MM 16 06 10 Rev30 Update Pages

MAINTENANCE MANUAL

AQUILA AT01A

MAINTENANCE MANUAL

AQUILA AT01 (A210)

Doc.-No. MM-AT01-1020-100

This document is protected by copyright. All associated rights, in particular those of translation, reprinting, reproductionby photo mechanical or similar means and storing in data processing facilities in whole or part are reserved.The technical content of this document is approved under the authority of DOA ref. EASA.21J.025.

AQUILA Aviation International GmbH Phone:++49 33 731 707 - 0Flugplatz Fax: ++49 33 731 707 - 1114959 Schönhagen e-mail: [email protected]

AQUILA Aviation International GmbH

MAINTENANCE MANUAL

AQUILA AT01A

MAINTENANCE MANUAL

AQUILA AT01A

TABLE OF CONTENTS

Cha/Sec/Sub Title Pages

TABLE OF CONTENTS 1-6INTRODUCTION 1-8LIST OF EFFECTIVE CHAPTERS 1-2

04 AIRWORTHINESS LIMITATIONS04-00-00 Airworthiness Limitations - General 1-2

05 TIME LIMITS / MAINTENANCE CHECKS05-00-00 Time Limits / Maintenance Checks - General 105-10-00 Component Time Limits 1-305-20-00 Scheduled Maintenance Checks 1-2705-30-00 Daily Inspections 105-50-00 Unscheduled Maintenance Checks 1-2

06 DIMENSIONS AND AREAS06-00-00 Dimensions and Areas - General 106-10-00 Aircraft Dimensions and Areas 1-306-20-00 Aircraft Zoning 1-206-30-00 Access/Inspection Plates 1-2

07 LIFTING AND SHORING07-00-00 Lifting and Shoring - General 107-10-00 Jacking 201-202

08 LEVELING AND WEIGHING08-00-00 Leveling and Weighing - General 108-10-00 Weighing 201-20308-20-00 Leveling 201-202

09 TOWING AND TAXIING09-00-00 Towing and Taxiing - General 109-10-00 Towing 201-20209-20-00 Taxiing 201

10 PARKING, MOORING, STORAGE AND RETURN TO SERVICE10-00-00 Parking, Mooring, Storage and Return to Service - General 110-10-00 Parking 20110-11-00 Storage 201-20210-20-00 Mooring 20110-30-00 Return to Service 201

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TABLE OF CONTENTS (Cont.)


11 PLACARDS AND MARKINGS11-00-00 Placards and Markings - General 111-20-00 Exterior Placards and Markings 201-20611-30-00 Interior Placards and Markings 201-208

12 SERVICING12-00-00 Servicing - General 112-10-00 Replenishing - Description 1-212-11-00 Fuel - Servicing 301-30212-12-00 Engine Oil - Servicing 301-30212-13-00 Induction Air Filter - Servicing 30112-14-00 Cooling System - Servicing 301-30212-15-00 Brake System - Servicing 30112-16-00 Tires - Servicing 30112-17-00 Battery - Servicing 30112-20-00 Scheduled Servicing - Description 112-21-00 Lubricants - Description 1-212-22-00 Lubrication - Servicing 301-30312-23-00 Aircraft Exterior - Cleaning and Care 701-70412-24-00 Aircraft Interior - Cleaning and Care 701-70212-30-00 Unscheduled Servicing 301

20 STANDARD PRACTICES AIRFRAME20-00-00 Standard Practices Airframe - General 120-10-00 Fastener Identification and Torque Data 1-420-11-00 Conversion Data 1-3

21 VENTILATION AND HEATING21-00-00 Ventilation and Heating - General 121-20-00 Fresh Air Distribution - Description 121-20-00 Fresh Air Distribution - Maintenance 20121-40-00 Heating - Maintenance 201

23 COMMUNICATIONS23-00-00 Communications - General 123-10-00 Speech Communication - Description 1-2/2/223-10-00 Speech Communication - Maintenance 201-202/202/20223-50-00 Audio Integrating - Maintenance 201-202/202

24 ELECTRICAL POWER24-00-00 Electrical Power - General 124-00-00 Electrical Power - Troubleshooting 101-10224-20-00 Alternator System - Description 1-224-20-00 Alternator System - Maintenance 201-204

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24-30-00 Battery System - Description 1-224-30-00 Battery System - Maintenance 201-20324-40-00 External Power - Maintenance 201-20324-60-00 Electrical Load Distribution - Description 124-61-00 Circuit Breaker - Maintenance 20124-97-00 Electrical System Wiring - Maintenance 201

25 EQUIPMENT / FURNISHINGS25-00-00 Equipment / Furnishings - General 125-10-00 Seats - Maintenance 201-20325-11-00 Restraint System - Maintenance 20125-12-00 Cabin Interior - Maintenance 201-20325-50-00 Cargo Tie Downs - Maintenance 20125-60-00 Emergency Equipment - Description 1-225-62-00 Emergency Locater Transmitter - Maintenance 201-20225-66-00 Fire Extinguisher - Maintenance 201-201/202

27 FLIGHT CONTROLS27-00-00 Flight Controls - General 127-10-00 Aileron Control System - Description 1-227-10-00 Aileron Control System - Maintenance 201-20727-20-00 Rudder Control System - Description 1-227-20-00 Rudder Control System - Maintenance 201-20527-30-00 Elevator Control System - Description 1-227-30-00 Elevator Control System - Maintenance 201-20527-31-00 Elevator Trim Control System - Description 1-227-31-00 Elevator Trim Control System - Maintenance 201-20227-50-00 Flap Control System - Description 1-227-50-00 Flap Control System - Maintenance 201-205

28 FUEL28-00-00 Fuel - General 1-228-10-00 Fuel Storage - Maintenance 20128-20-00 Fuel Distribution - Maintenance 201-20528-41-00 Fuel Quantity Indication - Maintenance 201-206

31 INDICATING / RECORDING SYSTEMS31-00 00 Indicating / Recording Systems - General 1-2/2/231-10-00 Instrument Panel - Maintenance 201-20231-30-00 Recorders - Maintenance 201-204

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32 LANDING GEAR32-00-00 Landing Gear - General 132-10-00 Main Gear - Description 132-10-00 Main Gear - Maintenance 201-20232-20-00 Nose Gear - Description 132-20-00 Nose Gear - Maintenance 201-20332-40-00 Wheels and Brakes - Description 132-40-00 Wheels and Brakes - Maintenance 201-208

33 LIGHTS33-00-00 Lights - General 133-10-00 Interior Lights - Maintenance 201-20233-40-00 Exterior Lights - Maintenance 201-

34 NAVIGATION34-00-00 Navigation - General 134-11-00 Pitot / Static System - Description 1-234-11-00 Pitot / Static System - Maintenance 201-20434-18-00 Stall Warning System - Description 134-18-00 Stall Warning System - Maintenance 20134-20-00 Attitude and Direction - Maintenance 201-20334-25-00 Integrated Flight System -34-40-00 Independent Position Determining - Maintenance 201-201/202/20534-45-00 Collision Warning System - Maintenance 201-20434-50-00 Dependent Position Determining - Maintenance 201-202/203

51 STRUCTURES51-00-00 Structures - General 1-251-10-00 Composite Damage Investigation 201-20351-20-00 Composite Repair 201-223

52 DOORS52-00-00 Doors - General 152-10-00 Canopy - Maintenance 201-20452-30-00 Baggage Door - Maintenance 201

53 FUSELAGE53-00-00 Fuselage - General 153-10-00 Fuselage Main Frame - Description 1-453-10-00 Fuselage Main Frame - Maintenance 201

203/202

Maintenance 201-204/205

53-20-00 Auxiliary Structure - Description 1

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55 STABILIZERS55-00-00 Stabilizers - General 155-10-00 Horizontal Stabilizer - Maintenance 20155-20-00 Elevator - Maintenance 201-20355-30-00 Vertical Stabilizer - Maintenance 20155-40-00 Rudder - Maintenance 201-202

57-00-00 Wings - General 157-10-00 Wing - Maintenance 201-20657-50-00 Control Surfaces - Maintenance 201-207

61 PROPELLER61-00-00 Propeller - General 161-00-00 Propeller - Troubleshooting 101-10361-10-00 Propeller Assembly - Maintenance 201-20461-20-00 Propeller Control - Maintenance 201-204/204/204

71 POWER PLANT71-00-00 Power Plant - General 171-00-01 Engine - Description 1-371-00-01 Troubleshooting - Rotax 912S 101-10471-00-01 Rotax 912S - Maintenance 201-20371-10-00 Cowling - Maintenance 201-20271-20-00 Engine Mount - Maintenance 20171-60-00 Air Induction System - Maintenance 201

74 IGNITION SYSTEM74-00-00 Ignition System - General 1-274-10-00 Ignition System - Maintenance 201-203

75 COOLING SYSTEM75-00-00 Cooling System - General 1-275-10-00 Cooling System - Maintenance 201-20275-10-01 Winterization Kit - Maintenance 201-202

76 ENGINE CONTROLS76-00-00 Engine Controls - General 176-00-00 Engine Controls - Maintenance 201-205

56 WINDOWS56-00-00 Windows - General 156-10-00 Flight Compartment Windows - Maintenance 201-203

57 WINGS

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77 ENGINE INDICATING77-00-00 Engine Indicating - General 177-10-00 Power Indication - Maintenance 201-20277-20-00 Temperature Indication - Maintenance 201

78 EXHAUST78-00-00 Exhaust - General 178-10-00 Exhaust - Maintenance 201-202

79 OIL79-00-00 Oil - General 1-279-10-00 Oil Tank - Maintenance 201-20279-20-00 Oil Cooler - Maintenance 20179-30-00 Oil Temperature Measuring System - Maintenance 20179-31-00 Oil Pressure Measuring System - Maintenance 201

80 STARTING80-00-00 Starting - General 180-10-00 Starter - Maintenance 1

91 CHARTS AND DIAGRAMS91-00-00 Charts and Diagrams - General 1-24

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Number

Revision

Number

Date of

Revision

Date of

Revision

Date

Inserted

Date

InsertedBy By

RECORD OF REVISIONS

Record of Revisions

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

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Temp. Revision

NumberPage Date of

RevisionBy ByDate

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 28.08.1576-10-00 p.203& 204

04 12-14-00 p.301 27.04.15& 30275-10-00 p.20179-20-00 p.201

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Revision

Number

Revision

Number

Date of

Revision

Date of

Revision

HIGHLIGHTS OF REVISIONS

Highlights of Revisions

Reason for Revision Reason for Revision

25 30.10.13 FAA validation:description/maintenanceof electrical system,avionics and structuresrevised; airworthinesslimitations;

26 02.03.15 Life time limit,6000 hour inspection

27 21.07.15 “Fuel” revision;fuel indicating systemcalibration procedures

28 28.08.15 TBO’s and maintenancechecklist revised; Temp.rev. 2 & 3 incorporated

29 29.02.16 Control surface plylay-up added; repairprocedures revised

30 10.06.16 6000h check & TBOsadded; battery checkprocedure added

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LIST OF EFFECTIVE CHAPTERS


Chapter Title Date*

GENERAL

Introduction 30.10.1304 Airworthiness Limitations 0205 Time Limits / Maintenance Checks 10.06.1606 Dimensions and Areas 2607 Lifting & Shoring 3008 Leveling and Weighing 2709 Towing and Taxiing 0210 Parking, Mooring, Storage & Return to Service 0211 Placards and Markings 0512 Servicing 30

AIRFRAME SYSTEMS

20 Standard Practices Airframe 0521 Ventilation and Heating 0823 Communications 3024 Electrical Power 1025 Equipment and Furnishings 30.10.1327 Flight Controls 3028 Fuel 21.07.1531 Indicating/Recording Systems 3032 Landing Gear 1533 Lights 30.10.1334 Navigation 30

STRUCTURES

51 Structures 29

53 Fuselage 3055 Stabilizers 14

57 Wings 18

PROPELLER

61 Propeller 19

Table of Contents 10.06.16

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.04.05

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.03.10

.03.10

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.03.02

.10.13

.02.1652 Doors 30.10.13

.10.13

.05.0256 Windows 19.07.13

.01.06

.03.13

List of Chapters

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POWER PLANT

71 Power Plant 2674 Ignition 2975 Cooling System 2676 Engine Controls 2877 Engine Indicating 2678 Exhaust 0779 Oil 0780 Starting 0591 Charts and Wiring Diagrams

* The date refers to the issue / revision date of the respective chapter.

.04.05

.10.01

.04.05

.08.15

.11.01

.11.01

.11.01

.11.0130.04.08


Chapter Title Date*

List of Chapters

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Page 2

The technical content of this document (revision 30) is approved under the authority ofDOA ref. EASA.21J.025.

Date, Signature Office of Airworthiness

MAINTENANCE MANUAL

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CHAPTER 5

TIME LIMITS / MAINTENANCE CHECKS

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05 - TOCPage 1

Maintenance Checks

TABLE OF CONTENTS

ChapterSection

TIME LIMITS / MAINTENANCE CHECKS - GENERAL ...........................05-00-00 1Introduction 05-00-00 1General Description 05-00-00 1

SCHEDULED MAINTENANCE CHECKS....................................................05-20-00 1General 05-20-00 1Inspection Time Intervals Chart 05-20-00 16000-Hour Inspection 05-20-00 17

DAILY INSPECTIONS......................................................................................05-30-00 1General 05-30-00 1Pre-Flight Check 05-30-00 1Post-Flight Check 05-30-00 1

UNSCHEDULED MAINTENANCE CHECKS .............................................05-50-00 1General 05-50-00 1Special Checks 05-50-00 1

Title Subject Page

COMPONENT TIME LIMITS .........................................................................05-10-00 1General 05-10-00 1Component Time Limits 05-10-00 1

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05-00-00

Maintenance Checks

TIME LIMITS / MAINTENANCE CHECKS - GENERAL

1.

A. This chapter provides scheduled and unscheduled maintenance checks and inspections,recommended by the type certificate holder as well as the time limits for service life limitedcomponents and parts.

2.

In the following, a brief description and intended purpose of each section of this chapter is given.

A. Section 05-00-00 - Time limits / Maintenance Checks - General. This section provides a generaloverview of the content and purpose of this chapter.

B. Section 05-10-00 – Component Time Limits. This section contains the time limits of all service lifelimited components and parts and recommended time between overhaul (TBO) for components.

C. Section 05-20-00 - Scheduled Maintenance Checks. This section contains information aboutrecommended scheduled maintenance and inspections. The recommended maintenance andinspection program for the systems and components as well as the relevant intervals areembodied in a checklist included in this section.

D. Section 05-30-00 - Daily Inspections. In this section pre-flight and post-flight checks are described,that have to be carried out every day the aircraft is in operation.

E. Section 05-50-00 - Unscheduled Maintenance Checks. This section specifies checks, which have tobe conducted after unusual events and incidences such as hard landings.

Introduction

General Description

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COMPONENT TIME LIMITS

Chapter Component / Part Replacement Time Overhaul

1.

A. Different components and parts of the aircraft are certified for specific service life. When reachingthis time limit, the respective item must be replaced or overhauled.In order to monitor permissible service life the installation or removal of each item must berecorded in the aircraft logbook.Where an interval is given in both flight time and calendar time, the limit which is reached firstmust be applied.

2.

A. Under certain circumstances the replacement or overhaul of components may be required beforethe time limits listed below are reached.

B. Replacement time limits, :

24 Ignition lock 6000h no

27 Elevator control rods 6000h noincl. rod ends

27 Rudder control cables 6000h no

28 Electrical fuel pump 3000h or 10 years no

32 Nose landing gear spring 5 years nopackage rubber elements

55 Lower rudder hinge bracket 6000h no

57 Wing attachment bolts 6000h no

71 Flexible teflon hoses 2000h or 15 years no

General

Component Time Limits

recommended by the type certificate holder

32 Main landing gear struts no 6000h

32 Flexible hoses 10 years noof the brake system

of the oil / fuel system

71 Flexible hoses of the 5 years nocooling system

1)

05-10-00

Maintenance Checks

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1) Hoses that are not covered by the engine type certificate (TC).

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05-10-00Page 2

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Maintenance Checks

C. Vendor Established Component Time Limits

25 ELT battery Note 1 no

25 Fire extinguisher 10 years Note 4Air Total

25 Fire extinguisher 12 years noH3R

31 ASPEN internal battery 800h or 3 years no

34 KMD 150 MFD/GPS 10 years nointernal battery (recommended)

34 WINTER instruments no

61 Propeller noMTV-21-A/175-05

61 Propeller governor noP-410-13

71 Engine ROTAX 912S no

71 ROTAX mechanical 5 years nofuel pump Note 3

71 ROTAX flexible teflon with engine overhaul nohoses of the fuel system Note 3

Chapter Component / Part Replacement Time Overhaul

Note 5

2000h or 6 yearsNote 2

61 Propeller governor no 6 years, with engineWoodward A210786 Note 6

2000h or 6 yearsNote 2

61 Propeller governor no 2000h or 6 yearsP-850-12 Note 2

2000h or 15 years,1500h or 12 years,1200h or 10 yearsNote 3

71 AQUILA engine mount 6000h noand attaching bolts

71 Engine shock with engine nomounts overhaul

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05-10-00Page 3

71 ROTAX rubber parts 5 years no

(V-belt, hoses,

Note 1: Refer to manufacturer instructions for battery replacement time limits.

Note 2: Refer to latest issue of the mt-propeller Service Bulletin No. 1.-( ), and to themt-Propeller E-124 Operation and Installation Manual.

Note 3: Refer to the latest issues of BRP-Rotax, i.e. Service Bulletins, Service Information andto the ROTAX Aircraft Engines Maintenance Manual for ROTAX Engine Type 912Series.

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 and altimeters are subjected toretesting after 5 years.

Note 6: The 6 year calendar time limit applies for units not in continuous service with aminimum of 120 hours per year. Refer to the latest issue of the Woodward ServiceBulletin S/B-33580-M.

of the engine Note 3

carburetor parts)

71 Spark plugs 200h noNote 3

NOTES:

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05-20-00

SCHEDULED MAINTENANCE CHECKS

Annual inspections and 100 hour inspections on the AQUILA AT01 must include all inspectionitems as required by FAR 43, Appendix D, “Scope and detail of annual/100h inspections”.Chapter 4 “Airworthiness Limitations“ of this manual defines the inspection intervals forcontinued airworthiness.

1.

A. The inspection time intervals chart contained in this chapter shows the recommended intervals atwhich maintenance and maintenance checks should be carried out on the aircraft.

B. If an aircraft is being operated under unusual environmental conditions, maintenance intervalsmay be reduced.

2.

A. The maintenance and checks listed are to be carried out at the specified intervals and documentedappropriately.

up to and including 100 h 10% of interval>100 h up to and including 1000 h 5% of interval>1000 h 50 hcalendar time limits 30 days

These tolerances must not me added up. For example: if the 100-hour inspection was done at107 h, the next inspection must be done at 200 10 h, not 207 10 h.

If an inspection is carried out earlier than allowed by the specified tolerance, all subsequentinspection intervals are counted from that inspection. For example: If the 100 h inspection wasdone at 87 h, the next inspection must be done at 187 10 h.

General

Inspection Time Intervals Chart

NOTE:

NOTE:

NOTE:

For new aircraft and new engines the first check is carried out after 25 hours and shouldbe of the extent of a 100-hour inspection. For new engines only an engine ground runand the checks listed in the “Engine” section have to be carried out.

If more than 30% of operation hours have been flown with leaded fuel (e.g. AVGAS100LL), an additional 50-hour inspection is necessary (refer to ROTAX Aircraft EnginesSI-912-016).

Where an interval is given in both flight time and calendar time, the limit which isreached first must be applied. The next interval starts with the flight time and calendartime of the latest performed maintenance check.

B. For intervals between maintenance work, the following tolerances must not be exceeded:

Interval Tolerance

± ±

±

Maintenance Checks

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05-20-00Page 2

Maintenance Checks

1. Check that the following documents are AT01 Xup-to-date and available upon request: Maintenance- AT01 Maintenance Manual Manual,- AT01 Airplane Flight Manual AT01- Aircraft Log Book and required certificates Airplane- Engine and Propeller Log Books Flight Manual- Equipment List and Weight and Balance Record- Airworthiness Directives- Service Bulletins and Service Information- Services Time Record

2. Airworthiness Directives - Verify all Airworthiness Directives Xhave been complied with.

3. Service Letters, Service Bulletins, and Service Information - XVerify all AQUILA GmbH and suppliers Service Letters, ServiceBulletins and Service Information have been complied with.

4. Service time records, equipment list and weight and balance Xrecords - Check. Update if necessary.

5. Aircraft file and technical documentation - Verify Xcomplete and in proper order.

No. Pre-Inspection / Engine Ground Test Reference Interval Initials100h other

Aircraft S/N Operating Hours Registration

Engine S/N Operating Hours DateTTSN / TTSO:

Propeller S/N Operating Hours Type ofTTSN / TTSO:

Number

Inspection

10.06.16

C. Due to recent ROTAX publications the maintenance checks given for the ROTAX engine may notbe up to date. Refer to the latest revisions of ROTAX Engine Type 912 Series Maintenance Manualand Service Bulletins.

D. Due to the multiplicity of equipment coming onto the market, no maintenance instructions aregiven for electronic equipment. For information on a certain component use the documentationprovided by the manufacturer of this component.

NOTES:

E. Inspection Time Intervals Chart:

R912* Maintenance Manual for ROTAX Engine Type 912 SeriesMT* mt-Propeller E-124 Operation and Installation ManualTTSN Total Time Since NewTTSO Total Time Since Overhaul

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6. Engine and engine compartment - Clean R912* 12-20-00 1) X1)

for leakage check.

7. Perform an engine test run as follows: R912* 12-20-00 8) X1)

Start engine and warm-up at 820 RPM for approx. 2 minutes,continue at 1030 RPM, duration depends on ambienttemperature until oil temperature reaches 50° C.

Rudder pedal brakes and parking brake - Check for proper 32-40-00operation.

Propeller governor - Set 1700 RPM and monitor the MT*manifold pressure. Reduce engine speed by moving thepropeller control by 200 RPM. Note the RPM drop andmanifold pressure. Increase RPM to 1700 RPM. Repeatthree times.

RPM drop: _______RPM / Man. press :_______in. Hg

Engine instruments - Check engine parameters.

Magneto RPM drop - Set 1700 RPM. Check that RPM dropis less than 120 RPM while operating on one magneto andno more than a 50 RPM drop difference between leftand right magnetos.

RPM drop left magneto :_______RPMRPM 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.Tachometer should read 750 +50 RPM.

Idle RPM:_______RPM

Cool down engine at 1100 RPM. Shut down engine,set the ignition switch and the master switch to the OFFposition. Remove ignition key from aircraft.

8. Airframe, power plant, propeller - Do a walk around X1)

to detect damages, fluid leaks or other abnormalities.

9. Fuselage and empennage - Clean. X

10. Aircraft interior - Clean and vacuum. X

11. Record all malfunctions and abnormalities. X

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Maintenance Checks

No. Pre-Inspection / Engine Ground Test (Cont.) Reference Interval Initials100h other

10.06.16

1) Check has to be carried out every 100 hours of operation or 12 month, whichever comes first.

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1. Engine cowling - Remove engine cowling. Check for cracks, Xoverheated areas, deformation, loose or missing fasteners.Check condition of fire protect paint and heat resistanceshielding.

2. Engine oil change - Remove oil drain screw from oil tank. 12-12-00 X2) 50h1)

Drain old oil and dispose in accordance with environmental R912* 12-20-00 11)regulations.

3. Oil tank - Check oil tank and clean if contaminated. R912* 12-20-00 11) X1) 200h

4. Oil filter - Remove old oil filter from engine and install new 12-12-00 X2) 50h1)

oil filter. Lubricate mating sealing ring of new oil filter with R912* 12-20-00 11)engine oil. Tighten new oil filter by hand.

Cut open old oil filter without producing any metal chips andinspect filter mat for particles.

Findings:_____________________

5. Oil change - Renew gasket ring of drain screw on oil tank. 12-12-00 X2) 50h1)

Tighten drain screw to 25 Nm (221 in.lbs). R912* 12-10-00 4)Refill oil tank with approx. 3 liters of oil. For oil quality, see R912* 12-20-00 11)Operators Manual and SI-912-016. SI-912-010

SB-912-040Refilled:______________Quantity:_______L

DO NOT USE AIRCRAFT ENGINE OIL.

Due to the friction clutch and the high stressesin the reduction gear 4-stroke motor cycle oils arerecommended. For suitable lubricants and oil changeintervals, see ROTAX Operators Manual and latestappropriate ROTAX publications.

6. Visual inspection of the magnetic plug for accumulation R912* 12-20-00 12) X2) 50h1)

of chips

7. Check compression by differential pressure method. R912* 12-20-00 5) 200 hTest pressure: 6 bar (appr. 6000 hPa / 87 psi)Pressure drop: max. 25%Cyl. 1 2 3 4

Pressure drop: _____ _____ _____ _____

8. Cooling air ducts, engine baffling and cylinder cooling R912* 12-20-00 3) X2)

fins - Check for obstructions, cracks, wear and general SB-912-029condition. Check for signs of abnormal temperatures.Check crankcase for cracks.

9. Leakage bore at the base of the water pump - Check for R912* 12-20-00 4) X2)

signs of leakage.

CAUTION:

Page 405-20-00

Maintenance Checks

No. Engine Reference Interval Initials100h other

1) If more than 30% of operation hours have been flown with leaded fuel e.g.: AVGAS 100LL2) Check has to be carried out every 100 hours of operation or 12 month, whichever comes first.

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Page 505-20-00

Maintenance Checks

No. Engine (Cont.) Reference Interval Initials100h other

10. Cooling system - Renew coolant (conventional coolant only). 12-14-00 2 years3)

Flush the cooling system. R912* 12-20-00 9)

11. Coolant hoses and lines - Check for damage, leakage, 75-00-00 X1)

hardening due to heat, porosity, loose connections and R912* 12-20-00 9)secure attachments. Check routing for kinks and narrowbends.

12. Coolant expansion tank - Check for damage and 75-00-00 X1)

abnormalities. Inspect rubber protection plate on tank base R912* 12-10-00 3)for secure fit. Check coolant level, replenish as necessary. R912* 12-20-00 9)Check gasket of radiator cover, inspect pressure control valve, SB-912-043and return valve. The pressure control valve opensat 1,2 bar (18 psi). Check coolant with densimeter or glycoltester.

13. Overflow bottle - Inspect for damage and abnormalities. 75-00-00 X1)

Verify coolant level, replenish as necessary. Inspect venting R912* 12-10-00 3)bore in cap of overflow bottle for clear passage. Check R912* 12-20-00 9)line from exp. tank to overflow bottle for damage,leakage and clear passage.

14. Oil and coolant radiator - Check for obstructions, leaks 75-00-00 X1)

and security of attachment. If necessary, clean cooling fins 79-20-00and do a pressure leakage test.

15. Oil lines - Inspect for damage, leakage, hardening due to heat, R912* 12-20-00 4) X1)

porosity, security of connections and attachments.Check routing for kinks or narrow bends. Check fireprotection shielding.

16. Oil tank vent line - Check for proper routing, for obstructions X1)

and clear passage

17. Fuel lines - Check for damage, leakage, hardening due to heat, R912* 12-20-00 4) X1)

porosity, secure connections and attachments.Check routing for kinks or narrow bends. Check metal fuellines for cracks and scuffing marks.

18. Fuel selector / shut-off valve - Check for security of X1)

attachment. Check that the valve engages noticeableinto the positions LEFT, RIGHT and OFF.

19. Filter element of electrical fuel pump - Inspect and clean. 28-20-00 X1)

20. Battery - Clean. Check charge. Measure residual capacity 2). 12-17-00 X1)

Residual capacity must be at least 19Ah 2). If applicable, check 24-30-00acid level and vent case. If necessary, charge/replace battery.

21. Battery tray, terminals and cables - Check for security, 12-22-00 X1)

corrosion and general condition. Grease battery terminals.

22. Starter - Check security of attachment and electrical X1)

connections.

10.06.16

1) Check has to be carried out every 100 hours of operation or 12 month, whichever comes first.2) N/VFR equipped aircraft only.3) If SB-AT01-025 or SB-AT01-029 (retrofit of a new cooling system) has been carried out.

MAINTENANCE MANUAL

AQUILA AT01A

Page 605-20-00

Maintenance Checks

23. Alternator - Check attachment and V-belt tension. R912* 12-20-00 6) X2)

Inspect electrical connections.

24. Spark plugs - Remove all spark plugs, check the heat range R912* 12-20-00 13) X2)

designation, clean, check electrode gap and adjust if necessary.Replace as required.

25. Spark plug connectors - Check that resistance spark plug 200hconnectors fit tightly on the spark plugs.Minimum pull-off force is 30 N (7 lb).

26. Spark plugs - Replace spark plugs R912* 12-20-00 13) X 1) 200h

27. Oil temperature / oil pressure sensor - Check for tight fit X2)

and condition.

28. Exhaust system - Check attachment screws and springs X2)

for security and fit. Inspect system for damage and missingparts. Visual inspection of the muffler, exaust pipes andmounting flanges for cracks, corrosion and leakage.Check heat shielding for condition.

29. Cabin heat - Check heat shroud and heat ducts for damage X2)

and security of attachment. Check heat control function.

30. Exhaust muffler - Remove heat shroud from muffler 78-10-00 200hand inspect muffler for condition, corrosion and leakage.

FAILURE TO INSPECT MUFFLER FOR LEAKS COULDRESULT IN CARBON MONOXIDE ENTERING THE CABIN,LEADING TO SERIOUS INJURY OR DEATH!

31. Propeller gear box - Check the friction torque in free rotation. R912* 12-20-00 14) X2)

Actual friction torque is measured: _________Nm

32. Propeller gear box - Inspect overload clutch. R912* 05-50-00 2) 600h1)

SB-912-033

33. Propeller gear box - Check the propeller gearbox (with R912* 12-20-00 14) 1000hoverload clutch).

34. Carburetors - Check carburetor synchronization. Mechanical R912* 12-20-00 10) X2)

and pneumatic synchronization.

35. Carburetors - Inspect the float chamber assy for R912* 12-20-00 10) 200hcontamination and corrosion. SI-912-021

36. Carburetors - Check the ventilation of the float chambers. 200hAny trouble with float chamber ventilation impairs engineand carburetor function and must therefore be avoided.Check that the passage of the ventilation lines is free and thatno kinks can arise.

WARNING:


10.06.16

1) If more than 30% of operation hours have been flown with leaded fuel e.g.: AVGAS 100LL2) Check has to be carried out every 100 hours of operation or 12 month, whichever comes first.

MAINTENANCE MANUAL

AQUILA AT01A

37. Carburetors - Removal/assembly of the two carburetors for Rotax Heavy MM 200hcarburetor inspection. 73-00-00 3.1)

38. Carburetors - Check the free movement of the carburetor R912* 12-20-00 10) X2)

actuation (throttle lever and starting carburetor). Check thatthe Bowden cable allows full travel of the throttle lever fromstop to stop. Check Bowden cables for bulging with controllever in the full throttle position. Adjust throttle control if 76-00-00necessary. Lubricate carburetor throttle shaft. 12-22-00

39. Carburetor sockets and drip tray - Inspect the carburetor for Rotax Heavy MM 200hdamage and abnormalities, check for cracks, wear and good 73-00-00 3.4.3)condition. Take note of any changes caused by temperature. SB-912-030

40. Airbox assy - Check for damage, security of attachment and X2)

condition. Inspect connected air hoses for condition andleakage. Check that the flaps can be moved through theirfull arc of travel for hot and filtered ram air.

41. Air filter - Inspect and clean. Renew if necessary. Clean air R912* 12-20-00 2) X2)

filter casing. Check the drain hole at the bottom of casingfor obstructions or blockage.

42. Other external engine accessories - Inspect screws and nuts X2)

of all other external engine parts and accessories for tight fit.Inspect safety wiring if applicable, replace as necessary.

43. Engine mounts (manufactured by ROTAX and AQUILA) - R912* 12-20-00 3) X2)

Check mounts for deformation, cracks, corrosion, SB-912-028security and damage from heat. Check mounting bolts for SB-AT01-022condition and correct torque value.At engine (4 bolts M10): 40 Nm (354 in.lbs)At shock mounts (4 bolts M10): 25 Nm (221 in.lbs)At firewall (4 bolts M10): 30 Nm (266 in.lbs)Inspect shock mounts for deterioration.

44. Engine test run - Attach cowling and perform an engine test 17-10-00 X2) 50h1)

run as described above. After engine test run, re-tighten oil 05-20-00filter by hand and examine engine and engine compartment R912* 12-10-00 8)for signs of leakage. Compare results with first engine test

run. Check oil level, replenish as necessary.

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Maintenance Checks


1) If more than 30% of operation hours have been flown with leaded fuel e.g.: AVGAS 100LL.2) Check has to be carried out every 100 hours of operation or 12 month, whichever comes first.

10.06.16

MAINTENANCE MANUAL

AQUILA AT01A

1. Spinner - Remove from aircraft and check for delamination 61-10-00 Xand cracks.

2. Spinner plate - Check for cracks and fit. X

3. Blade root and hub area - Examine for oil and grease leaks. X

4. Propeller blades - Check blade play (up to 3 mm [1/8 in.] Xallowed).

5. Propeller blades - Check blade angle play. (max. 2°) X

6. Hub - Inspect outside condition of the hub and parts for Xcracks, corrosion and deterioration.

7. Check nuts for low pitch - Inspect for tightness and Xsafety wire.

8. Propeller assy - Check safetying. X

9. Propeller flange stop nuts - Check correct torque Xvalue (45 - 47 Nm [398 - 416 in.lbs]).

10. Propeller blades - Visual inspection for damage, repair if MT* 6.2) - 6.10) Xnecessary. Attach spinner.

11. Propeller governor - Visually inspect for signs of oil leakage. 61-20-00 XCheck bolts and nuts are tightened properly and safety wired.Check governor actuation for free movement and bulging.

Page 805-20-00

Maintenance Checks

1. Prepare aircraft for visual checks: XRemove cabin carpets and floorboards;Remove glare shield;Remove baggage compartment floorboard;Remove access panel of the baggage compartmentbulkhead;Remove access panel 210AB. 06-30-00

2. Fuselage shell - Visual inspection for paint coat damage, Xdents, cracks, holes, distortion and other evidence of failure.All unpainted parts for delamination (white spots).

3. Lower fin - Inspect fin and lower rudder for signs of Xbreakage. Check skid plate for wear.

4. Canopy - Examine the acrylic glass for cracking, crazing Xand general condition.Inspect tubular canopy hinge frame and brackets for cracks,distortion, corrosion, wear, and security of attachment.Check the gas spring strut for sufficient power andevidence of leakage.

No. Fuselage / Cabin Reference Interval Initials100h other

No. Propeller Reference Interval Initials100h other

10.06.16

MAINTENANCE MANUAL

AQUILA AT01A

Page 905-20-00

Maintenance Checks

5. Canopy locking - Check the canopy locking mechanism 52-10-00 Xoperates correctly. Check wear of parts. Check existence ofthe locking pin. The pin has to protrude the cover by approx.2 mm. Cases of lacking locking pins have to be reported to thetype certificate holder (contact information: see cover sheet).Check function of the locking pin. The canopy lockingmechanism must not be too smooth-running. In the lockedposition of the latch, a smooth running release of the latchdue to in-flight vibrations must not be possible.If necessary, readjust locking pin.

6. Lubricate canopy lock assembly. 12-22-00 annual

7. Baggage door - Check door seal, door latching mechanism, Xand door hinge for defects and condition. Lubricate if needed. 12-22-00Inspect door structure for cracks or other damage.

8. ELT - Perform ELT inspection. Check ELT mount and Velcro 25-62-00 annualstrap for security of attachment. Replace strap if necessary.

9. Seat belts/harnesses for pilot / co-pilot - Check components for Xcompleteness of the label, deformation, cracks, fractures,functioning of moveable parts, corrosion, surface finishcondition and security of attachment.Check textile components for damaged stitching, injuriousmarks, 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 Xaircraft structure. Check operation of seat adjustmentmechanism and seat stops. Inspect gas spring struts for oilleakage or other damage.

11. Seats - Check ease of movement - if required remove seats, 25-10-00 annualclean and lubricate seat rails.

12. Center Console - Visually examine the parts of the engine annualcontrols, lines and cables, located in the center console.

13. Main landing gear - Inspect fuselage structure at such Xpoints and areas where the main landing gear is attached.Check for stress marks, distortion, disbonding, anddelamination. Inspect main landing gear strut bracketsfor distortion, cracks, corrosion, and security of attachment.Check wear and condition of the polyamide inserts.Check bolts for correct torque.

14. Parking brake valve - Check for evidence of leakage especially Xat the brake line connections. Check control assy for damage.

15. Flap actuator - Check for wear and damage, for secure Xmechanical connections and loose or missing lock devices.Check electrical wiring for wear, damage, and proper routing.Inspect electrical connections and switches for security,corrosion and poor condition. Check function of the limitswitches and position indicator.

No. Fuselage / Cabin (Cont.) Reference Interval Initials100h other

10.06.16

MAINTENANCE MANUAL

AQUILA AT01A

16. Elevator trim system - Check the actuator and the springs Xfor security, wear and damage. Check safetying.Check electrical wiring for wear, insulationdamage, and proper routing.Inspect electrical connections and switches for security,corrosion and poor condition. Perform system test and checkthe correct function of the position indicator.

17. Aileron and elevator control - Check the control sticks, the Xbrackets and the control rods for distortion, cracks, chafing,corrosion and security. Examine all bearings for conditionand secure fit. Check safetying.Check travel of control surfaces if the control stick is in thefull forward /neutral/ aft, and full left /neutral/ right positions.Verify no binding or jumpy movement of the control sticksthrough their full range of travel.

18. Rudder control - Check rudder control weldment and rudder Xbellcrank for cracks, distortion, chafing and security. Examinerudder control support brackets, rudder pedal pivot bracketsand connection of the rudder controls with the nose gearsteering tubes for security, condition and correct splintering.Check centering of springs and cables. Inspect control cables,control cable guides, cable connections, turnbuckles andhardware for correct installation, corrosion, wear, safetyingand proper operation.

19. Rudder / aileron control interconnection - Check condition Xand correct function.

20. Rudder pedal bearing - Lubricate. 12-22-00 annual

21. Brake master cylinders and brake lines in the cabin Xarea - Check for security, condition and signs of leakage.

22. Brake reservoir - Check for leakage and system for trapped Xair. Inspect the vent valve in the filler cap of the brake reser-voir for obstruction and blockage. Make sure the hydraulicbrake fluid level is correct and replenish, if necessary.Only use hydraulic brake fluid of the required grade.

23. Hydraulic brake fluid - Renew. 12-15-00 2 years

24. Fuel lines - Check for leakage and security. X

25. Wing main bolts - Inspect for proper fit, condition and 57-10-00 Xcorrect safetying.

26. Wing main bolts - Remove for visual inspection and 57-10-00 500h1)

lubrication. 12-22-00 5years1)

orLube type used: ___________________ annual1)

27. Engine and propeller controls - Check for proper function, Xsecurity of attachment and for evidence of wear.

Page 1005-20-00

Maintenance Checks


10.06.16

1) Interval depends on lube type. Refer to 12-22-00.

MAINTENANCE MANUAL

AQUILA AT01A

1. Wings with winglets, ailerons, and flaps - Visual inspection Xfor paint coat damage, dents, cracks, holes, distortion andother evidence of failure. Examine all unpainted parts fordelamination (white spots).

2. Wing spars in the fuselage belly - Remove spar covering annualand perform visual inspection of the spar web, the bondingbetween the spar web and the carbon fiber spar cap strip,as well as the attachment of the root ribs to the spars. Checksecurity and function of control system brackets attached tothe spars.

3. Drain and vent holes - Check for blockage and suspect Xappearance of any liquid.

4. Ailerons - Check aileron hinges, bearings, and hinge brackets Xfor security and excessive play. Check hinge bushings andreplace if necessary. Check bolts and nuts for proper safetying.Examine aileron pushrod for correct installation with stop nuts.Check actuation assembly for suspect binding, excessive play.

5. Aileron hinges - Check play. Maximum play approx.: X- Axial ± 1,00 mm (± 0.04 in.)- Radial ± 0,30 mm (± 0.01 in.)

6. Aileron control system - Measure the play in the aileron Xcontrol 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 bothcontrol sticks. If excessive play is detected, investigate cause.

7. Flaps - Check hinge brackets for damaged paint, cracks and Xdelamination. Check bearings for correct fit and excessive play.Check hinge bushings and replace if necessary. Check correctsafetying of all hinge bolts and castle nuts with cotter pins.

8. Flap hinges - Check play. Maximum play approx.: X- Axial ± 0,30 mm (± 0.01 in.)- Radial ± 0,30 mm (± 0.01 in.)Measure the play in the flap control system at the flap trailingedge, at the inboard flap end. Max. play allowed with flaps intake-off and landing positions: ± 5 mm (0.2 in.). No play withflaps retracted.

Page 1105-20-00

Maintenance Checks

No. Wings, Ailerons, Flaps Reference Interval Initials100h other

10.06.16


28. Exterior / interior placards and markings - Check presence, 11-20-00 Xlegibility, and security. 11-30-00

29. Fire extinguisher - Check for physical damage, corrosion, annualleakage or clogged nozzle. Weigh unit to determine fullness.Check for obstructions to access or visibility, safety seal is notbroken or missing, HMIS label in place, instructions are legible.

MAINTENANCE MANUAL

AQUILA AT01A

1. Empennage - Inspect complete surface of the vertical and Xhorizontal stabilizers, the elevator and the rudder fordents, cracks, holes and delamination.

2. Rudder hinge, elevator hinge and bellcranks - Check brackets Xand bellcranks for security of attachment and corrosion.Examine bearings for binding and excessive play. Check hingebushings and replace if necessary. Check correct safetying ofthe lower rudder pivot pin with castellated nut and cotter pin.

3. Hinge play and control surface positioning - Verify clearance annualbetween horizontal stabilizer and elevator horns andclearance between vertical stabilizer and rudder horn is atleast 1 mm (0.04 in.). Check elevator hinge and rudderhinge play. Maximum play approx.:- Axial ± 0,30 mm (± 0.01 in.)- Radial ± 0,30 mm (± 0.01 in.)

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Maintenance Checks

No. Reference Interval Initials100h other

Empennage, Elevator, Rudder

10.06.16

No. Wings, Ailerons, Flaps (Cont.) Reference Interval Initials100h other

9. Flaps and ailerons - Check that the gap between fuselage and Xflaps, between flaps and ailerons, and at the outboard end ofthe ailerons is at least 2 mm ( 0.08 in.).

10. Stall warning system - Check for condition and proper Xoperation.

11. For serial numbers from AT01-100 to AT01-126: 57-10-00 annualBonding between wing spar and upper shell - Check SB-AT01-002condition.

12. Navigation / strobe lights - Check operation, condition 33-40-00 Xof glass, and security of attachments.

13. Inner fuel tank ribs - Check connection of fuel and vent 28-10-00 annuallines to the fuel tank and the flange gasket of the fuel level 28-20-00sensors for signs of leakage. 28-40-00

14. Fuel vent lines - Check for blockage. X

15. Fuel tank drain valves - Check for correct function and Xleakage.

16. Fuel filler caps - Check for proper function and leakage. X

17. Tank inlet and upper wing shell in the fuel tank area - Check SB-AT01-027 annualsealing of the bore hole in the tank inlet. Check wing skin forbubble formation or bulging.

18. Tie-down points - Check thread and structure around the tie- 10-20-00 Xdown attach points for any damage.

MAINTENANCE MANUAL

AQUILA AT01A

1. Wheel fairings - Check condition and correct fit. Remove and Xclean. Check for paint coat damage, cracks, dents anddelamination.

2. Fairing mounts - Inspect for cracks, distortion or other damage. X

3. Nose gear strut mount and wheel fork - Check for deformation, Xcracks and corrosion. Check nose gear strut journal bearing forproper operation, play and correct safetying.

4. Nose gear strut and elastomer package - Check strut for Xdeformation, stress marks, and cracks. Inspect correctinstallation of the nose wheel fork. Inspect elastomer packagefor wear, deterioration, cracks, correct fit and security.Check journal bearings of the elastomer package for play andcondition.

5. Nose wheel steering - Inspect nose wheel steering tubes for Xcondition, excessive play and correct safetying. Check returnsprings at nose gear strut for security and verify they aretension-free, when the nose wheel is in neutral position.

6. Main landing gear - Check main gear struts for deformation, Xcracks, damage to the paint coat, and corrosion. Inspect

wheel axles for security of attachment to struts and for anydamage.

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Maintenance Checks

10.06.16


Nose and Main Landing Gear

No. (Cont.) Reference Interval Initials100h other

Empennage, Elevator, Rudder

4. Elevator control system - Measure the play in the elevator annualcontrol system with the control surface locked. Apply a forceof 50 N (11.2 lb) forwards and then backwards to the controlstick - the maximum play allowed on the top of the stick is10 mm (0.4 in.) for both sides.

5. Rudder - Remove rudder if there is noticeable play. 55-40-00 annualExamine the elevator actuation assembly inside the verticalstabilizer. Check for any damage, for correct installationand function and for security and wear.Inspect rudder hinge brackets, rudder yoke and control cablethimble-eyes for security, conditions and wear.Lubricate control cable thimble-eyes as required.

6. Rudder rigging - Set rudder pedals in neutral position. 27-20-00 XVerify the rudder and the nose landing gear are also inneutral position. Set rudder pedals to fully left and thento full right. The rudder must hit the rudder travel stopsand the distance from rudder pedal to firewall must besufficient to apply the pedal brake. Adjust position ofthe rudder pedals by varying the length of nose wheelsteering tubes. Adjust rudder neutral position and controlcable tension by means of the turnbuckles in the cabin area.

MAINTENANCE MANUAL

AQUILA AT01A

7. Wheels and rims - Clean. Check tires for wear, cuts, Xforeign matter and deterioration. Inspect rims for security,deformation, cracks and other damage. Examine wheelbearings for excessive play, corrosion and irregular operation.Check tire pressure and proper location of the red slide marks.

8. Wheel bearings - Clean and lubricate. 12-22-00 500hannual

9. Wheel brakes - Clean. Apply brakes, examine system for leaks. 32-40-00 XInspect brake fluid carrying lines at the main landing gear forcondition, leakage and security of attachment. Inspect brakediscs for cracks, corrosion and wear. Replace brake discs ifworn below 4.3mm (0.17 in.). Inspect brake pads for conditionand wear. Replace linings when worn to 2.6mm (0.10 in.).Check freedom of movement of the pistons and pressure plates.

10. Wheel axles - Clean. Visually inspect for cracks, nicks, every wheelcorrosion or other damage. removal

1. Electrical wiring system - Check the complete electrical R912* 12-20-00 13) X1)

wiring system for security, damage, wear and secure fit.Check all cable connections for tight fit, good contact,corrosion and condition.

2. Tank inlet bonding wires - Check bonding between electric annualground (exhaust port) and tank inlet (max. 1 ).

3. Tank inlet bonding wires - Check bonding wires at the SB-AT01-027 annualairframe ground tube for yellow discoloration.

4. Instruments - Check instrument panel mounting brackets for annualsecurity and condition. Examine instruments for security ofattachment. Check electrical cables, hoses and lines for correctinstallation, condition and proper routing. Inspect air filterof the pitot / static system for obstructions and contamination.

5. Pitot / static system - Check pitot tube for security of 34-11-00 Xattachment, condition and obstructions. Check pitot andstatic pressure lines for correct installation, condition,water and proper routing. Check water traps for water.2)

6. Pitot heating system - Carefully check pitot tube for heating up X2)

with pitot heating switched ON.

RISK OF SKIN BURNS! DO NOT TOUCHPITOT TUBE WHEN HEATING IS SWITCHED ON!

Ω

WARNING:

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Maintenance Checks


Electrical System / Avionics

10.06.16


Nose and Main Landing Gear (Cont.)

1) Check has to be carried out every 100 hours of operation or 12 month, whichever comes first.2) If installed.

MAINTENANCE MANUAL

AQUILA AT01A

1. Install wheel fairings. XInstall seats (if removed).Install cabin floor boards.Install baggage compartment floorboard.Install access panel of the baggage compartment bulkhead.Install access panel 210AB. 06-30-00

2. Flight controls - Check for full range of travel and excessive Xfriction.

3. Flaps - Operate through full extension and retraction for Xsteady and complete deployment. Check correct limitswitches operation at CRUISE, T/O and LDG flap positions.Verify the corresponding flap switch position and thecorresponding flap position indicator reading.

4. Elevator trim - Check for full range of travel and excessive Xfriction. Inspect proper operation of the trim control switch,limit switches, and the trim position indicator. Verify thatelevator control forces decrease or increase whenoperating elevator trim.

5. Engine and propeller controls - Check full range of motion Xwithout 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


Return to Service

Page 1505-20-00

Maintenance Checks

10.06.16

No. (Cont.) Reference Interval Initials100h other

Electrical System / Avionics

7. Garmin G500 system - Check all components and wiring for 34-25-00 X1) 2)

damage, corrosion, proper operation and security ofattachment.

8. Garmin G500 system - Check bonding. 34-25-00 2000h2)

10 years2)

9. Aspen EFD1000 system - Check all components and wiring for 34-25-00 annual2)

damage, corrosion, proper operation and security ofattachment. Perform bonding check.

1) Check has to be carried out every 100 hours of operation or 12 month, whichever comes first.2) If installed.

MAINTENANCE MANUAL

AQUILA AT01A

The aircraft is airworthy and meets the condition specified in the aircraft data sheet. All maintenance required by ServiceInformation and Airworthiness Directives and all prescribed scheduled maintenance checks have been carried out.

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 1605-20-00

10.06.16

MAINTENANCE MANUAL

AQUILA AT01A

Page 1705-20-00

10.06.16

Maintenance Checks

3.

A. The airframe of the type AQUILA AT01 is limited to 6.000 hours of flight time (refer to 04-00-00).An inspection program to reach an extension of replacement time can be obtained from the typecertificate holder on request.For all S/N`s having performed the 6000-hour inspection and possible maintenance actionsresulting thereof no further life time limit beyond 6000 operating hours will be established and thecomposite structure is then considered to have "Safe Life".

B. All inspection items listed in the following table ”6000-Hour Inspection Checklist” must beperformed within . The inspection

listed for theairframe (refer to “Inspection Time Intervals Chart” above).All items performed, all findings discovered and their follow up corrections have to be recorded inacc. with an approved quality procedures manual.

6000-Hour Inspection

every 6000 hours of flight time must be performed inconjunction with a 100-hour inspection including all annual inspection items

NOTE: The first 6000-hour inspection is replaced by an inspection program to reach anextension of life time (refer to 04-00-00). It can be obtained from the type certificateholder on request.

C. The inspection table shows three different types of inspections listed in the column“Method/Inspection”:

V Visual inspectionT Tap testF Functional / fit check

Refer to 51-10-00 for a description of visual inspection and tap test methods.

D. Prior to inspection all aircraft log-books have to be checked to establish the aircraft data set and therepair history of the aircraft.

Before starting the 6000-hour inspection the following actions are required:(1) Fix the fuselage on jacks (refer to 07-10-00).(2) Remove wing (refer to 57-00-00).(3) Remove rudder (refer to 55-40-00).(4) Remove elevator (refer to 55-20-00).(5) Remove ailerons (refer to 57-50-00).(6) Remove flaps (refer to 57-50-00).(7) Remove cowling (refer to 71-10-00).

MAINTENANCE MANUAL

AQUILA AT01A

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10.06.16

Maintenance Checks

Aircraft S/N Operating Hours RegistrationTTSN

Engine S/N Operating Hours DateTTSN / TTSO

Propeller S/N Operating Hours DateTTSN / TTSO

Number

E. 6000-Hour Inspection Checklist

Root Ribs (in front of and behind wing spar)

Inner Flap Hinge Support Rib

Wing Main Spar

Upper and Lower Wing Shell

1. Bonding area of ribs to the wing shell - delamination, cracks. V, T

2. Condition of rib laminate, delamination, cracks. V, T

3. Bonding area at the main wing spar web. V

4. Wing attachment bolt bushing - bonding in the rib. V

5. Condition of bushing, wear of bearing area, corrosion. V

6. Bonding area of rib to the wing shell - delamination, cracks. V, T



9. Areas around bushing - delamination, cracks. V

10. Condition of ball bearing, wear, corrosion. V

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 root rib and Vinspection opening in lower wing shell. Bonding to the wingshell (cracks), condition of the main shear web (delamination).

14. Wing shell - delamination, cracks, scratches in shell surfaces, V, Tchipping of paint, UV damage.

15. Wing shell - core damage and dents in sandwich, disbond of V, Tshell laminate from core material.

No. Inspection Items Inspection Finding / InitialsMethod ConditionLeft Wing

MAINTENANCE MANUAL

AQUILA AT01A

Page 1905-20-00

10.06.16

Maintenance Checks

No. Inspection Items Inspection Finding / InitialsMethod ConditionLeft Wing (Cont.)

16. Areas around inspection openings - delamination, cracks. V

17. Wing leading edge bonding area - disbonds, cracks. V, T

18. Area around pitot-static tube opening - delamination, cracks. V, T

19. Area around tie-down fixation point - delamination, cracks. V, T

20. Area around NAV-light opening - delamination, cracks. V

21. Area around winglet root upper wing shell - cracks. V, T

22. Area around ring insert of the tank filler - cracks, disbonding. V, T

23. Wing trailing edge, flap area - bonding lower to upper shell, V, Tdisbond, cracks.

24. Wing trailing edge, flap area - laminate condition, cracks. V

25. Wing trailing edge, aileron area - bonding area shear web to V, Twing 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




Trailing Edge Shear Web

Tank Rib

No. Inspection Items Inspection Finding / InitialsRight Method ConditionWing

Root Ribs (in front of and behind wing spar)

1. Bonding area of ribs to the wing shell - delamination, cracks. V, T



4. Wing attachment bolt bushing - bonding in the rib. V

5. Condition of bushing, wear of bearing area, corrosion. V

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Maintenance Checks

No. Inspection Items Inspection Finding / InitialsRight Method ConditionWing (Cont.)

Inner Flap Hinge Support Rib

Wing Main Spar

Upper and Lower Wing Shell

Trailing Edge Shear Web




9. Areas around bushing - delamination, cracks. V

10. Condition of ball bearing, wear, corrosion. V

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 root rib and Vinspection opening in lower wing shell. Bonding to the wingshell (cracks), condition of the main shear web (delamination).

14. Wing shell - delamination, cracks, scratches in shell surfaces, V, Tchipping of paint, UV damage.

15. Wing shell - core damage and dents in sandwich, disbond of V, Tshell 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 - delamination, cracks. V

20. Area around winglet root upper wing shell - cracks. V, T

21. Area around ring insert of the tank filler - cracks, disbonding. V, T

22. Wing trailing edge, flap area - bonding lower to upper shell, V, Tdisbond, cracks.

23. Wing trailing edge, flap area - laminate condition, cracks. V

24. Wing trailing edge, aileron area - bonding area shear web to V, Twing shell, disbonds, cracks.

25. Wing trailing edge, aileron area - laminate condition, cracks. V

26. Bonding left an right of hinge levers for flap and aileron. V, T

27. Aileron hinge levers - delamination at bolt area, bolt corrosion. V

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No. Inspection Items Inspection Finding / InitialsRight Method ConditionWing (Cont.)

28. Flap hinge levers - delamination at bolt area, bolt corrosion. V


30. Condition of rib laminate - delamination, cracks. V, T


Tank Rib

No. Inspection Items Inspection Finding / InitialsControl Surfaces Method Condition

Ailerons

Flaps

1. Aileron surfaces - Check for delamination of shells, scratches. V, T

2. Paint surfaces - Check for condition, scratches, UV damage, Vchipping of paint.

3. Damage of core, dents to core, disbond between core and skin. V, T

4. Aileron trailing 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 - Vdelamination 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 repairs and repaintings. VIf so, check aileron mass and static moment to be withinspecified limits (refer to 57-50-00).

11. Flap surfaces - Check for delamination of shells, scratches. V, T



14. Flap trailing and leading edges - bonding delamination. V, T

15. Inner and outer flap ribs - bonding delamination with skin. V, T

16. Check condition of drain holes in inner and outer ribs. V

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No. Inspection Items Inspection Finding / InitialsControl Surfaces Method Condition(Cont.)

17. Areas around hinge fasteners - delamination from skin, cracks. V

18. Condition of control horn bearing, corrosion, play. V


20. Inspect for previously performed repairs and repaintings. VIf so, check flap mass and static moment to be withinspecified limits (refer to 57-50-00).

21. Rudder surfaces - Check for delamination of shells, scratches. V, T



24. Rudder trailing and leading edges - bonding delamination. V, T

25. Lower rudder hinge rib - 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. VIf so, check rudder mass and static moment to be withinspecified limits (refer to 55-40-00).

31. Bolts at lower hinge - Check for condition, cracks, corrosion, Vthread.

32. Elevator surfaces - Check for delamination of shells, scratches. V, T


34. Damage of core, dents in core, disbond between core and skin. V, T

35. Elevator trailing and leading edges - bonding delamination. V, T

36. Inner elevator ribs - bonding delamination with skin. V, T

37. Check condition of drain holes in inner ribs. V

38. Areas around hinges - delamination from skin, cracks. V

39. Mass balance horn - Check for cracks and delamination. V, T

Rudder

Elevator

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No. Inspection Items Inspection Finding / InitialsControl Surfaces Method Condition(Cont.)


41. Inspect for previously performed repairs and repaintings. VIf so, check elevator mass and static moment to be withinspecified limits (refer to 55-20-00).

42. Bolts at inner hinge - Check for condition, cracks, corrosion, Vthread.

No. Inspection Items Inspection Finding / InitialsHorizontal Stabilizer Method Condition

1. Stabilizer surfaces - Check for delamination of shells, scratches. V, T



4. Stabilizer leading edges - Check for bonding delamination. V, T

5. Trailing edge spar - Check for cracks and bonding V, Tdelamination with skin.

6. Areas around hinge supports in trailing edge spar - Check Vfor cracks and delamination.


No. Inspection Items Inspection Finding / InitialsFuselage Method Condition

Fuselage Skin Structure and Vertical Stabilizer Skin

1. Skin surfaces - Check for delamination of shells, scratches. V, T



4. Areas near bonding seam at centerline on upper and lower V, Tfuselage surfaces - Inspect for cracks in paint.

5. Check condition of drain holes in lower fuselage. V

6. Inspect for previously performed repairs and repaintings. V

7. Areas near bonding seam at connection between horizontal Vand vertical stabilizer on upper and lower horizontal surfaces -Inspect for cracks in paint.

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No. Inspection Items Inspection Finding / InitialsFuselage Method Condition(Cont.)

Fuselage / Wing Interconnection

Bulkheads, Ribs and Hinges in Vertical Stabilizer

Firewall

8. Root ribs and intersection to fuselage - Check for cracks in Vpaint and structure.

9. Area around wing attachment bolt bushings - Check for cracks Vand disbonding.

10. Wing attachment bolt bushings - Check for wear, scratches, Vcorrosion and tightness of fit with the bolt.

11. Seat bulkhead and forward landing gear bulkhead in spar V, Tbridge - Check condition of laminate and bonding areas withthe fuselage shell.

12. Forward landing gear bulkhead - Check laminate around V, Tfasteners of landing gear supports for cracks and delamination.

13. Upper and lower shear web in vertical stabilizer - Check for Vdelamination and cracks.

14. Upper and lower shear web in vertical stabilizer - Check V, Tbonding 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 - VCheck laminate.

18. Bushing in lower hinge bracket - wear, corrosion, fit/play. V

19. Lower end of the stabilizer (bumper) - delamination, cracks. V

20. Bumper plate at lower end of the stabilizer - Check fixation Vand condition.

21. Check firewall bulkhead (from cockpit side) for cracks in the Vlaminate (around cut outs).

22. Firewall bulkhead - Check bonding to the fuselage skin. V, T

23. Areas around engine brackets - delamination, cracks. V, T

24. Firewall metal shield - condition, wear, corrosion. V

25. Fire resistant firewall sealer around the fire shield - condition, Vcorrosion.

26. Areas around Camloc fasteners at fuselage cowling support - VCheck laminate for cracks and delamination.

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27. Area around pedal control brackets - delamination, cracks. V

28. Front cockpit floor - Check for delamination and cracks. V, TCheck bonding area to the fuselage structure for disbonding.

29. Front shear bulkhead - Check for delamination and cracks. V, TCheck bonding area to the fuselage structure for disbonding.

30. Front seat bulkhead - Check for delamination and cracks. V, TCheck bonding area to the fuselage structure for disbonding.

31. Seat elements and attachments - delamination, cracks. V, T

32. Rear seat bulkhead - Check for delamination and cracks. V, TCheck bonding area to the fuselage structure for disbonding.

33. Front landing gear bulkhead - Check for delamination and V, Tcracks. Check bonding area to the fuselage structure fordisbonding.

34. Rear landing gear bulkhead - Check for delamination and V, Tcracks. Check bonding area to the fuselage structure fordisbonding.

35. Baggage bulkhead - Check for delamination and cracks. V, TCheck bonding area to the fuselage structure for disbonding.

36. Lower lap belt attachments - Check for delamination and Vcracks. Check bonding area to the fuselage structure fordisbonding.

37. Lower lap belt fitting - Check for wear and corrosion. V

38. Upper lap belt attachments - Check for delamination and V, Tcracks at the baggage bulkhead.

39. Baggage compartment floor supports - Check for delamination Vand cracks. Check bonding area to the fuselage structure fordisbonding.

40. Gas spring supports - Check for delamination and cracks. VCheck bonding area to the fuselage structure for disbonding.

41. Composite tube stiffener and attachments - Check for Vdelamination and cracks. Check bonding area to the fuselagestructure for disbonding.

42. Baggage compartment door, doorframe and supports - Check Vfor delamination and cracks. Check bonding area to thefuselage structure for disbonding.

43. Tailboom bulkheads - Check for delamination and cracks. VCheck bonding area to the fuselage structure for disbonding.

Cockpit Area and Baggage Compartment

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44. Elevator control lever mounting supports on baggage Vbulkhead - Check for delamination and cracks. Check bondingarea to the fuselage structure for disbonding.

45. Flap actuator mounting supports in middle tunnel - Check for Vdelamination and cracks. Check bonding area to the fuselagestructure for disbonding.

46. Canopy frame (at the fuselage) - Check for delamination and V, Tcracks.

47. Step supports - Check for delamination and cracks. Check Vbonding area to the fuselage structure for disbonding.

48. Check step component for wear and corrosion. V

49. Canopy frame - Check for delamination and cracks. Check Vbonding area of Plexiglas to the canopy frame structure fordisbonding.

50. Canopy latching components - corrosion, wear, damage. V

51. Canopy pin and bushing components - Check for corrosion, Vwear and fit/play.

52. Canopy Plexiglas including side windows - cracks, damage. V

Canopy

No. Inspection Items Inspection Finding / InitialsLanding Gear Method Condition

Main Landing Gear

Nose Landing Gear and Engine Mount

1. Main landing gear struts - Check condition (distortion, Vcorrosion, wear and paint damages).

2. Remove main wheels from axles and check axles for distortion, Vcorrosion, wear and damages.

3. Check inner and outer main brackets for fit of shims, cracks Vand wear.

4. Nose landing gear main strut and wheel fork - Check Vcondition (cracks, distortion, corrosion, wear and paintdamages).

5. Nose wheel steering tubes - Check condition (cracks and Vdistortion).

6. Engine mount - Check the entire tube frame and all welded Vjoints, in particular at the firewall and nose gear suspension,for distortion, wear and cracks.

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No. Inspection Items Inspection Finding / InitialsLanding Gear Method Condition(Cont.)

7. Engine mount attachment bolts - Check for cracks and wear. V

8. Nose wheel axle - Check for cracks and distortion. V

The aircraft is airworthy and meets the condition specified in the aircraft data sheet.All prescribed 6000-hour inspection items and maintenance actions resulting thereof have been carried out.

Service Station:

Place, Date

Name, Signature of Mechanic Name, Signature of Inspector Stamp

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05-30-00

DAILY INSPECTIONS

1.

A. Pre-flight and post-flight checks must be carried out daily when the aircraft is in operation.

2.

A. This check must be carried out before the first flight of the day. In this way, the general conditionof the aircraft and its engine can be ascertained.

The scope of the pre-flight check is listed in the AQUILA AT01 Flight Manual, section 4.

3.

A. This check should be carried out after the final flight of the day. For the most part, it is a visualinspection.

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 parked (refer to 10-10-00).(c) Check the logbook entries for remarks about faults or defects, and for correct number of

landings and flight hours.(d) If necessary, moor the aircraft (refer to 10-20-00).

General

Pre-Flight Check

Post-Flight Check

Pre-flight checks are essential for flight safety asnumerous accidents can be traced back to inadequate pre-flight checks.

Maintenance Checks

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05-50-00

Maintenance Checks

UNSCHEDULED MAINTENANCE CHECKS

1.

A. Special checks are to be carried out when an incident has occurred that may have caused damageto the aircraft or impaired airworthiness.

In addition, a 25-hour inspection must be carried out on new aircraft and its engine, onoverhauled engines and after extensive airframe repairs.

2.

A. 25-Hour InspectionAfter the first 25 hours of operation of a new aircraft and its engine or an overhauled engine orafter extensive airframe repairs, an inspection of the extent of a 100-hour inspection must becarried out (refer to 05-20-00).

After the first 25 hours of operation of a new or overhauled engine, the engine and the propellermust be inspected. Refer to ROTAX Aircraft Engines Maintenance Manual for ROTAX EnginesType 912 Series for detailed information on this inspection.

B. Hard LandingAfter an excessively hard landing or other unusual loading of the landing gear a thoroughinspection of the affected components and their attachments is required. Even if no obviousdefects 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 brackets (refer to 25-12-00).(2) Inspect main landing gear.

(a) Check wheel fairings for cracks, dents and delamination.(b) Check fairing mounts for cracks, distortion and other damage.(c) Check fuselage structure visually at such points and areas where the main landing gear

is attached. Check for stress marks, distortion, disbonding, and delamination. Checkmain landing gear strut brackets for distortion, cracks and security of attachment. Checkcondition of the polyamide inserts. Check bolts for correct torque.

(d) Check main gear struts for deformation and cracks. Examine wheel axles for security ofattachment to struts and for any damage.

(e) Inspect tires for integrity and proper location of the red slide marks.(f) Inspect brake fluid carrying lines at the main landing gear for condition, leakage, and

security of attachment.

General

Special Checks

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Maintenance Checks

(3) Inspect nose landing gear.(a) Check wheel fairing for cracks, dents and delamination.(b) Inspect fairing mounts for cracks, distortion and other damage.(c) Check nose gear strut mount for deformation and cracks. Check nose gear strut journal

bearing for proper operation and play.(d) Check strut for deformation, stress marks, and cracks. Check elastomer package for

deterioration, cracks, correct fit and security. Check journal bearings of the elastomerpackage for play and condition.

(e) Inspect nose wheel steering tubes for condition and excessive play.(f) Inspect tire for integrity and proper location of the red slide marks.

(4) Re-mount all items removed during the inspection.(5) Perform a brake and steering system operational test (refer to 32-40-00).

C. Engine FireAfter an engine fire, carry out the following:

IF IT IS SUSPECTED THAT PARTS OF THE STRUCTURE OR COWLING COULDHAVE BEEN DAMAGED BY HIGH TEMPERATURES (INDICATED BYBLISTERING ON THE PROTECTIVE COATING), THE MANUFACTURER MUSTBE CONTACTED FOR DEFECT APPRAISAL BEFORE THE AIRCRAFT ISFLOWN AGAIN.

(1)(2)(3)(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) Check all other hoses and pipes, as well as all gaskets and seals for fire damage.(10) Replace damaged items.(11) Re-mount engine cowling (refer to 71-10-00).(12) Perform an engine test run (refer to 05-20-00).

D. Violent Stop of the EngineIn event that the propeller has touched the ground or the engine has been inadvertently stoppedviolently (shock loading), the propeller gear box must be disassembled and inspected by anauthorized workshop. For further information on engine inspections necessary after a propellerground strike and for more general information, refer to the relevant technical documents and theROTAX Maintenance Manual.

ONLY QUALIFIED TECHNICIANS (AUTHORIZED BY THE NATIONALAVIATION AUTHORITY AND AFTER SUCCESSFULLY COMPLETING THERELEVANT ROTAX TRAINING COURSE) ARE AUTHORIZED TO PERFORMTHIS WORK.

Check additional equipment (external alternator, hydraulic governor, ignition unit, coolant and oilhoses) for damage.

WARNING:

CAUTION:

Remove engine cowling (refer to 71-10-00).Examine engine cowling. Check for signs of fire damage.Disconnect battery (refer to 24-30-00).

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CHAPTER 24

ELECTRICAL POWER

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Page 124 - TOC

Electrical Power

TABLE OF CONTENTS

ChapterSection

ELECTRICAL POWER - GENERAL...............................................................24-00-00 1Introduction 24-00-00 1General Description 24-00-00 1

ELECTRICAL POWER - TROUBLESHOOTING.........................................24-00-00 101Troubleshooting 24-00-00 101

ALTERNATOR SYSTEM - DESCRIPTION....................................................24-20-00 1Introduction 24-20-00 1Description and Operation 24-20-00 1

ALTERNATOR SYSTEM - MAINTENANCE ................................................24-20-00 201General 24-20-00 201External Alternator Removal/Installation 24-20-00 201

BATTERY SYSTEM - DESCRIPTION ............................................................24-30-00 1Introduction 24-30-00 1Description and Operation 24-30-00 1

BATTERY SYSTEM - MAINTENANCE..........................................................24-30-00 201General 24-30-00 201Battery Removal/Installation 24-30-00 201

EXTERNAL POWER - MAINTENANCE.......................................................24-40-00 201 Ext. powerGeneral 24-40-00 201 Ext. powerExternal Power Receptacle Removal/Installation 24-40-00 201 Ext. powerExternal Power Relay Removal/Installation 24-40-00 201 Ext. powerAdjustment/Test 24-40-00 203 Ext. powerInspection/Check 24-40-00 203 Ext. power

ELECTRICAL LOAD DISTRIBUTION - DESCRIPTION............................24-60-00 1Introduction 24-60-00 1Description and Operation 24-60-00 1

CIRCUIT BREAKER - MAINTENANCE........................................................24-61-00 201General 24-61-00 201Circuit Breaker Removal/Installation 24-61-00 201

Title Subject Page Effectivity

External Alternator Drive Belt Removal/Installation 24-20-00 201Rectifier-Regulator Unit Removal/Installation 24-20-00 203 Night-VFR

Battery Relay Removal/Installation 24-30-00 201Battery Condition Check 24-30-00 203

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ELECTRICAL SYSTEM WIRING - MAINTENANCE..................................24-97-00 201General 24-97-00 201Splicing 24-97-00 201Wire Replacement 24-97-00 201


ChapterSection

Title Subject Page Effectivity

24 - TOCPage 2

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24-00-00

Electrical Power

ELECTRICAL POWER - GENERAL

1.

A. This chapter describes the units and components, which generate, control and supply AC and DCelectrical power for other systems.

2.

A. The aircraft is equipped with a 12V DC electrical system. It is powered by a belt driven 600Walternator and a 12V battery which is installed on the front-right side of the firewall.All essential electrical accessories in the system are protected by circuit breakers. These are to befound on the right side of the instrument panel.Electrical power distribution to the various accessories is characterized through functionality andsafety. It is accomplished by two main bus bars - the aircraft bus bar and the avionics bus bar.

If the aircraft is equipped for Night-VFR, the internal alternator integrated in the ROTAX engine isactivated in order to provide a second independent power source.To supply DC to the aircraft electrical system this permanent magnet generator is used incombination with a ROTAX specified rectifier-regulator, which is installed at the front-left side ofthe firewall.

As an option, the aircraft may be equipped with an external power receptacle mounted on theright side of fuselage just forward of the firewall. The receptacle permits the use of an externalpower source for cold weather starting and maintenance procedures requiring reliable power foran extended period.

Introduction

General Description

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ELECTRICAL POWER - TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE REMEDY

1.

A. If a power problem or a complete blackout occurs, first check all connections to the componentsand the circuit breakers.

B. Troubleshooting Chart:

No alternator ALT 1 switch OFF Turn switch ON.output, voltmeter Defective alternator Replace alternator.indicates 12 V, Circuit breaker activated Troubleshoot circuit and reset circuitammeter indicates (open) breaker.discharge

Battery will not Battery is discharged Step 1:supply power or Place BAT switch and LDG LIGHTis incapable of switch in ON Position. Measure batterycranking engine. voltage. A normally charged battery

will indicate 12,5 volts or more. If .voltage is low, proceed to step 2.If voltage is normal proceed to step 3.

Defective battery Step 2:Charge battery approx. 30 minutes.If the battery tester indicates a goodbattery, the cause was a dischargedbattery. If the tester indicates a defectivebattery, replace the battery.

Defective wiring or electrical Step 3:connection between battery With switch BAT in ON position,terminal and battery relay. measure voltage between battery terminal

and battery relay.Correct value would be 0 V.If voltage reads 0 V, proceed to step 4.If a voltage reading is obtained, checkwiring between battery terminal andbattery relay.

Defective battery relay. Step 4:With switch BAT in ON position,measure voltage between relay terminals.Correct value would be 0 V.If voltage reads 0 V, proceed to step 5.

Troubleshooting

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Electrical Power

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If a voltage reading is obtained, replacebattery relay.

Defective wiring or electrical Step 5:connection between battery With switch BAT in ON position,relay and starter relay. measure voltage between starter side relay

terminal, and starter relay.

If a voltage reading is obtained, checkwiring between starter side relay terminaland starter relay

Correct value would be 0 V.

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24-20-00

ALTERNATOR SYSTEM - DESCRIPTION

1.

A. The alternator system supplies the electrical equipment with electrical power when the engine isrunning and is the main current source in the power supply design.

B. The alternator system consists of the following components:

- external alternator- alternator circuit breakers- alternator warning light(s)- alternator

2.

A. The external alternator (ALT 1) is installed in the forward left side of the engine, to the left of thegearbox. It is belt-driven and incorporates an internal voltage regulator.

The alternator circuit breaker is installed in the circuit breaker panel on the far right side of theinstrument panel and it protects the system from overloading. The red ALT 1 warning light islocated in the row of annunciator lights on the instrument panel and indicates undervoltage.

Introduction

Description and Operation

switch- internal alternator (only Night-VFR equipped aircraft)- rectifier-regulator unit (only Night-VFR equipped aircraft)

The external alternator issupplied with an excitation voltage by the battery when the ALT1/BAT switch is turned ON. Whenthe engine is running, the alternator generates a three-phase current that is rectified and regulatedby the internal voltage regulator. The voltage regulator supplies a 14 V DC voltage to the aircraftbus when engine speed is at or above 800 rpm. The maximum current load is approx. 45 A.

B. Aircraft equipped for Night-VFR additionally use the internal alternator (ALT 2) integrated in theROTAX engine as a second independent power source. This permanent magnet alternator (250W)does not need any external voltage supply for excitation. To supply DC to the aircraft electricalsystem it is used in combination with a ROTAX specified rectifier-regulator unit, which is installedon the front-left side of the firewall. The red ALT 2 warning light is located in the row ofannunciator lights on the instrument panel. It is controlled by the rectifier-regulator unit andindicates undervoltage.

C. An ammeter monitors power supply. The voltmeter is connected with the aircraft bus bar. Theammeter measures the charge or discharge current to/from the battery. Both instruments arefound on the right side of the instrument panel in the instrument cluster.

D. The alternator warning lights and ammeter discharge indication may illuminate during low rpmwith an electrical load on the system, for example during low rpm taxi. The lights will extinguishat higher rpm.

E. Refer to the ROTAX Installation Manual (P/N 898643) for more information on the external andinternal alternators and the rectifier-regulator unit.

Electrical Power

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24-20-00Page 2

Electrical Power

ROTAX Internal Alternator System (Schematic, Night-VFR equipped aircraft only)Figure 2

External Alternator System (Schematic)Figure 1

external alternator

warning light

“ALT 1”

ALT 1

BAT

to a

ircra

ft b

us s

yste

m

circuit breaker

“ALT 1 Excitation”

circuit breaker

“Warning Lights”

circuit breaker

“ALT 1”

fire

wa

ll

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warning light

“ALT 2”

to a

ircra

ft b

us s

yste

m

circuit breaker

“Warning Lights”

circuit breaker

“ALT 2”

ROTAX

internal alternator

rectifier-

regulator

unit

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24-20-00Page 201

ALTERNATOR SYSTEM - MAINTENANCE

1.

A. Maintenance is limited to the (external) alternator, drive belt andrectifier-regulator unit (only Night-VFR equipped aircraft). Refer to the appropriate ROTAXpublications for maintenance procedures on the internal alternator.

2.

A. Remove External Alternator(1) Ensure electrical power to aircraft and ignition switch is OFF. Remove key.(2) Remove cowling (refer to 71-10-00).(3) Disconnect battery (refer to 24-30-00).(4) Disconnect electrical cables (include ground cable) from alternator.(5) Cut safety wire and loosen adjusting bolt and alternator mounting bolts.(6) Slip drive belt off alternator pulley.(7) Remove mounting bolts securing alternator to engine. Remove alternator from engine.

B. Install External Alternator(1) Position alternator into mounting bracket.(2) Install shim and mounting bolt as shown in figure 201. Do not tighten yet.(3) Loosely secure lower alternator mounting boss to adjustment cam using washers and bolt

(refer to figure 201).(4) Place drive belt on alternator pulley. Verify pulleys are aligned.

IF A NEW DRIVE BELT IS INSTALLED: THE ENGINE BELT TENSION SHOULDBE RECHECKED WITHIN THE FIRST 15 TO 20 HOURS OF OPERATION.

(5) Apply a torque wrench to the alternator pulley nut and adjust belt tension so the belt slips at:(a) 10 - 12 Nm (88 - 106 in.lbs) of torque with a used belt;(b) 15 - 18 Nm (133 - 159 in.lbs) of torque with a new belt

(6) Tighten adjusting bolt. Torque to 22 Nm (195 in.lbs).(7) Tighten alternator mounting bolts.

(a) Torque M10 bolt (upper alternator mounting bracket) to 40 Nm (355 in.lbs).(b) Torque M8 bolt to 22 Nm (195 in.lbs).

(8) Safety wire all bolts.(9) Reconnect electrical cables including the ground cable.(10) Reconnect battery (refer to 24-30-00).(11) Install cowling (refer to 71-10-00).

3.

A. Remove Alternator Drive Belt(1) Ensure electrical power to aircraft and ignition switch is OFF. Remove key.(2) Remove engine cowling (refer to 71-10-00).(3) Disconnect battery (refer to 24-30-00).

General

External Alternator Removal/Installation

CAUTION:

External Alternator Drive Belt Removal/Installation

removal and installation of the

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External Alternator InstallationFigure 201

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A

ADetail-

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(4) Cut safety wire and loosen adjusting bolt and alternator mounting bolts.(5) Slip drive belt off alternator pulley.(6) Remove propeller (refer to 61-10-00).(7) Remove alternator drive belt.

B. Install Alternator Drive Belt(1) Install alternator drive belt around drive pulley.(2) Install propeller (refer to 61-10-00).(3) Place drive belt on alternator pulley. Verify pulleys are aligned.

IF A NEW DRIVE BELT IS INSTALLED: THE ENGINE BELT TENSION SHOULDBE RECHECKED WITHIN THE FIRST 15 TO 20 HOURS OF OPERATION.

(4) Apply a torque wrench to the alternator pulley nut and adjust the belt tension so the beltslips at:(a) 10 - 12 Nm (88 - 106 in.lbs) of torque with a used belt;(b) 15 - 18 Nm (133 - 159 in.lbs) of torque with a new belt

(5) Tighten adjusting bolt. Torque to 22 Nm (195 in.lbs).(6) Tighten alternator mounting bolts.

(a) Torque M10 bolt (upper alternator mounting bracket) to 40 Nm (355 in.lbs).(b) Torque M8 bolt to 22 Nm (195 in.lbs).

(7) Safety wire all bolts.(8) Reconnect battery (refer to 24-30-00).(9) Install engine cowling (refer to 71-10-00).

CAUTION:

4. (Ref. Fig. 202, Night-VFR equipped aircraft only)

A. Remove Rectifier-Regulator Unit(1) Ensure electrical power to aircraft is OFF.(2) Remove engine cowling (refer to 71-10-00).(3) Disconnect battery (refer to 24-30-00).(4) Disconnect all wires from rectifier-regulator unit.(5) Remove the attachment bolt and the nuts from the mounting plate and rectifier-regulator

unit. Attend to the ''Nordlock'' washers.

B. Install Rectifier-Regulator Unit(1) Install the rectifier-regulator unit with two screws M8x20 (DIN ISO 4762), four ''Nordlock''

washers and two nuts M8 (DIN ISO 934) on the mounting plate. Attend to the variouswashers and their installation sequence.

(2) Connect the wire to the rectifier-regulator unit.(3) Reconnect battery (refer to 24-30-00).(4) Install engine cowling (refer to 71-10-00).

Rectifier-Regulator Unit Removal/Installation

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Rectifier-Regulator Unit Installation (Figure 202

Night-VFR equipped aircraft only)

rectifier-regulator unit

“Nordlock” washer (4ea)

bolt M8x20 (2ea)

nut M8 (2ea)

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A

“Nordlock”washer

BDetail-

B

B

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24-30-00

BATTERY SYSTEM - DESCRIPTION

1.

A. The battery system supplies power to the electrical equipment if the alternator fails. It representsthe auxiliary power source in supply design.

B. The battery system consists of the following components:

- battery- battery relay- BAT switch- voltmeter- ammeter

2.

A. The aircraft has a 12-volt lead-acid battery, which is installed in a battery tray on the front-rightside of the firewall. It is accessible by removing the upper engine cowling. The battery box isvented. The vent line discharges out of the bottom of the engine cowling, preventing the build upof dangerous or explosive gases in the engine compartment. The battery relay is fixed above thebattery at the engine mount.

B. To connect the battery to the aircraft bus the switch, located on the lower left instrumentpanel, must be in the ON position, thus connecting one battery relay terminal to aircraft ground.The other relay terminal is permanently supplied with a positive voltage by the battery. In thisway the aircraft bus bar is supplied with current via the battery relay.The voltmeter is connected with the aircraft bus bar. The ammeter measures the charge ordischarge current to/from the battery via a shunt. Both instruments are located on the rightinstrument panel in the instrument cluster.

Introduction


BAT

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Battery System (Schematic)Figure 1

battery-

relay

to aircraft

bus bar

to clock,

ELT

battery

ALT 1

BAT

ammeter

AMPS- +

DC VOLTS

circuit breaker

“Battery”

firewall

BATTERY SYSTEM (SCHEMATIC)

24-30-00

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voltmeter

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BATTERY SYSTEM - MAINTENANCE

1.

A. Maintenance is limited to the removal and installation of the battery and the battery relay and abattery condition check. For information on the regular servicing required, refer to 12-17-00.

2.

A. Remove Battery(1) Ensure BAT switch is in OFF position.(2) Remove upper engine cowling (refer to 71-10-00).(3) Remove battery hold down strap.(4) Disconnect battery cables.(5) Remove battery from mounting tray.

B. Install Battery(1) Place battery into mounting tray and secure with battery hold down strap. Torque nuts to

max. 2 Nm (18 in.lbs).

(2) Reconnect battery vent line.(3) Reconnect battery cables.(4) Install engine cowling (refer to 71-10-00).

General

Battery Removal/Installation

CAUTION:

NOTE:

Battery Relay Removal/Installation

ALWAYS DISCONNECT THE BATTERY BEFORE DOING ANY MAINTENANCE ONTHE ELECTRICAL SYSTEM. DISCONNECT THE NEGATIVE LEAD FIRST. RECONNECTTHE NEGATIVE LEAD LAST. SECURE THE BATTERY LEADS FROM ACCIDENTALCONNECTION DURING MAINTENANCE WORKS.

It is recommended to remove the battery from the aircraft before doing any maintenanceon the electrical system to avoid the risk of accidental connection.

3. (Ref. Fig. 201)

A. Remove Battery Relay(1) Ensure electrical power to aircraft is OFF.(2) Remove engine cowling (refer to 71-10-00).(3) Disconnect battery (refer to 24-30-00).(4) Identify and disconnect wires at battery relay.(5) Remove nuts, washers and bolts securing relay to engine mount and remove relay.

CAUTION: EXCESSIVELY HIGH TORQUES COULD RESULT IN DAMAGE TO THEBATTERY AND ESCAPING BATTERY ACID.

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B. Install Battery Relay(1) Position and secure battery relay to engine mount using bolts, washers and nuts.(2) Identify and reconnect wires to relay.

DO NOT REMOVE INNER NUT WHEN ASSEMBLING. USE WRENCH TOHOLD INNER NUT IN PLACE WHEN APPLYING OUTER NUT.

(3) Reconnect battery (refer to 24-30-00).(4) Install engine cowling (refer to 71-10-00).

CAUTION:

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batteryrelay

1,4-2 Nm

5-6 Nm

12-18 in.lbs

44-55 in.lbs

Battery Relay InstallationFigure 201

A

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4.

For Night-VFR equipped aircraft, check the battery condition according to one of the followingmethods:

A. Measure „cold cranking amps“ (CCA) according to SAE using specialized test equipment(Schumacher PTI900X or similar). The battery is airworthy if the tester displays a CCA of at least80% of the following test values:

AT01-8210-131 Odyssey PC-310 100AT01-8210-130 Odyssey PC-1100 500AT01-8210-129 Odyssey PC-950 400AT01-8210-128 Exide Sprinter P12V600 200AT01-8210-125 Concorde RG25XC 350

B. Measure capacity by discharging the battery with a current of approximately 10% of the batterycapacity. Use automated test equipment that stops discharging at a voltage not lower than11,0 Volts. The battery is airworthy if the measured capacity is at least 19 Ampere-hours.

Method B is harder on the battery and takes more time, but is more accurate.Test only fully charged batteries and re-charge battery immediately after test.

Batteries with P/N AT01-8210-123, AT01-8210-122, AT01-8210-121, AT01-8210-120and AT01-8210-100 are NOT approved for Night-VFR!

Select battery type „AGM“, „SLA“ or „VRLA“ if a setting is available in the test equipment.

Battery Condition Check

NOTE:

NOTE:

NOTE:

Battery P/N Battery description CCA

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EXTERNAL POWER - MAINTENANCE

1.

A. This section covers that portion of the system which connects external electrical power to theaircraft's electrical systems. It includes items such as external power receptacle and relays.

B. As an option the aircraft may be equipped with an external power receptacle mounted on theright side of the engine mount, just below the battery. The standard, oval shaped, 3-pin receptacleis accessible through an hinged access plate in the right side of the engine cowling. Furthermore,the system includes an external power relay attached to the engine mount and a relay behind theinstrument panel. For wiring refer to 91-00-00.When a 12 V DC power supply is connected to the external power receptacle the shorter, thirdconnector engages the external power relay, which connects the external power to the aircraftmain bus. Simultaneously, the battery switch will be disconnected from the ground terminal bythe second relay behind the instrument panel. This prevents an energizing of the battery relaywhile an external power supply is being used.The signal power to the external power relay contains an isolation diode to prevent reversepolarity.

C. Maintenance is limited to the removal and installation of components.

2. (Ref. Fig. 201)

A. Remove External Power Receptacle(1) Ensure electrical power to aircraft is OFF.

(3) Disconnect battery (refer to 24-30-00).(4) Identify and disconnect all wires at EPU receptacle.(5) Remove nuts, washers and bolts securing receptacle to engine mount and remove receptacle.

B. Install External Power Receptacle(1) Position and secure EPU receptacle to engine mount using bolts, washers and nuts.(2) Identify and reconnect wires to EPU receptacle.(3) Reconnect battery (refer to 24-30-00).(4) Install engine cowling (refer to 71-10-00).(5) Perform an external power system functional check (refer to “Adjustment/Test” below).

3.

A. Remove External Power Relay(1) Ensure electrical power to aircraft is OFF.(2) Remove engine cowling (refer to 71-10-00).(3) Disconnect battery (refer to 24-30-00).(4) Identify and disconnect wires at external power relay.(5) Remove nuts, washers and bolts securing relay to engine mount and remove relay.

General

External Power Receptacle Removal/Installation

External Power Relay Removal/Installation

(2) Remove engine cowling (refer to 71-10-00).

(Ref. Fig. 201)

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External Power Receptacle InstallationFigure 201

Aircraft equipped with an external power receptacle

EFFECTIVITY

A

ADetail-

ground

power

Signal

4 Pl.

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BDetail-

externalpowerrelay

8212A04N

8212B04

8212A20

1,4-2 Nm

5-6 Nm

12-18 in.lbs

44-55 in.lbs

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B. Install External Power Relay(1) Position and secure external power relay to engine mount using bolts, washers and nuts.(2) Identify and reconnect wires to external power relay.

(3) Reconnect battery (refer to 24-30-00).(4) Install engine cowling (refer to 71-10-00).(5) Perform an external power system functional check (refer to “Adjustment/Test below).

4.

A. External Power System Functional Check(1) Connect an 14 V DC external power supply to aircraft.(2) Place the BAT switch to the ON position.(3) Verify the voltmeter shows 14 V.(4) Disconnect external power supply from aircraft.(5) The voltmeter must show 12 V.(6) Place the BAT switch in OFF position.

5.

A. External Power System Inspection/Check(1) Check latching mechanism and hinge of the external power access plate for integrity and

condition.(2) Remove engine cowling (refer to 71-10-00).(3) Remove glare shield (refer to 31-10-00).(4) Check external power receptacle for security.(5) Check system relays for condition and security.(6) Inspect electrical cables of the system for proper routing, chafing, broken or loose terminals,

general condition, and sharp bends in wiring.(7) Verify the external power placard is firmly in place and legible.(8) Install glare shield (refer to 31-10-00).(9) Install engine cowling (refer to 71-10-00).

CAUTION: DO NOT REMOVE INNER NUT WHEN ASSEMBLING. USE WRENCH TOHOLD INNER NUT IN PLACE WHEN APPLYING OUTER NUT.

Adjustment/Test

Inspection/Check

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24-60-00

ELECTRICAL LOAD DISTRIBUTION - DESCRIPTION

1.

A. Distribution of electrical power supplied by the external and optional the internal alternator andthe battery is accomplished by bus bars. The bus architecture allows power to be routed to theessential circuitry if any one of the main power sources fails.All essential electrical accessories in the system are protected by push pull type circuit breakerswhich can be reset in flight. The circuit breaker panel is on the far right of the instrument paneland each circuit breaker is labeled. All circuit breakers have their rated values identified on thetop of the shaft.

B. For power routing throughout the aircraft, refer to wiring diagrams shown in 91-00-00.

2.

A. The electrical system has two main bus bars: the aircraft bus bar and the avionics bus bar. Allsystems are connected to the aircraft bus bar. Theavionics bus bar supplies the avionics equipment with power.

B. The external alternator output and the battery are connected with the aircraft bus via 50A circuitbreakers. Optional the internal alternator is connected with the aircraft bus via a rectifier-regulatorunit and a 25A circuit breaker. The circuit breakers are located on the right side of the instrumentpanel in the circuit breaker panel.The current is distributed from the aircraft bus bar via circuit breakers to the electrical circuits ofseveral systems and components and via the switch to the avionics bus bar. Fromthere, it is further distributed to the several components of the avionics equipment via circuitbreakers. The AVIONICS switch allows avionics equipment to be removed separately from theresidual electrical system.

Introduction


which are essential for aircraft operation

AVIONICS

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CIRCUIT BREAKER - MAINTENANCE

1.

A. The circuit breaker panel is equipped with circuit breakers of the push to reset type.One terminal of each switch/breaker is directly connected to the appropriate bus bar, the other iswired to the component/system it protects.

2.

A. Remove Circuit Breaker(1) Ensure electrical power to aircraft is OFF.(2) Disconnect battery (refer to 24-30-00).(3) Remove glare shield (refer to 31-10-00).(4) Disconnect wire and bus from selected circuit breaker.(5) Remove retaining ring and washer from circuit breaker on the front of the instrument panel.(6) Remove circuit breaker.

It may be necessary to loosen more than one circuit breaker to remove the selectedcircuit breaker.

B. Install Circuit Breaker(1) Place circuit breaker into position on the instrument panel and secure.(2) Identify and connect wire and bus to the selected circuit breaker.(3) Reinstall glare shield (refer to 31-10-00).(4) Reconnect battery (refer to 24-30-00).

General

Circuit Breaker Removal/Installation

NOTE:

" "

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ELECTRICAL SYSTEM WIRING - MAINTENANCE

1.

A. Repairs of the electrical system wiring are limited to the replacement and splicing of electricalwires. In general all repairs have to be carried out by certified repair stations or properly certifiedand trained persons.

B. Carry out a complete functional check of the concerned equipment after every repair.

C. Refer to 91-00-00 for wiring diagrams.

A. Splicing is permitted on wiring as long as it does not affect the reliability and theelectromechanical characteristics of the wiring. Splicing of power wires, coaxial cables, shieldedwires or wire sizes above AWG 18 is not permitted. There should not be more than one splice inany one wire segment between any two connectors or other disconnect points.

3 “Splicing splicing procedures andequipment

General

2.

3.

A. If wires are replaced, they have to be replaced by identical ones (same MIL specification andAWG). New wires have to be routed, fixed and protected in the same manner as the old wires.

Splicing

Wire Replacement

Refer toAC 43.13-1B, chapter 11, section 1 ” for further information on

.

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