AEROPRAKT -32 Maintenance Manual

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Page 1 Tel: 0038 044 496-77-21 Fax: 0038 044 496-77-31 e-mail: air@prakt.kiev.ua www.aeroprakt.kiev.ua AEROPRAKT-A32 Airplane Maintenance Manual A32-002-AMM Airplane Model: AEROPRAKT-32 (A-32) Airplane Registration Number: Airplane Serial Number: Date of issue: 07.04.2015 Approved by: Yuriy Yakovlyev Position: Chief designer Date of approval: 07.04.2015...
Page 2 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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 must be recorded by the Manual holder in the following table according to information from the Manufacturer.
Page 3: Table Of Contents
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Contents General ......................... 4 ..........................5 OURCES TO PURCHASE PARTS ..............................5 QUIPMENT LIST ........................5 ISPOSABLE REPLACEMENT PARTS ............................6 NGINE SPECIFICATIONS ........................7 EIGHT AND BALANCE INFORMATION ............................ 7 IRE INFLATION PRESSURE ........................ 8...
Page 4: General
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.
Page 5: Sources To Purchase Parts
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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.
Page 6: Engine Specifications
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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:...
Page 7: Weight And Balance Information
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 1.5 Weight and balance information The airplane CG position must be between 1.53 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 C.G.
Page 8: Approved Fuel, Oils And Capacities
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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 ×...
Page 9: General Safety Information
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.
Page 10: Inspections
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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 ...
Page 11 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Inspection/Servicing action  and its interval in hours  Check the torque of the engine mount attachment bolts Inspect the rubber mounts for damage (deep cracks, etc.) Check the intake airbox function, condition and attachment...
Page 12 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Inspection/Servicing action  and its interval in hours  Clean rectifier-regulator and condenser terminals/connectors of corrosion, if any Check condition of electric switches and warning lights Clean fuse block terminals of corrosion, if any. Check fuses...
Page 13: Structures
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 3 Structures The airframe of A-32 airplane includes the following parts: fuselage with polycarbonate glass windscreen, wings, wing struts, all-flying horizontal tail (AFHT), vertical tail unit, wing fillets, strut fairings and engine cowling. Fuselage with fin and wing struts are made of aluminum alloys.
Page 14 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Instructions: 1.1 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 15 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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.
Page 16 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 1.7 Inspect the tail skid for damage and cracks. When detecting a serious damage replace the cracks. Recommended special tools: none. Necessary parts/materials: none. 1.8 Remove the top and bottom engine cowling and inspect for cracks, ruptures, as well as damaged paint coating.
Page 17: Landing Gear
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 4 Landing gear A-32 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 LG. The float and skis type LG is not included in this manual.
Page 18 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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.
Page 19 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM - 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.
Page 20 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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. 1.11 Remove the wheel fairing. Inspect the tire for cracks and cuts. Determine the nature and degree of the tire wear.
Page 21: Brake System
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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.
Page 22 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Copper tubes 200 h Reinforced rubber hose 200 h Instructions: 1.13 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.
Page 23 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM - 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.
Page 24 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Necessary parts/materials: Loctite 222. 1.18 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 25: 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 26 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Instructions: 1.19 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.
Page 27 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM installing the airbox do not let vent tubes of the carburetors 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, oil line plugs 1.20 Remove the top and bottom engine cowling.
Page 28 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM - 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;...
Page 29: Cooling System
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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.
Page 30: Lubrication System
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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.).
Page 31: Fuel System
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 9 Fuel system The fuel system of A-32 (see Fig. 2) includes two wing fuel tanks 1 (each 45 l capacity) with filler inlets (2) and fuel lines d8 (6) connecting the tanks to each other and to the engine fuel pump (9) via two fuel valves (3), mud box (11) and fuel filter (5).
Page 32 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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 Instr.
Page 33: Exhaust System
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 10 Exhaust system The exhaust system of A-32 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 34: Propeller
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 11 Propeller A-32 airplane may be fitted with three-blade on-ground adjustable propeller of 1.71 m (67 diameter manufactured 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.
Page 35: Airplane Control System
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 12 Airplane control system The A-32 airplane control system consists of control systems of ailerons, all-flying horizontal tail (AFHT), AFHT trim tab, and aileron drooping mechanism. Control systems of ailerons and elevator may be with either yokes or central stick. The control system of AFHT trim tab is mechanical one.
Page 36 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 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 AFHT ant its trim tab and serve to retain the cables.
Page 37 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Instr. Part No. Description Interval RCO TM LC A32-0-271090-00-000 Inner pushrod, 2 pcs. 100 h 12.2 A32-0-271060-00-000 Inner bellcrank, 2 pcs. 100 h 12.2 A32-0-271120-00-000 Pushrod 2 pcs. 100 h 12.2 A32-0-271140-00-000 Cable, 2 pcs.
Page 38 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Instructions: 1.37 Inspect aileron for fatigue cracks, deformation, loose rivets, as described in 1.1 (paragraphs 2 and 3). Pay special attention to the areas near the aileron hinge brackets. Check the play in the aileron hinge brackets. Grease the slide bearings if necessary.
Page 39 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 1.42 Inspect the rudder for fatigue cracks, deformation, loose rivets, as described in 1.1 (paragraphs 2 and 3). Pay special attention to the areas near the rudder control arms and hinge brackets. Check play in the rudder hinges. Grease the slide bearings if necessary.
Page 40: Electrical System
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 13 Electrical system The major components of the electrical system of A-32 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 41 AEROPRAKT-22LS Airplane Maintenance Manual A32-002-AMM Fig. 3 Wiring diagram of A-22LS electric system (main)
Page 42 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Fig. 4. Wiring diagram for installation of SV-EMS-220...
Page 43 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Fig. 5. Wiring diagram for installation of SV-D1000, SV-GPS-250, SV-BAT-320, SV-ADAHRS-200...
Page 44 AEROPRAKT-22LS Airplane Maintenance Manual A32-002-AMM Fig. 6 Wiring diagram for Dynon SkyView radio Fig. 7. Wiring diagram for installation of PTT and trimmer control button...
Page 45 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Fig. 8. Wiring diagram for installation of strobes...
Page 46 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM INSPECTION CHART Part No. Description Interval RCO Instr. No. TM Battery 100 h 13.1 See Rotax P/N Starter relay 100 h 13.2 Power cables 100 h 13.3 See Rotax P/N Rectifier-regulator 100 h 13.4 Condenser 100 h 13.4...
Page 47 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 1.50 Inspect terminals and connectors for corrosion and clean if necessary. Recommended special tools: none. Necessary parts/materials: none. 1.51 Remove the fuse block cover. Take out the fuses and inspect their sockets. If corrosion is detected the fuses and sockets must be cleaned. After servicing put in place the fuses and fuse block cover.
Page 48 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 1.55 Remove top cowling. Inspect the electrical harness for damage (chaffing, broken wires). Restore damaged insulation by setting a piece of thermoshrinkable tube over it. Connect broken wires by soldering with following insulation of the soldered areas with thermoshrinkable tube.
Page 49: Cockpit Heating System
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 14 Cockpit heating system Cockpit heating system of A-32 airplane consists of air tunnel (where the water and oil radiators are installed), two warm air ducts, two warm air shutters which are kinematic linked to the air throttle, and its actuator. The control handle of the actuator (No. 4 on Fig.
Page 50: Instruments And Avionics
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 15 Instruments and Avionics Instrument panel is shown on Fig. 9 below. The list of instruments and avionics are installed in the airplane is in subsection 1.2 Equipment list. The instruments and avionics of A-32 are located on the main and additional (lower) instrument panels in the cockpit.
Page 51 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 2. Placard with operating limitations: OPERATE UNDER VFR ONLY NEVER EXCEED SPEED = 124 KTS IAS MAX CONTINUOUS ENGINE SPEED = 5500 RPM MAX TAKEOFF MASS = 600 KG (1320 LB) LIMIT LOAD FACTOR = +4.0 / -2.0 3.
Page 52: Full And Static Pressure System
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 16 Full and static pressure system The full and static pressure system (see Fig. 10) supplies the full (dynamic) and static pressure of the outside air to the instruments measuring the flight parameters: airspeed, rate of climb and altitude. The system consists of the full and static pressure probe (1) and full (2) and static (3) pressure lines connecting the probe to the instruments.
Page 53 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM INSPECTION CHART Part No. Description Interval RCO Instr. No. TM Switches 100 h 15.1 Lights 100 h 15.2 Instruments and avionics 100 h 15.3 Full and static pressure system 100 h 15.4 Instructions: 1.60 Switch on the master switch. Check operation of the switches, by switching them ON one by one.
Page 54: Pilot Seats And Harness Belts
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 17 Pilot seats and harness belts The pilot seats of A-32 airplane are adjustable (they have 4 fixed settings) with pivoted seatback 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 55: Cockpit Doors
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 18 Cockpit doors The cockpit doors are made in form of a PVC glass on a fibergluss framework. The doors may be fitted optionally with locks. The doors are retained in their open position with a gas strut.
Page 56: Recovery System
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 19 Recovery system A-32 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 behind the luggage container. The system actuation handle is installed on the panel between the pilot seats.
Page 57: Structural Repair
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 20 Structural repair 20.1 General This section describes the repairs that can be performed by aircraft owners, LSA repairmen or aircraft and powerplant mechanics without further consultation with the aircraft manufacturer. However when planning to perform the particular repair work it is recommended to consult the aircraft manufacturer in order to verify that the necessary repair was correctly identified and properly prepared.
Page 58: Fabric Covering Repair
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 20.3 Fabric covering repair The fabric covering of the wing, flaperons, elevator and rudder is soft and therefore it may be damaged accidentally in operation. If minor damage (holes, cuts or rupture of size less...
Page 59: Composite Parts' Repair
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 20.4 Composite parts’ repair Some parts of the aircraft such as engine cowlings, wheel fairings, wing tips, fin tip, wing root fairings are made of composite materials. Those parts may be damaged in operation accidentally. If during inspection any damage of those parts such as cracks, dents, etc. is found it can be repaired as described below.
Page 60 AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM Cut several patches of fiberglass cloth of suitable shape and size that cover the damaged area as shown on Fig. 13 above (at least 25 mm to the damaged spot from any edge of the patch). The number of the patches should be such that the total thickness of the patches is approximately equal to the thickness of the repaired part in the damaged area.
Page 61: Restoring Of Damaged Paint/Coating
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 20.5 Restoring of damaged paint/coating It is recommended to restore the damaged paint/coating in a closed room with ventilation and temperature sufficient for the paint/coating to dry. The parts/components requiring restoring of the paint/coating must be removed from the airplane.
Page 62: Feedback Form
AEROPRAKT-32 Airplane Maintenance Manual A32-002-AMM 21 Feedback Form This section contains a form for the aircraft owner or maintainer to provide notification to the manufacturer about issues and anomalies identified during the operation or maintenance of the aircraft or in the content of the manual.

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