Aquila AT01-100 User manual

MAINTENANCE MANUAL
AQUILA AT01-100
A
TABLE OF CONTENTS
Cha/Sec/Sub Title Pages
TABLE OF CONTENTS 1-6
INTRODUCTION 1-8
LIST OF EFFECTIVE CHAPTERS 1-2
04 AIRWORTHINESS LIMITATIONS
04-00-00 Airworthiness Limitations - General 1-2
05 TIME LIMITS / MAINTENANCE CHECKS
05-00-00 Time Limits / Maintenance Checks - General 1
05-10-00 Component Time Limits 1-3
05-20-00 Scheduled Maintenance Checks 1-15
05-30-00 Daily Inspections 1
05-50-00 Unscheduled Maintenance Checks 1-2
06 DIMENSIONS AND AREAS
06-00-00 Dimensions and Areas - General 1
06-10-00 Aircraft Dimensions and Areas 1-3
06-20-00 Aircraft Zoning 1-2
06-30-00 Access/Inspection Plates 1-2
07 LIFTING AND SHORING
07-00-00 Lifting and Shoring - General 1
07-10-00 Jacking 201-202
08 LEVELING AND WEIGHING
08-00-00 Leveling and Weighing - General 1
08-10-00 Weighing 201-203
08-20-00 Leveling 201-202
09 TOWING AND TAXIING
09-00-00 Towing and Taxiing - General 1
09-10-00 Towing 201
09-20-00 Taxiing 201
10 PARKING, MOORING, STORAGE AND RETURN TO SERVICE
10-00-00 Parking, Mooring, Storage and Return to Service - General 1
10-10-00 Parking 201
10-11-00 Storage 201
10-20-00 Mooring 201
10-30-00 Return to Service 201
10-40-00 Transport 201-202
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Cha/Sec/Sub Title Pages
11 PLACARDS AND MARKINGS
11-00-00 Placards and Markings - General 1
11-20-00 Exterior Placards and Markings 201-206
11-30-00 Interior Placards and Markings 201-208
12 SERVICING
12-00-00 Servicing - General 1
12-10-00 Replenishing - Description 1-2
12-11-00 Fuel - Servicing 301-302
12-12-00 Engine Oil - Servicing 301-302
12-13-00 Induction Air Filter - Servicing 301
12-14-00 Cooling System - Servicing 301-302
12-15-00 Brake System - Servicing 301
12-16-00 Tires - Servicing 301
12-17-00 Battery - Servicing 301
12-20-00 Scheduled Servicing - Description 1
12-21-00 Lubricants - Description 1-2
12-22-00 Lubrication - Servicing 301-303
12-23-00 Aircraft Exterior - Cleaning and Care 701-704
12-24-00 Aircraft Interior - Cleaning and Care 701-702
12-30-00 Unscheduled Servicing 301
20 STANDARD PRACTICES AIRFRAME
20-00-00 Standard Practices Airframe - General 1
20-10-00 Fastener Identification and Torque Data 1-4
20-11-00 Conversion Data 1-3
21 VENTILATION AND HEATING
21-00-00 Ventilation and Heating - General 1
21-20-00 Fresh Air Distribution - Maintenance 201-203
21-40-00 Heating - Maintenance 201
23 COMMUNICATIONS
23-00-00 Communications - General 1
23-10-00 Speech Communications - Description 1-2/2
23-10-00 Speech Communications - Maintenance 201-202/202
23-50-00 Audio Integrating - Maintenance 201-202/202
24 ELECTRICAL POWER
24-00-00 Electrical Power - General 1
24-00-00 Electrical Power - Troubleshooting 101-102
24-20-00 Alternator System - Description 1-2
24-20-00 Alternator System - Maintenance 201-204
24-30-00 Battery System - Description 1-2
1)
1)
1)
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24-30-00 Battery - Maintenance 201
24-40-00 External Power - Maintenance 201-203
24-60-00 Electrical Load Distribution - Description 1
24-61-00 Circuit Breaker - Maintenance 201-202
24-97-00 Electrical System Wiring - Maintenance 201
25 EQUIPMENT / FURNISHINGS
25-00-00 Equipment / Furnishings - General 1
25-10-00 Seats - Maintenance 201-203
25-11-00 Restraint System - Maintenance 201
25-12-00 Cabin Interior - Maintenance 201-203
25-50-00 Cargo Tie Downs - Maintenance 201
25-60-00 Emergency Equipment - Description 1-2
25-62-00 Emergency Locater Transmitter - Maintenance 201-202
25-66-00 Fire Extinguisher - Maintenance 201/202
27 FLIGHT CONTROLS
27-00-00 Flight Controls - General 1
27-10-00 Aileron Control System - Description 1-2
27-10-00 Aileron Control System - Maintenance 201-207
27-20-00 Rudder Control System - Description 1-2
27-20-00 Rudder Control System - Maintenance 201-205
27-30-00 Elevator Control System - Description 1-2
27-30-00 Elevator Control System - Maintenance Practices 201-205
27-31-00 Elevator Trim Control System - Description 1-2
27-31-00 Elevator Trim Control System - Maintenance 201-202
27-50-00 Flap Control System - Description 1-2
27-50-00 Flap Control System - Maintenance 201-205
28 FUEL
28-00-00 Fuel - General 1-2
28-10-00 Fuel Storage - Maintenance 201
28-20-00 Fuel Distribution - Maintenance 201-206
28-41-00 Fuel Quantity Indication - Maintenance 201-203/203
31 INDICATING / RECORDING SYSTEMS
31-00 00 Indicating / Recording Systems - General 1-2/2/2
31-10-00 Instrument Panel - Maintenance 201-202
32 LANDING GEAR
32-00-00 Landing Gear - General 1
32-10-00 Main Landing Gear - Description 1
32-10-00 Main Landing Gear - Maintenance 201-202
1)
1)
1)
28-44-00 Fuel Pressure Indication - Maintenance 201
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32-20-00 Nose Landing Gear - Description 1
32-20-00 Nose Landing Gear - Maintenance 201-203
32-40-00 Wheels and Brakes - Description 1/1
32-40-00 Wheels and Brakes - Maintenance 201-221/208
33 LIGHTS
33-00-00 Lights - General 1
33-10-00 Interior Lights - Maintenance 201-202
33-40-00 Exterior Lights - Maintenance 201-202
34 NAVIGATION
34-00-00 Navigation - General 1
34-11-00 Pitot / Static System - Description 1-2
34-11-00 Pitot / Static System - Maintenance 201-204
34-18-00 Stall Warning System - Description 1
34-18-00 Stall Warning System - Maintenance 201
34-20-00 Attitude and Direction - Maintenance 201-203
34-25-00 Integrated Flight System -
34-40-00 Independent Position Determining - Maintenance 201-201/204
34-50-00 Dependent Position Determining - Maintenance 201-203
51 STRUCTURES
51-00-00 Structures - General 1-2
51-10-00 Composite Damage Investigation 201-203
51-20-00 Composite Repair 201-223
52 DOORS
52-00-00 Doors - General 1
52-10-00 Canopy - Maintenance 201-204
52-30-00 Baggage Door - Maintenance 201
53 FUSELAGE
53-00-00 Fuselage - General 1
53-10-00 Fuselage Main Frame - Description 1-4
53-10-00 Fuselage Main Frame - Maintenance 201
55 STABILIZERS
55-00-00 Stabilizers - General 1
55-10-00 Horizontal Stabilizer - Maintenance 201
55-20-00 Elevator - Maintenance 201-203
55-30-00 Vertical Stabilizer - Maintenance 201
55-40-00 Rudder - Maintenance 201-202
1)
1)
1)
1)
Maintenance 201-204/205
53-20-00 Auxiliary Structure - Description 1
TABLE OF CONTENTS (Cont.)
Cha/Sec/Sub Title Pages
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56 WINDOWS
56-00-00 Windows - General 1
56-10-00 Flight Compartment Windows - Maintenance 201-203
57 WINGS
57-00-00 Wings - General 1
57-00-00 Wings - Maintenance 201-205
57-50-00 Control Surfaces - Maintenance 201-207
61 PROPELLER
61-00-00 Propeller - General 1
61-00-00 Propeller - Troubleshooting 101-103
61-10-00 Propeller Assembly - Maintenance 201-204
61-20-00 Propeller Control - Maintenance 201-204
71 POWER PLANT
71-00-00 Power Plant - General 1-2
71-00-00 Power Plant - Troubleshooting 101-104
71-00-00 Power Plant - Maintenance 201-203
71-10-00 Cowling - Maintenance 201-202
71-20-00 Engine Mount - Maintenance 201-202
71-60-00 Air Induction System - Maintenance 201
74 IGNITION SYSTEM
74-00-00 Ignition System - General 1-2
74-00-00 Ignition System - Maintenance 201-203
75 COOLING SYSTEM
75-00-00 Cooling System - General 1-2
75-00-00 Cooling System - Maintenance 201-202
76 ENGINE CONTROLS
76-00-00 Engine Controls - General 1
76-00-00 Engine Controls - Maintenance 201-205
77 ENGINE INDICATING
77-00-00 Engine Indicating - General 1
77-10-00 Power Indication - Maintenance 201/201
77-20-00 Temperature Indication - Maintenance 201-202/202
77-40-00 Engine Monitoring System - Maintenance 201-202
78 EXHAUST
78-00-00 Exhaust System - General 1
78-00-00 Exhaust System - Maintenance 201-202
1)
1)
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79 OIL
79-00-00 Oil - General 1-2
79-10-00 Oil Tank - Maintenance 201-202
79-20-00 Oil Cooler - Maintenance 201-202
79-31-00 Oil Pressure Indication - Maintenance 201/201
79-33-00 Oil Temperature Indication - Maintenance 201/201
80 STARTING
80-00-00 Starting - General 1
80-11-00 Starter - Maintenance 201
91 CHARTS AND DIAGRAMS
91-00-00 Charts and Diagrams - General 1-40
1)
1)
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Revision
Number
Revision
Number
Date of
Revision
Date of
Revision
Date
Inserted
Date
Inserted
By By
RECORD OF REVISIONS
Record of Revisions
A.01 30.04.13
A.02 26.08.13
A.03 24.10.13
A.04 02.03.15
A.05 20.08.15
A.06 29.02.16

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Temp. Revision
Number
Page Date of
Revision By By
Date
Removed
RECORD OF TEMPORARY REVISIONS
Record of Temp. Revisions
01 05-10-00 p.1 & 3 11.06.14 20.08.15
02 05-20-00 p.7 14.08.14 20.08.15
76-00-00 p.203
& 204

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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
A.01 30.04.13 Initial issue.
A.02 26.08.13 SB-AT01-027
A.03 24.10.13 FAA validation
(airworthiness limitations,
wire routing diagrams);
lubrication revised;
standard torque ROTAX
engine mount revised
A.04 02.03.15 Life time limit,
6000 hour inspection
A.05 20.08.15 Fuel quantity indicating
system calibration
procedures added;
TBO’s and maintenance
checklist revised;
Temporary revisons 1
& 2 incorporated
A.06 29.02.16 Control surface ply
lay-up added; repair
procedures revised

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LIST OF EFFECTIVE CHAPTERS
LIST OF EFFECTIVE CHAPTERS
Chapter Title Date*
GENERAL
Introduction 30.04.13
04 Airworthiness Limitations 02
05 Time Limits / Maintenance Checks 20.08.15
06 Dimensions and Areas
07 Lifting & Shoring
08 Leveling and Weighing
09 Towing and Taxiing
10 Parking, Mooring, Storage & Return to Service
11 Placards and Markings
12 Servicing 24
AIRFRAME SYSTEMS
20 Standard Practices Airframe
21 Ventilation and Heating
23 Communications
24 Electrical Power
25 Equipment and Furnishings 30.04.13
27 Flight Controls
28 Fuel 20.08.15
31 Indicating/Recording Systems
32 Landing Gear
33 Lights 30.04.13
34 Navigation
STRUCTURES
51 Structures 29
53 Fuselage
55 Stabilizers
57 Wings
PROPELLER
61 Propeller
Table of Contents 29.02.16
.03.15
30.04.13
30.04.13
30.04.13
30.04.13
30.04.13
30.04.13
.10.13
24.10.13
30.04.13
30.04.13
30.04.13
30.04.13
30.04.13
30.04.13
30.04.13
.02.16
52 Doors 30.04.13
30.04.13
30.04.13
56 Windows 30.04.13
30.04.13
30.04.13
List of Chapters
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Page 1

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LIST OF EFFECTIVE CHAPTERS
POWER PLANT
71 Power Plant
74 Ignition
75 Cooling System
76 Engine Controls 2
77 Engine Indicating
78 Exhaust
79 Oil
80 Starting
91 Charts and Wiring Diagrams
* The date refers to the issue / revision date of the respective chapter.
30.04.13
30.04.13
30.04.13
0.08.15
30.04.13
30.04.13
30.04.13
30.04.13
24.10.13
LIST OF EFFECTIVE CHAPTERS
Chapter Title Date*
List of Chapters
29.02.16
Page 2
The technical content of this document (revision A.06) is approved under the authority of
DOA ref. EASA.21J.025.
Date, Signature Office of Airworthiness

MAINTENANCE MANUAL
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CHAPTER 51
STRUCTURES

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Page 1
51 - TOC
TABLE OF CONTENTS
Chapter
Section
STRUCTURES - GENERAL..............................................................................51-00-00 1
Introduction 51-00-00 1
General Description 51-00-00 1
COMPOSITE DAMAGE INVESTIGATION ..................................................51-10-00 201
General 51-10-00 201
Inspection Methods 51-10-00 201
Damage Classification 51-10-00 202
COMPOSITE REPAIR.......................................................................................51-20-00 201
General 51-20-00 201
Repair Requirements 51-20-00 201
Approved Materials 51-20-00 202
Tools, Equipment and Material 51-20-00 203
Material Data Sheet 51-20-00 204
Repair of Sandwich Components 51-20-00 217
Repair of Monolithic Components 51-20-00 222
Exterior Finish 51-20-00 223
Title Subject Page
Structure Classes 51-00-00 2
Structures
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51-00-00
STRUCTURES - GENERAL
1.
A. This chapter provides a general overview of the structural design. The chapter contains
information and procedures applicable to all composite repairs as well as information and
procedures for aircraft painting and priming.
B. Please contact AQUILA Aviation GmbH for support in case damage to the aircraft structure the
cause of which is unknown or suspect, and prior to major repairs to obtain detailed information.
AQUILA Tel.: [phone]
Flugplatz Fax.: [phone]
14959 Schönhagen
Germany
2.
Most of the aircraft structure is made from composite materials. Glass-fiber (GFRP) and carbon-fiber
reinforced plastics (CFRP) are used which are bedded in an epoxy resin matrix. The aircraft structure
consists of monolithic GFRP or CFRP shells and structure components as well as sandwich shells
which have a rigid foam core.
A. Fuselage
The fuselage with the vertical and horizontal stabilizers represents one component. Including the
vertical stabilizer, it consists of two half-shells. The fuselage portion of the half-shells is made from
solid (non-foam) fiberglass laminate, the vertical stabilizer has a sandwich structure. The fuselage
GFRP skin is reinforced by four carbon-fiber stringers, arranged lengthwise through the entire
fuselage.
Four ring frames and a baggage compartment frame provide support to the fuselage shells in the
tail section. A landing gear bulkhead, a seat bulkhead and a side-force bulkhead carry single
loads.
The front of fuselage ends with the firewall which includes the metal fittings for supporting the
engine mount. The firewall, constructed of a GFRP/CFRP composite sandwich, has a fire
protection lining which consists of an especially fire-resistant ceramic fleece and
a stainless-steel sheet.
The landing gear bulkhead which together with the seat bulkhead supports the main landing
gear struts, is complemented upwards through a compact CFRP/GFRP roll-over bar.
B. Wings
The plan view of the wing is a triple trapezoid that is complemented by a winglet at its end.
The wing has top and bottom shells, constructed of a GFRP composite sandwich and locally
reinforced by CFRP straps. The aircraft has a one-piece wing because the wing spar is
manufactured in one piece and is continuous from wing tip to wing tip. The I-section spar has
caps made from unidirectional carbon-fiber and a GFRP composite sandwich web.
Each wing half ends inboard with a front root rib and a rear root rib, which are mounted to the
fuselage center section with a bolt apiece.
Introduction
General Description
Aviation GmbH
on the front side
Structures
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AQUILA AT01 Primary Structure
Figure 01
The four lateral force bolts are inserted from the cabin through the fuselage bushings into the
wing bolt casings and secured axially with screws.
The outboard end of the wing has a winglet with the NAV lights and the fuel tank vents.
The inboard portion of the wings contains an integral fuel tank.
The ailerons are located at the wing trailing edge near the wing tips. They are of a semi-
monocoque sandwich construction consisting of rigid foam core and glass and carbon fiber layers.
The flaps, of a semi-monocoque CFRP sandwich construction, are mounted to the trailing edge of
each wing between the inboard end of the ailerons and the fuselage.
They are attached to the wings using hinges that are located below the bottom of the wing. This
results in the gap between wing trailing edge and flap leading edge and increases as the flap
extend. This increases the lift force and simultaneously the drag force.
C. Stabilizers
The vertical and horizontal stabilizers, as well as the elevator and rudder are of semi-monocoque
design consisting of shells fabricated from GFRP sandwich reinforced with CFRP.
The vertical and the horizontal stabilizers have a main spar and a rear shear web with integrated
hinges. The horizontal stabilizer is molded to the fuselage and cannot be removed.
3.
A. Primary Structure
These parts are important for the structural integrity of the aircraft. For example: fuselage, wing,
stabilizer and control surface shells, spars, frames, joints, brackets.
B. Secondary Structure
These parts are not important for the structural integrity of the aircraft. For example: panels,
covers, access plates, fairings.
Structure Classes
Structures