Aquila AT01 Maintenance Manual Download

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MAINTENANCE MANUAL

AQUILA AT01

Revision

Number

Revision

Number

Date of

Revision

Date of

Revision

HIGHLIGHTS OF REVISIONS

Highlights of Revisions

Reason for Revision

30.10.13

FAA validation:
description/maintenance
of electrical system,
avionics and structures
revised; airworthiness
limitations;

02.03.15

Life time limit,
6000 hour inspection

21.07.15

“Fuel” revision;
fuel indicating system
calibration procedures

28.08.15

TBO’s and maintenance
checklist revised; Temp.
rev. 2 & 3 incorporated

29.02.16

Control surface ply
lay-up added; repair
procedures revised

10.06.16

6000h check & TBOs
added; battery check
procedure added

09.10.18

Rotax: new spark plugs

16.09.19

TBO’s and maintenance
checklist revised

Summary of Contents for AT01

Page 1: ...1 01 10 01 2 29 10 01 3 05 11 01 4 07 11 01 5 26 11 01 6 01 03 02 7 15 03 02 8 22 03 02 9 14 05 02 10 18 05 02 11 08 07 02 12 26 04 05 13 28 10 05 14 18 01 06 15 30 04 08 16 15 09 09 17 02 03 10 18 21 06 10 19 25 11 10 20 24 02 11 21 05 11 12 22 19 03 13 23 19 07 13 24 15 08 13 25 30 10 13 26 02 03 15 27 21 07 15 28 28 08 15 29 29 02 16 30 10 06 16 31 09 10 18 32 16 09 19 ...

Page 2: ...MAINTENANCE MANUAL AQUILA AT01 A ...

Page 3: ... Revision By By Date Removed RECORD OF TEMPORARY REVISIONS Record of Temp Revisions 01 05 20 00 p 4 24 01 13 19 03 13 02 05 10 00 p 1 2 11 06 14 28 08 15 03 05 20 00 p 7 14 08 14 28 08 15 76 10 00 p 203 204 04 12 14 00 p 301 27 04 15 302 75 10 00 p 201 79 20 00 p 201 ...

Page 4: ...MAINTENANCE MANUAL AQUILA AT01 A ...

Page 5: ...and structures revised airworthiness limitations 26 02 03 15 Life time limit 6000 hour inspection 27 21 07 15 Fuel revision fuel indicating system calibration procedures 28 28 08 15 TBO s and maintenance checklist revised Temp rev 2 3 incorporated 29 29 02 16 Control surface ply lay up added repair procedures revised 30 10 06 16 6000h check TBOs added battery check procedure added 31 09 10 18 Rota...

Page 6: ...MAINTENANCE MANUAL AQUILA AT01 A ...

Page 7: ...rvice 02 03 10 11 Placards and Markings 05 11 12 12 Servicing 30 10 13 AIRFRAME SYSTEMS 20 Standard Practices Airframe 09 10 18 21 Ventilation and Heating 08 07 02 23 Communications 30 10 13 24 Electrical Power 10 06 16 25 Equipment and Furnishings 30 10 13 27 Flight Controls 30 10 13 28 Fuel 21 07 15 31 Indicating Recording Systems 30 10 13 32 Landing Gear 15 03 02 33 Lights 30 10 13 34 Navigatio...

Page 8: ... 11 01 78 Exhaust 07 11 01 79 Oil 07 11 01 80 Starting 05 11 01 91 Charts and Wiring Diagrams 30 04 08 The date refers to the issue revision date of the respective chapter LIST OF EFFECTIVE CHAPTERS Chapter Title Date List of Chapters 16 09 19 Page 2 The technical content of this document revision 32 is approved under the authority of DOA ref EASA 21J 025 Date Signature Office of Airworthiness ...

Page 9: ...MAINTENANCE MANUAL AQUILA AT01 A CHAPTER 5 TIME LIMITS MAINTENANCE CHECKS ...

Page 10: ...MAINTENANCE MANUAL AQUILA AT01 A ...

Page 11: ... 1 COMPONENT TIME LIMITS 05 10 00 1 General 05 10 00 1 Component Time Limits 05 10 00 1 SCHEDULED MAINTENANCE CHECKS 05 20 00 1 General 05 20 00 1 Inspection Time Intervals Chart 05 20 00 1 6000 Hour Inspection 05 20 00 17 DAILY INSPECTIONS 05 30 00 1 General 05 30 00 1 Pre Flight Check 05 30 00 1 Post Flight Check 05 30 00 1 UNSCHEDULED MAINTENANCE CHECKS 05 50 00 1 General 05 50 00 1 Special Che...

Page 12: ...MAINTENANCE MANUAL AQUILA AT01 A ...

Page 13: ...ime Limits This section contains the time limits of all service life limited components and parts and recommended time between overhaul TBO for components C Section 05 20 00 Scheduled Maintenance Checks This section contains information about recommended scheduled maintenance and inspections The recommended maintenance and inspection program for the systems and components as well as the relevant i...

Page 14: ...MAINTENANCE MANUAL AQUILA AT01 A ...

Page 15: ...e time limits listed below are reached B Replacement time limits recommended by the type certificate holder Chapter Component Part Replacement Time Overhaul 24 Ignition lock 6000 h no 24 Starter relais 2000 h no 27 Elevator control rods 6000 h no incl rod ends 27 Rudder control cables 6000 h no 27 Control surface 6000 h no plain bearing bushings 28 Electrical fuel pump 3000 h or 10 years no 32 Nos...

Page 16: ...ents no Note 5 61 Propeller no 2000 h or 6 years MTV 21 A 175 05 Note 2 61 Propeller governor no 6 years with engine Woodward A210786 Note 6 61 Propeller governor no 2000 h or 6 years P 410 13 Note 2 61 Propeller governor no 2000 h or 6 years P 850 12 Note 2 71 Engine ROTAX 912S no 2000 h or 15 years 1500 h or 12 years 1200 h or 10 years Note 3 71 Flexible hoses of the 5 years no cooling system 71...

Page 17: ...E 124 Operation and Installation Manual Note 3 Refer to the latest issues of BRP Rotax i e Service Bulletins Service Information and to the ROTAX Aircraft Engines Maintenance Manual for ROTAX Engine Type 912 Series Note 4 Refer to manufacturer instruction for overhauling Note 5 Though there is no TBO for these instruments the manufacturer Gebr Winter GmbH Co KG recommends that airspeed indicators ...

Page 18: ...MAINTENANCE MANUAL AQUILA AT01 A Maintenance Checks ...

Page 19: ...y an engine ground run and the checks listed in the Engine section have to be carried out NOTE If more than 30 of operation hours have been flown with leaded fuel e g AVGAS 100LL an additional 50 hour inspection is necessary refer to ROTAX Aircraft Engines SI 912 016 NOTE Where an interval is given in both flight time and calendar time the limit which is reached first must be applied The next inte...

Page 20: ...rds Check Update if necessary 5 Aircraft file and technical documentation Verify X complete and in proper order No Pre Inspection Engine Ground Test Reference Interval Initials 100h other Aircraft S N Operating Hours Registration Number Engine S N Operating Hours Date TTSN TTSO Propeller S N Operating Hours Type of TTSN TTSO Inspection 16 09 19 C Due to recent ROTAX publications the maintenance ch...

Page 21: ...erence between left and right magnetos RPM drop left magneto _______RPM RPM drop right magneto _______RPM Carburetor heat Pull carburetor heat knob at 1700 RPM Engine RPM should show a drop of at least 20 RPM RPM drop _______RPM Engine full power Advance throttle to full forward Tachometer should read 2265 50 RPM Full power RPM _______RPM Engine idle Move throttle control lever to full aft Tachome...

Page 22: ...of oil For oil quality see R912 12 20 00 11 Operators Manual and SI 912 016 SI 912 010 SB 912 040 Refilled ______________Quantity _______L CAUTION DO NOT USE AIRCRAFT ENGINE OIL Due to the friction clutch and the high stresses in the reduction gear 4 stroke motor cycle oils are recommended For suitable lubricants and oil change intervals see ROTAX Operators Manual and latest appropriate ROTAX publ...

Page 23: ...f necessary clean cooling fins 79 20 00 and do a pressure leakage test 1 15 Oil lines Inspect for damage leakage hardening due to heat R912 12 20 00 4 X porosity security of connections and attachments Check routing for kinks or narrow bends Check fire protection shielding 1 16 Oil tank vent line Check for proper routing for obstructions X and clear passage 1 17 Fuel lines Check for damage leakage...

Page 24: ...muffler 78 10 00 200h and inspect muffler for condition corrosion and leakage WARNING FAILURE TO INSPECT MUFFLER FOR LEAKS COULD RESULT IN CARBON MONOXIDE ENTERING THE CABIN LEADING TO SERIOUS INJURY OR DEATH 2 31 Propeller gear box Check the friction torque in free rotation R912 12 20 00 14 X Actual friction torque is measured _________Nm 1 32 Propeller gear box Inspect overload clutch R912 05 50...

Page 25: ...er casing Check the drain hole at the bottom of casing for obstructions or blockage 2 42 Other external engine accessories Inspect screws and nuts X of all other external engine parts and accessories for tight fit Inspect safety wiring if applicable replace as necessary 2 43 Engine mounts manufactured by ROTAX and AQUILA R912 12 20 00 3 X Check mounts for deformation cracks corrosion SB 912 028 se...

Page 26: ...nuts are tightened properly and safety wired Check governor actuation for free movement and bulging Page 8 05 20 00 Maintenance Checks 1 Prepare aircraft for visual checks X Remove cabin carpets and floorboards Remove glare shield Remove baggage compartment floorboard Remove access panel of the baggage compartment bulkhead Remove access panel 210AB 06 30 00 2 Fuselage shell Visual inspection for p...

Page 27: ...arts corrosion surface finish condition and security of attachment Check textile components for damaged stitching injurious marks broken fabric threads chafe marks and fusing Perform functional check of buckle and inertia reel 10 Seats Check security of attachment of the seat assy to X aircraft structure Check operation of seat adjustment mechanism and seat stops Inspect gas spring struts for oil ...

Page 28: ...Examine all bearings for condition and secure fit Check safetying Check travel of control surfaces if the control stick is in the full forward neutral aft and full left neutral right positions Verify no binding or jumpy movement of the control sticks through their full range of travel 22 Rudder control Check rudder control weldment and rudder X bellcrank for cracks distortion chafing and security ...

Page 29: ...y in the aileron X control system with the control surface locked Apply a lateral force of 30 N 6 7 lb to the control stick the maximum play allowed on the top of the stick is 10 mm 0 4 in for both sides The play should be measured for both control sticks If excessive play is detected investigate cause 7 Flaps Check hinge brackets for damaged paint cracks and X delamination Check bearings for corr...

Page 30: ... Flaps and ailerons Check that the gap between fuselage and X flaps between flaps and ailerons and at the outboard end of the ailerons is at least 2 mm 0 08 in 10 Stall warning system Check for condition and proper X operation 11 For serial numbers from AT01 100 to AT01 126 57 10 00 annual Bonding between wing spar and upper shell Check SB AT01 002 condition 12 Navigation strobe lights Check opera...

Page 31: ...n Check elevator hinge and rudder hinge play Maximum play approx Axial 0 30 mm 0 01 in Radial 0 30 mm 0 01 in 4 Elevator control system Measure the play in the elevator annual control system with the control surface locked Apply a force of 50 N 11 2 lb forwards and then backwards to the control stick the maximum play allowed on the top of the stick is 10 mm 0 4 in for both sides 5 Rudder Remove ru...

Page 32: ...nt 1 Check has to be carried out every 100 hours of operation or 12 month whichever comes first 2 If installed 5 Nose wheel steering Inspect nose wheel steering tubes for X condition excessive play and correct safetying Check return springs at nose gear strut for security and verify they are tension free when the nose wheel is in neutral position 6 Main landing gear Check main gear struts for defo...

Page 33: ...e and propeller controls Check full range of motion X without any obstruction or excessive friction to travel Check throttle and propeller control levers friction lock 6 Foreign items Remove any foreign items from the aircraft X No Reference Interval Initials 100h other Return to Service Page 15 05 20 00 Maintenance Checks 16 09 19 No Cont Reference Interval Initials 100h other Electrical System A...

Page 34: ...aintenance required by Service InformationandAirworthinessDirectivesandallprescribedscheduledmaintenancecheckshavebeencarriedout Service Station Next inspection when _______ hours of operation have been reached Place Date Name Signature of Mechanic Name Signature of Inspector Stamp Maintenance Checks Page 16 05 20 00 16 09 19 ...

Page 35: ...on Time Intervals Chart above All items performed all findings discovered and their follow up corrections have to be recorded in acc with an approved quality procedures manual NOTE The first 6000 hour inspection is replaced by an inspection program to reach an extension of life time refer to 04 00 00 It can be obtained from the type certificate holder on request C The inspection table shows three ...

Page 36: ...ng shell delamination cracks V T 7 Condition of rib laminate delamination cracks V T 8 Bonding area at the main wing spar web V 9 Areas around bushing delamination cracks V 10 Condition of ball bearing wear corrosion V Wing Main Spar 11 Spar cap between root ribs bonding to shear web cracks V 12 Shear web between root ribs condition cracks delamination V 13 Spar cap inspection through openings in ...

Page 37: ...ndition cracks V 25 Wing trailing edge aileron area bonding area shear web to V T wing shell disbonds cracks 26 Wing trailing edge aileron area laminate condition cracks V 27 Bonding left an right of hinge levers for flap and aileron V T 28 Aileron hinge levers delamination at bolt area bolt corrosion V 29 Flap hinge levers delamination at bolt area bolt corrosion V Tank Rib 30 Bonding area of rib...

Page 38: ...shell delamination cracks scratches in shell surfaces V T chipping of paint UV damage 15 Wing shell core damage and dents in sandwich disbond of V T shell laminate from core material 16 Areas around inspection openings delamination cracks V 17 Wing leading edge bonding area disbonds cracks V T 18 Area around tie down fixation point delamination cracks V T 19 Area around NAV light opening delaminat...

Page 39: ...ng and leading edges bonding delamination V T 5 Inner and outer aileron ribs bonding delamination with skin V T 6 Check condition of drain holes in inner and outer ribs V 7 Areas around hinges and aileron control horn fasteners V delamination from skin cracks 8 Condition of control horn bearing corrosion play V 9 Condition of hinges bushings corrosion play V 10 Inspect for previously performed rep...

Page 40: ...ib bonding delamination with skin V T 26 Check condition of drain hole in lower hinge rib V 27 Area around upper hinge delamination from skin cracks V 28 Mass balance horn Check for cracks and delamination V T 29 Condition of hinge bushing corrosion play V 30 Inspect for previously performed repairs and repaintings V If so check rudder mass and static moment to be within specified limits refer to ...

Page 41: ...dges Check for bonding delamination V T 5 Trailing edge spar Check for cracks and bonding V T delamination with skin 6 Areas around hinge supports in trailing edge spar Check V for cracks and delamination 7 Condition of hinges bushings corrosion play V No Inspection Items Inspection Finding Initials Fuselage Method Condition Fuselage Skin Structure and Vertical Stabilizer Skin 1 Skin surfaces Chec...

Page 42: ...in vertical stabilizer Check for V delamination and cracks 14 Upper and lower shear web in vertical stabilizer Check V T bonding to the stabilizer shell 15 Upper hinge plate check for delamination and cracks V 16 Bushing in upper hinge plate wear corrosion fit play V 17 Lower shear web around fasteners for lower hinge bracket V Check laminate 18 Bushing in lower hinge bracket wear corrosion fit pl...

Page 43: ...ead Check for delamination and V T cracks Check bonding area to the fuselage structure for disbonding 35 Baggage bulkhead Check for delamination and cracks V T Check bonding area to the fuselage structure for disbonding 36 Lower lap belt attachments Check for delamination and V cracks Check bonding area to the fuselage structure for disbonding 37 Lower lap belt fitting Check for wear and corrosion...

Page 44: ...rea of Plexiglas to the canopy frame structure for disbonding 50 Canopy latching components corrosion wear damage V 51 Canopy pin and bushing components Check for corrosion V wear and fit play 52 Canopy Plexiglas including side windows cracks damage V No Inspection Items Inspection Finding Initials Landing Gear Method Condition Main Landing Gear 1 Main landing gear struts Check condition distortio...

Page 45: ...Engine mount attachment bolts Check for cracks and wear V 8 Nose wheel axle Check for cracks and distortion V Theaircraftisairworthyandmeetstheconditionspecifiedintheaircraftdatasheet Allprescribed6000 hourinspectionitemsandmaintenanceactionsresultingthereofhavebeencarriedout Service Station Place Date Name Signature of Mechanic Name Signature of Inspector Stamp ...

Page 46: ...MAINTENANCE MANUAL AQUILA AT01 A Maintenance Checks ...

Page 47: ...ed back to inadequate pre flight checks The scope of the pre flight check is listed in the AQUILA AT01 Flight Manual section 4 3 Post Flight Check A This check should be carried out after the final flight of the day For the most part it is a visual inspection B The check should contain all points of the pre flight check 1 Supplementary measures a Re fuel b Check that the aircraft is properly parke...

Page 48: ...MAINTENANCE MANUAL AQUILA AT01 A ...

Page 49: ...omponents and their attachments is required Even if no obvious defects are detectable a visual inspection must be carried out Perform the following 1 Prepare aircraft for visual checks as follows a Remove engine cowling refer to 71 10 00 b Remove landing gear fairings c Inside the cabin and baggage compartment remove carpets and floorboards as required to gain access to the landing gear mounting b...

Page 50: ...owling refer to 71 10 00 2 Examine engine cowling Check for signs of fire damage 3 Disconnect battery refer to 24 30 00 4 Examine electrical cables for damaged insulation 5 Examine fuel lines for damage of the fire protection sleeves 6 Check oil lines for damage of the fire protection sleeves 7 Check air filter element for fire damage 8 Examine engine mount and shock mounts for any fire damage 9 C...

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