance Manual – Issue1 2. Upload the JDU firmware: a. Disconnect JDU from USB to serial connector b. Connect the USB to serial cable to the PC and wait ensure the hardware is recognised. c. Run Flash loader d.
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JS1 Jet Maintenance Manual – Issue1 3. Load settings: a. Start-up the JDU while the rotary button is kept pushed in b. Confirm “Load factory default settings” by pushing the rotary button for 2 seconds. c. Wait until the initialization on the JDU is completed d.
JS1 Jet Maintenance Manual – Issue1 9. Trouble Shooting Troubleshooting problems the jet system can be broken down into two sections: Start-up Running 9.1 Start-up Problems Start-up problems are normally associated with in flight problems that are caused by the flow of air over the glow-plug or a glow plug that is too cold to reach the flashpoint for the fuel.
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JS1 Jet Maintenance Manual – Issue1 3. RPM Reading OK? 4. Start-valve open 5. Pump start voltage 6. Ignition 7. Temperature rise 8. Run-Valve Open 9. Pump Ramp Voltage 10. Check 30 000RPM Once the jet is running the RPM is controlled by adjusting the pump voltage: 1.
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JS1 Jet Maintenance Manual – Issue1 Start-up Note: Airborne specific start-up problems are related to the following: Airspeed > 140km/h No-RPM Glow Plug Position Low Battery Voltage Check: Sensor Position Initial A to D Board Ignition ...
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JS1 Jet Maintenance Manual – Issue1 Running + Spool–Up Problems Spooling–Up past a certain RPM Spooling–Up past a certain RPM not possible characterised by: not possible characterised by: Rough Running Stable Running of engine Unstable Temperature Readings Increase in requested Throttle ...
10.Equipment and accessories 10.1 Refuelling kit To ensure safe filling of the jet system a Jet Refuelling kit is supplied by JS and includes the following: 1. Refuelling/De-fuelling kit box 2. Fuel Hose 1 (Quick connector fitting at only one end) 3.
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A quick connector fitting as illustrated in Fig 10.1-2 located inside the jet box on the left hand side is used for fuelling and defueling of the tanks Figure 10.1-2: Quick Connector for Refuelling Instructions for filling of the system is found in Section 4.10.3 of the Jet Flight Manual Supplement 10.2 Jet Front Cover The jet front cover is provided to cover the engine intake during either storage or...
11.Placards In addition to the normal placarding for the pure glider the following placarding is required when the Jet Sustainer System is fitted: 11.1 Limitations placards The emergency fuel shutoff placard is positioned above the fuel lever on the left side of the cockpit.
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Figure 11.1-3: Engine Operating Limits Date of issue: 26 May 2016 Page 11 - 2 SACAA Accepted section...
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11.2 Engine operating procedure Procedure for start-up and shutdown is illustrated in Figure 11.2-1 and Figure11.2-2. Both placards are located on the right hand side channel inside the cockpit. ENGINE START-UP PROCEDURE 1. OPEN FUEL VALVE 2. SELECT BATTERY 3. SELECT MASTER SWITCH “ON” 4.
12.Deactivation/decommissioning of Jet Sustainer System An operational engine must be decommissioned in the following cases: The engine has been commissioned on an aircraft but a certificate of airworthiness for the use of the jet is not valid. An experimental Certificate of Airworthiness was issued and has lapsed, reverting back to the use of a standard CoA ...
13.Cleaning and care 13.1 General JS1 Revelation is manufactured from composites of glass, carbon and aramid fibres in an epoxy matrix. Finishing is done in gel coat with a polyurethane acrylic 2K paint topcoat. Pure gel coat finish is also available on request of the client. Care must be taken to ensure that the structure of the sailplane is kept free of fuel or oil 13.2 Cleaning of spilled fuel on the aircraft surface Fuel spilled on the aircraft surface can be wiped off by either using a dry cloth or a paper towel...
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WARNING:Never use any of the following products on your aircraft: Trichloroethylene Carbon tetrachloride or similar hydrocarbon chlorides Any product containing silicon 13.5 Long-term storage To store the aircraft for long periods the following actions are recommended on the Jet Sustainer System: 1.
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APPENDIX A – Annual inspection checklist ANNUAL (OR 10 HOUR ENGINE OPERATION) INSPECTION CHECKLIST Check for any play on Pylon when extended Inspect rubber hoses (Aeroquip FC332-04) in box for cracks or signs of damage Inspect filters in rubber hoses (Speedflow PFE 608-4 44 μm) Inspect drain in box, check the o-ring and for blockages Check position of limit switches Inspect needle bearing in cam, lubricate if required...
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e can also discuss a time to set up the Skype call so we can assist you with reloading the settings. Regards Back cover Date of issue: 26 May 2016 Page A - 2 SACAA Accepted section...
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