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AMS-Flight Carat A Maintenance Manual

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MAINTENANCE MANUAL FOR THE
POWERED GLIDER
Carat A
Model:
Carat A
CAA RS Type
TC-SVN-JL-01/02-CARAT-A
Certificate no.
SVN.CAA:
.....................................................
Civil Aviation Administration, Republic of Slovenia
..................................................
This powered glider is to be operated in compliance with information and limitations
contained herein.
Approval of translation has been done by best knowledge and judgment.
In any case the original text in German language is authoritative.
Status: November 2002
Report no. / Rev. no.: 0
AMS-flight d.o.o.
Kavčičeva 4
SI – 1000 Ljubljana
www.ams-flight.si
Serial number
Registration
(signature)
(authority)
(stamp)
(date of approval)
Document No. MM3

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  • Page 1 AMS-flight d.o.o. Kavčičeva 4 SI – 1000 Ljubljana www.ams-flight.si MAINTENANCE MANUAL FOR THE POWERED GLIDER Carat A Model: Carat A Serial number CAA RS Type TC-SVN-JL-01/02-CARAT-A Registration Certificate no. SVN.CAA: ............. (signature) Civil Aviation Administration, Republic of Slovenia (authority) (stamp) ..........
  • Page 2 Maintenance Manual Carat A (intentionally left blank) Status: November 2002 Report no. / Rev. no.: 0...
  • Page 3 Maintenance Manual Carat A Validity and Organisation of the Maintenance Manual 0.1 Deviations from the standard maintenance manual 0.2 Revision filing instructions 0.3 Log of effective pages 0.4 Table of contents Status: November 2002 Report no. / Rev. no.: 0...
  • Page 4 CAA RS-approved. The inspector confirms with his stamp that the manual contains the following information and that it belongs to the aircraft named below. valid for: Carat A, serial number Item Rev. no. SB number Date Sign./Stamp...
  • Page 5 Maintenance Manual Carat A Revision filing instructions All revisions to this manual must be recorded in the table below, excepting current mass and balance data. New or amended text will be indicated by a black vertical line in the right-hand margin. The revision number and date will be shown on the bottom left-hand of the page.

  • Page 6: Log Of Effective Pages

    Maintenance Manual Carat A Log of effective pages This log is only valid for the aircraft with the serial number as given on the title page of this manual. Chapter Page Reference Date of issue November 02 June 04 June 04...
  • Page 7 Maintenance Manual Carat A Chapter Page Reference Date of issue November 02 November 02 November 02 November 02 November 02 November 02 November 02 November 02 November 02 4.10 November 02 4.11 November 02 4.12 November 02 4.13 November 02 4.14...

  • Page 8: Table Of Contents

    Maintenance Manual Carat A Table of contents Chapter 0. Validity and organisation of the maintenance manual 1. General 2. Description of aircraft systems 3. Storage, transportation, assembly and servicing 4. Maintenance instructions 5. Inspections 6. Weighing 7. Placards and markings 8.

  • Page 9: Validity And Organisation Of The Maintenance Manual

    Maintenance Manual Carat A Chapter 0: Validity and Organisation of the Maintenance Manual 0.1 Deviations from the standard maintenance manual 0.2 Revision filing instructions 0.3 Log of effective pages 0.4 Table of contents Chapter 1: General 1.1 Maintenance principles and responsibilities 1.2 Description and technical data...

  • Page 10: Storage, Transportation, Assembly And Servicing

    Maintenance Manual Carat A 2.3.3. Rudder controll system 2.3.4. Airbrake controll system 2.3.5. Trimm controll system 2.4 Powerplant 2.4.1 Engine and accessories 2.4.2 Propeller 2.4.3 Fuel system 2.5 Electric system 2.6 Cockpit and equipment 2.6.1 Heating 2.6.2 Instrumentation 2.7 Pitot and static pressure system Chapter 3: Storage, Transportation, Assembly and Servicing 3.1 Rigging and de-rigging...

  • Page 11: Inspections

    Maintenance Manual Carat A 4.4 Settings 4.5 Control surface masses and residual moments 4.6 Landing gear 4.6.1 Main landing gear 4.6.2 Tail landing gear 4.6.3 Brake system 4.7 Fuel system 4.8 Lubrication schedule 4.9 Pressure lines and instrument connections 4.10 Airframe 4.10.1 Minor repair work on the airframe...

  • Page 12: Weighing

    Maintenance Manual Carat A Chapter 6: Weighing 6.1 Weighing procedures 6.2 Weighing sheet Chapter 7: Placards and Markings 7.1 Placards and their positions 7.2 Other markings Chapter 8: Supplements 8.1 Summary of airworthiness directives and service bulletins 8.2 Maintenance instructions for optional equipment 0.10...
  • Page 13 Maintenance Manual Carat A 1. General 1.1 Maintenance principles and responsibilities 1.2 Description and technical data Status: November 2002 Rep. no / Rev. no.: 0...
  • Page 14 Maintenance Manual Carat A Maintenance principles and responsibilities It is the responsibility of the owner of the "Carat A" powered glider to ensure that the aircraft is maintained according to the directives given in this manual. This includes the following: Inspections, adjustments, lubricant change, replacement of parts which have exceeded their life cycle, minor repairs.

  • Page 15: Description And Technical Data

    Carat A Description and technical data The AMS "Carat A" is a single-seater, self-launching powered glider made from composite materials with a T-type empennage with fixed damping surfaces. The reliable engine with the new type of forward-folding propeller and the retractable landing gear ensure good soaring performance and very high cruising speeds.
  • Page 16 Maintenance Manual Carat A Landing gear: After engaging the 3-position switch, the robust, leaf-spring main landing gear is retracted electro-hydraulically. The fairings fit tight and thus ensure aerodynamic performance. The landing gear can be extended manually in an emergency. Powerful disk brakes are operated simultaneously using a brake lever on the control stick where the lock for the parking brake is also located.
  • Page 17 Maintenance Manual Carat A Technical data "Carat A" Single-seater powered glider for soaring and fast cruising, composite material construction with a retractable landing gear and a folding propeller. Engine: Sauer S 1800 –1- ES1C, four-cylinder four-stroke, air-cooled 45 (60) kW (PS)
  • Page 18 Maintenance Manual Carat A (intentionally left blank) Status: November 2002 Rep. no. / Rev. no.: 0...

  • Page 19: Description Of Aircraft Systems

    Maintenance Manual Carat A 2. Description of Aircraft Systems 2.1 Airframe, primary and secondary structures 2.1.1 Wing 2.1.2 Fuselage 2.1.3 Empennage 2.2 Landing gear 2.2.1 Main landing gear 2.2.2 Tail landing gear 2.2.3 Brake system 2.3.Control systems 2.4 Powerplant 2.4.1 Engine and accessories 2.4.2 Propeller...
  • Page 20 Maintenance Manual Carat A Airframe, primary and secondary structures The primary structures are: • wing spars, root ribs • wing shells • fuselage shell and vertical fin • fire wall, main frames, normal force tubes, landing gear frame, landing gear legs •...

  • Page 21: Landing Gear System

    The fuselage is a glass-fibre, full laminate, monocoque construction. The fuselage shell also includes the vertical fin which is a glass-fibre-sandwich construction. The Carat A is a single-seater aircraft. The seat bucket and the seat back are also glass- fibre constructions.
  • Page 22 Maintenance Manual Carat A Schematic diagram of the main landing gear system: to left hydraulic to right landing cylinder landing gear leg gear leg lines hand lever hydraulic pump electric motor battery The main landing gear tyres are of the type TOST Aero 4004 6 PR.

  • Page 23: Control Systems

    Maintenance Manual Carat A Control systems The main and secondary control systems are described below. The main control systems of the "Carat A" comprise the following: • elevator control • aileron control • rudder control • air brake control The following comprise the secondary control systems: •...
  • Page 24 Maintenance Manual Carat A Status: November 2002 Rep. no. / Rev. no.: 0...
  • Page 25 Powerplant 2.4.1 Engine and accessories The "Carat A" is equipped with a Sauer aviation engine, model S 1800 –1-ES1C, producing 40 kW (54 hp) at 3000 rpm. This engine can run either on AVGAS 100 LL or lead-free premium petrol EN 228 / DIN 51676 (98 Octane / ROZ 98).
  • Page 26 The fuel tank is welded aluminium construction with a wall thickness of 1.5 mm (0,06 in). It is located in the cockpit of the "Carat A" above the pilot's legs. The filler opening is made of carbon-fibre material and is located outside the cockpit above the tank.

  • Page 27: Electric System

    The electric system is supplied with power by a battery with a voltage of +/- 12 V and a maximum current of 7 A. The electric system set-up for the "Carat A" is given in the following wiring diagram: Status: November 2002...
  • Page 28 Maintenance Manual Carat A The key for the fuses and the units is on the next page. 2.10 Status: November 2002 Rep. no. / Rev. no.: 0...
  • Page 29 Maintenance Manual Carat A Fuses: 25 A Charge regulator (generator) Transponder, oil temperature indicator, oil pressure indicator Operating hours meter, variometer Landing gear controls, fuel indicator, rpm indicator 15 A Regulator, starter, fuel pump 25 A Landing gear motor Radio...
  • Page 30 Head E-Variometer Slip ind. Transponder Radio Hour meter The components comprising the minimum equipment of the "Carat A" are shown by unbroken lines. The broken lines indicate optional equipment. 2.12 Status: November 2002 Rep. no. / Rev. no.: 0...

  • Page 31: Pitot And Static Pressure System

    Maintenance Manual Carat A Pitot and static pressure system Pitot pressure pick-up is at the top of the vertical tail fin. The pick-up for total-energy compensation is located below. Static pressure is acquired through four holes in one plane in the fuselage tube in the front of the vertical tail fin.
  • Page 32 Maintenance Manual Carat A (intentionally left blank) 2.14 Status: November 2002 Rep. no. / Rev. no.: 0...
  • Page 33 Maintenance Manual Carat A 3. Storage, Transportation, Assembly and Servicing 3.1 Assembly and dismounting 3.1.1 Assembly 3.1.2 Dismounting 3.2 Storage 3.3 Transportation 3.4 Servicing Status: November 2002 Rep. no. / Rev. no.: 0...

  • Page 34: Rigging And De-Rigging

    "Carat A". 3.1.1 Rigging The "Carat A" can be assembled by one person as follows: Open trailer and pull out the guide rails for the fuselage trolley completely. Lift fuselage behind the tail wheel about 10 cm (4 in), pull out of the trailer to trolley stop and set the fuselage down on the tail wheel.
  • Page 35 Helping hands can replace the wing assembly trolleys. 3.1.2 De-rigging After removing the tapes, the "Carat A" is de-rigged as follows: Disconnect the total energy and pitot pressure tubing, screw in the horizontal tail assembly screw.
  • Page 36 Should thunderstorms or heavy winds be forecast, the "Carat A" should be tied down, preferably in front of the horizontal tail fin and at the wing tips. If hail is expected, the varnish can be protected against damage by covering the "Carat A" with a large tarpaulin.
  • Page 37 Servicing After every flight the surface of the "Carat A" should be washed using a sponge and clear water only. The surface should then be dried using a slightly damp chamois. A so-called "fly-sponge"...
  • Page 38 Maintenance Manual Carat A (intentionally left blank) Status: November 2002 Rep. no. / Rev. no.: 0...
  • Page 39 Maintenance Manual Carat A 4. Maintenance Instructions 4.1 General information 4.2 Empty mass centre of gravity 4.3 Torque values 4.4 Settings 4.5 Control surface masses and residual moments 4.6 Landing gear 4.6.1 Main landing gear 4.6.2 Tail landing gear 4.6.3 Brake system 4.7 Fuel system...

  • Page 40: General Information

    The following documentation is relevant to the "Carat A": 1. The current maintenance manual for the "Carat A" powered glider, 2. The operating and maintenance manual for the Sauer engine S 1800-1 – ES1C, 3.

  • Page 41: Torque Values

    Maintenance Manual Carat A Torque values The following maximum permissible torque values for screws and nuts must be adhered Metric thread Moment (daNm) (kpm) / [lb . ft] 0,18 0,36 0,64 1,60 11,8 M 10 3,20 23,6 M 12 5,70...
  • Page 42 Maintenance Manual Carat A Settings The settings and control surface deflections together with the relevant tolerances are given in the table below. SETTINGS Reference line Nom. value Tolerance Wing angle of angle between wing chord and 1,62° ±15´ incidence fuselage longitudinal axis...
  • Page 43 Maintenance Manual Carat A Status: November 2002 Rep. no. / Rev. no.: 0...
  • Page 44 Control surface masses and residual moments If repair work is carried out on the control surfaces, it must be ensured that control surface mass and moment limitations are upheld as the flutter behaviour of the "Carat A" is essentially dependent upon these values.

  • Page 45: Landing Gear

    (2.5 bar – 36 psi). 4.6.2 Tail landing gear The tail landing gear of the "Carat A" is damped by a rubber element. It is virtually maintenance-free, excepting the following points which should be checked regularly: •...

  • Page 46: Fuel System

    Maintenance Manual Carat A Purging the brakes: The wheel brakes must be bled separately for each wheel. Customary brake fluid (DOT 4) is pressed into the system via the bleed valve on the wheel brake cylinder. A suitable plastic tube (brake fluid resistant) is attached to a syringe filled with brake fluid, the tube is then itself filled with brake fluid and attached to the bleed valve.
  • Page 47 Maintenance Manual Carat A Pressure lines and instrument connections If necessary, instrument pressure lines can be cleared of foreign objects and dampness using compressed air. It is, however, essential that all lines are disconnected from the instruments and the compensators as these would be damaged by such high pressure.
  • Page 48 Maintenance Manual Carat A • Any holes, cracks or blisters in the wing, horizontal tail or control surface shells, the size of which does not exceed the following limitations: average hole crack length [mm/in] diameter [mm/in] Wing / horizontal tail fin...
  • Page 49 Maintenance Manual Carat A 4.10.3 Instructions for repair work on composite materials Cut out, scarf and carefully roughen the damaged area. A scarf ratio of 1:50 should be used for glass-fibre cloth and 1:100 for carbon-fibre cloth. It is essential that any bonding repair work should follow the rule wet on dry. Information on how to work with glass-fibre materials is given in U.
  • Page 50 Maintenance Manual Carat A foam to shape (approx. 1-2 mm(0,04-0,08 in) thinner than the original foam) and glue in place with micro balloons while the inner repair layer is still wet. If the inner layer is so badly damaged that the procedure described above cannot be followed, a new inner layer must first be attached to the foam required for the repair.

  • Page 51: Materials List

    The jacking point for weighing can also be used if the aircraft has to be jacked in the course of maintenance work. The fully assembled "Carat A" can easily be raised at the wing tip and rested on a support so that the landing gear strut no longer has ground contact.
  • Page 52 Maintenance Manual Carat A be pushed through the front aileron fittings and a support placed under each end of the rod. (intentionally left blank) 4.14 Status: November 2002 Rep. no. / Rev. no.: 0...
  • Page 53 Maintenance Manual Carat A 5. Inspections 5.1 Pre-flight checks 5.2 Scheduled inspections 5.3 Inspection list 5.4 Inspection after a hard landing 5.5 Inspection to extend operational life 5.6 List of components with limited life cycles Status: November 2002 Rep. no. / Rev. no.: 0...

  • Page 54: Pre-Flight Checks

    Maintenance Manual Carat A Pre-flight checks Cf. flight manual Scheduled inspections The operational safety and airworthiness of an aircraft depends mainly upon the proper maintenance of all its parts. Airworthiness is not assured if the aircraft is not maintained and operated according to the instructions in this maintenance manual and additional documents referenced in Chap.
  • Page 55 Maintenance Manual Carat A Item 50 h 100 h Ann. POWERPLANT Check engine cowling for cracks, deformation and loose or missing locks Check fire protection coating, repair damaged areas, if necessary Visually check the oil system for leakage Clean engine...
  • Page 56 Maintenance Manual Carat A Item 50 h 100 h Ann. PROPELLER Check spinner for cracks, loose screws, buckling and tracking Check security of attachment of the blades, blade tip play max. 5 mm (total travel in direction of rotation) Check freedom of movement of the folding mechanism...
  • Page 57 Maintenance Manual Carat A Item 50 h 100 h Ann. HORIZONTAL TAIL Check surface (incl. elevator) for damage and cracks, check paintwork Check elevator bearing for corrosion and proper function, grease if necessary Check drainage holes Check horizontal tail fittings for corrosion, grease slightly if...
  • Page 58 Maintenance Manual Carat A Item 50 h 100 h Ann. ASSEMBLED AIRCRAFT Check control surface deflections (according to the settings in Chap. 4.4) Check re-mounted cowlings etc. for security of attachment Carry out maintenance flight to check all instruments, electric...
  • Page 59 Maintenance Manual Carat A • Torsion check Secure the fuselage, turn the vertical tail fin against the fuselage and check the following: Do cracks appear? Do unusual deformations appear on the fuselage? Are cracks visible in the fuselage-fin transition area?
  • Page 60 Procedures to extend operation once this final mark of 12,000 hours has been reached will be defined when the occasion arises. The test programme for the "Carat A" is available from the manufacturer. The inspections may only be carried out by the manufacturer or an approved aviation workshop with the appropriate rating.
  • Page 61 Maintenance Manual Carat A 6. Weighing 6.1 Weighing procedures 6.2 Mass and balance log Status: November 2002 Rep. no. / Rev. no.: 0...

  • Page 62: Weighing Procedures

    Maintenance Manual Carat A Weighing procedures The "Carat A" has a re-inforced jacking point below the firewall which is used during weighing procedures. To determine the empty mass of the aircraft, it must be suspended on the jacking point described above and the tail wheel and brought into the horizontal position. The aircraft is in the horizontal position when the left canopy frame is horizontal.
  • Page 63 The weighing results must be recorded in the "Mass and balance log" in Chapter 6.2. of the flight manual. Generally, the load range for the pilot's seat in the "Carat A" is greater than the 70kg (154lbs) to 110kg (242 lbs) range. For this reason, load checks are usually restricted to maximum load levels.
  • Page 64 Maintenance Manual Carat A :=400 mm Aftmost permissible centre of gravity :=260 mm Foremost permissible centre of gravity :=425 mm Small pilot sitting far forward Pklein :=525 mm Large pilot sitting far forward Pgross :=1160 mm Baggage Gepäck := -332 mm...

  • Page 65: Placards And Markings

    Maintenance Manual Carat A 7. Placards and Markings 7.1 Placards and their positions 7.2 Other markings Status: November 2002 Rep. no. / Rev. no.: 0...
  • Page 66 Carat A Placards and their positions The placards required by the "Carat A" are depicted in this chapter. They are shown in their actual size so that they can be copied from the manual if they have to be replaced.
  • Page 67 Maintenance Manual Carat A landing gear emergency extension: At the bottom left of the instrument panel: pull out lever, pump until increase in resistance noticeable. • On the instrument panel below the landing gear switch: • stop • down landing gear...

  • Page 68: Other Markings

    Maintenance Manual Carat A Other markings The following markings are to be found in the "Carat A" in addition to the placards described above. These are also depicted in their actual size so that they can be copied if necessary.
  • Page 69 Maintenance Manual Carat A 8. Supplements 8.1 Summary of airworthiness directives and service bulletins 8.2 Maintenance instructions for optional equipment Status: November 2002 Rep. no. / Rev. no.: 0...
  • Page 70 Carat A Summary of airworthiness directives and service bulletins The following table lists those service bulletins and airworthiness directives which are valid for the aircraft with the serial number given. valid for: CARAT A, Serial number Item SB/AD number Date Sign./Stamp...
  • Page 71 Maintenance Manual Carat A Maintenance instructions for optional equipment Optional equipment has not influence on the contents of Chapters 1 to 7 of this maintenance manual. However, it can require additional instructions which should be filed under this chapter and recorded in the table below.
  • Page 72 Maintenance Manual Carat A (intentionally left blank) Status: November 2002 Rep. no. / Rev. no.: 0...

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