Jonker Sailplanes JS1 Series User manual

JS1 Jet Revelation Maintenance Manual –Issue 1

JS1 Jet Maintenance Manual –Issue1
JS1 JET SUSTAINER
MAINTENANCE MANUAL
Model: JS1-B, JS1C-18m, JS1C-21m
Serial number:
Registration Number:
Document part number: 1A-5.04.80
Title: JS1 Jet Sustainer Maintenance Manual
Date of issue: 26 May 2016
Prepared by: Name: A.P. Kotze Signature:
Approved by: Name: J.S.U. Jonker Signature:
Approval:
Pages marked
‘Approved’are approved by:
Name: K. Debipersad Signature:
Agency: SACAA
Stamp & Date:

JS1 Jet Maintenance Manual –Issue1
Date of issue: 26 May 2016 Page 0 - 1 SACAA Accepted section
0. General
This Maintenance Manual has been prepared to provide maintenance personnel with the
necessary information to maintain the JS1 Revelation Jet Sustainer System. All the data
required to be furnished to the pilot and the maintenance personnel, by the Airworthiness
Requirement CS-22, is contained in this manual. Supplementary data is also provided by
the sailplane manufacturer.
0.1. Record of Revision
Any revision of the present manual, except actual weighing data, must be recorded in the
following table and, in case of approved sections, endorsed by the Agency.
New or amended text in the revised pages will be indicated by a black vertical line in the left
hand margin. The revision number and the date will also be illustrated on the bottom left
hand side of the page.

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Rev.
No.
Affected
Pages
Date of
Issue
Change Description
1
ALL
26.05.2016
First Issue

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0.2. List of effective pages
Affected
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JS1 Jet Maintenance Manual –Issue1
Date of issue: 26 May 2016 Page 0 - 4 SACAA Accepted section
TABLE OF CONTENTS
General
Section 1
Description of Systems and Equipment
Section 2
Control Deflection and Play
Section 3
Airworthiness limitations and inspections
Section 4
Control surfaces masses and moments
Section 5
Maintenance Schedule
Section 6
Lubrication
Section 7
Software/Firmware Upgrade
Section 8
Trouble Shooting
Section 9
Equipment and accessories
Section 10
Placards
Section 11
Deactivation/ decommissioning of Jet Sustainer System
Section 12
Cleaning and care
Section 13
APPENDIX A

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ABBREVIATIONS
AMO
-
Approved Maintenance Organisation
LE
-
Leading Edge
NAA
-
National Aviation Authority
OEM
-
Original Equipment Manufacturer
TCDS
-
Type Certificate Data Sheet
TE
-
Trailing Edge
JDU
-
Jet Display Unit
ECU
-
Electronic Computer Unit
LiFePo
-
Lithium Ferrite Polymer
JSS
-
Jet Sustainer System
EGT
-
Exhaust Gas Temperature

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1. General
1.1 Descriptive Data
The JS1 JET SUSTAINER SYSTEM is a propulsion system used to sustain flight when
soaring conditions become unfavourable. Propulsion is made possible by means of a jet
turbine mounted on a retractable pylon in the rear section of the fuselage. Normal
performance of the sailplane continues when the turbine is retracted.

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1.2 Technical data
Engine technical data
Engine
M&D TJ-42
Manufacturer
M&D Flugzeugbau GmbH, Friedeburg
Max thrust
35 daN (ISA conditions)
Max Engine RPM
97 000 RPM
Max Continuous RPM
80 000 RPM
Max continuous EGT
790 °C
Fuel
Diesel mixed with 2% 2-stroke oil
Oil
Synthetic two stroke oil complying with specification
API TA, API TB, API TC or JASO FC
Fuel capacity
42 liters
Usable fuel
41.6 liters
Fuel consumption
70 liters per hour at max power (sea level)
Battery Type
12 V LiFePo
Table 1: Engine Technical Data

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1.3 Three-view drawing
Illustrated in Fig 1.3-1 is a three view drawing of the Jet Box System.
Figure 1.3-1: Jet Box Layout

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2. Description of Systems and Equipment
2.1 Introduction
The JET SUSTAINER SYSTEM comprises of the following systems:
Control System
Kinematics
Fuel system
Electrical system
2.2 Control System
The pilot controls the system by using a Jet Display Unit (JDU) installed on the instrument
panel. Data from the JDU is sent to the Electronic Computer Unit (ECU) where the data is
processed. Various control inputs includes; extension/retraction, start-up/shutdown and
desired throttle setting. RPM is regulated by the ECU by adjusting the fuel pump voltage.
Note: The ECU contains pre-loaded default settings preventing the pilot from operating
the engine outside of its envelope. RPM and the Exhaust Gas Temperature (EGT)
is restricted within the operational limits by lowering the pump voltage until the
desired setting is achieved.
2.3 Pylon Extension/Retraction Kinematics
Pylon extension/retraction kinematics is contained inside the jet box and controls the pylon
position as well as the operation of the jet doors.
This system comprises of a single pylon, for the mounting of the engine, driven by an
electromechanical actuator. The pylon is connected through a cam and bell-crank system
allowing the doors to open in sequence with the movement of the pylon.
See Section 2.3.1 and 2.3.4 for further description of the kinematics.

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2.3.1 Engine Assembly
The pylon for the JET SUSTAINER SYSTEM was developed to accommodate the MD TJ 42
Turbine engine. The turbine is held in place by two 127 -152mm Heavy Duty Hose Clamps.
Bolts on the hose clamps are secured by locking wire to ensure that they are not loosened
by vibration during operation. The engine assembly is illustrated in Fig 2.3.1-1.
No
Description
No
Description
1
Fuel Manifold Assembly
9
M4A12
2
Engine Pylon Shroud Assembly
10
M5 Crush Washer
3
Engine Intake Cover
11
M3 x 10 Washer
4
M3AB5
12
Jet Pylon
5
Pylon Fairing (Left)
13
Start Line Assembly
6
Pylon Fairing (Right)
14
Fuel Line Assembly
7
Jet Engine Clamp
15
TJ 42
8
Start Line Adapter
-
-
Figure 3.3.1-1: Engine Assembly

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Two fuel lines run from the bottom of the pylon to the top of the jet engine. The left hand
line, the Fuel Line Assembly, is connected to a fuel manifold that distributes the fuel through
the turbine. The right hand line, the Start Line Assembly, is only active during the start-up
sequence.
The start line adapter serves as an adapter between the aluminium tubing and the glow plug
holder. The start line adapter also operates as a restrictor during the start-up sequence
ensuring high pressure is maintained.
An intake cover is fitted over the front of the engine to ensure that none of the wiring and
tubing is exposed during operation. The cover is held in place by 4 M3 Allen cap bolts with
washers to distribute the load over the fastening area.

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2.3.2 Jet Pylon Assembly
The Jet Pylon Assembly, illustrated in Fig 2.3.2-1, contains the cam system that allows the
doors to be opened when the actuator is extended.
No
Description
No
Description
1
Jet Pylon
10
Fuel Line Attachment Bracket
2
Jet Pylon Cam
11
Nut: Nylock: M6
3
Jet Pylon Bearing (SKF 61804)
12
Nut: Nylock: M3
4
Jet Pylon Bearing Cap
13
Washer: Plain: M6
5
M6AB16
14
Washer: Plain: M3
6
Actuator Front Attachment Bolt Bush
15
M3A16
7
Rod End Bush
16
M3FCSP15
8
Swivel Ball Link 6:32: Monster
17
M4A12
9
Cam Rod End Washer (M4 x 15)
18
M6H28/36 –Bolt Type 4
Figure 2.3.2-1: Pylon Assembly

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2.3.3 Main Door Bell Crank
The main door bell-crank assembly, illustrated in Fig 2.3.3-1, is installed in the Jet Box and
connects the main doors to the pylon.
No
Description
No
Description
1
Main Door Bell Crank
5
M4FCSF12
2
Main Door Bell Crank Bearing Cap
6
M4H11/18 –Bolt Type 5
3
Bearing: Ball: 6802 DCUC3
7
Nut: Nylock: M4
4
Bearing: Needle: HK0408
8
Washer: Plain: M4
Figure 2.3.3-1: Main Door Bellcranck Assembly

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2.3.4 Engine Box Assembly
Kinematics to extend and retract the engine is contained inside the engine box. The engine
box, as illustrated in Fig 2.3.4-1, is secured to the fuselage with 6 x M5FCSF25 screws and
Tinnerman washers to distribute the load on the composite lip.
NO
DESCRIPTION
NO
DESCRIPTION
1
Jet Box
12
M3 AB 10
2
Drain Tube
13
Washer: Star: M4
3
Electrical Attachment Bracket
14
M4 AB 12
4
Fuel Line Attachment Bracket
15
M5 Anchor Nut
5
Limit Switch Attachment Bracket
16
Washer: Tinnerman: M5
6
Actuator Rear Attachment Bracket
17
M5FCSF25
7
Actuator Rear Attachment Bolt Bush
18
Nut: Nylock: M6
8
Fuel Drain Assembly
19
Washer: Plain: M6
9
Nut: Nylock: M3
20
M6 AB 16
10
19x19 Strapmount
21
M5H23.32 –Bolt Type 3
11
Washer: Plain: M3
22
Rivet: CS: 2.5 x 10
Figure 2.3.4-1: Engine Box Assembly

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2.3.5 Engine Bay Doors
The engine bay doors consist of the following main components:
Main doors
Front cover plate
Front door
The main doors are connected by means of a single pushrod and control horn to a bell-
crank. During the extension of the engine the movement of the actuator is translated to the
main doors by the bell crank, the cam and the follower system. The cam allows the doors to
close fully once the engine is extended, while the front door remains in the open position.
The connection between the bell-crank and pushrod is by means of a quick release rod end
that can be disconnected for maintenance purposes. This allows for easy connection
between the bell-crank and pushrod. The control horn is connected to the pushrod by an
adjustable rod end. The front door pushrod consists of a spring with a sliding rod through
the centre. This allows the front door to retract into the fuselage and remain retracted while
the main doors are closed during the extension operation.

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2.3.6 Main Door Assembly
The main doors are attached to the main door bell crank with 2 pushrods as illustrated in Fig
2.3.6-1. Two hinges per door connects the doors to the fuselage.
NO
DESCRIPTION
NO
DESCRIPTION
1
Ball Link Nut
9
Main Door Pushrod Assembly
2
Jet Left Door
10
Bearing: Balljoint FM: M6
3
Jet Left Door Control Horn
11
6-32 Monster Ball Link
4
Jet Rigth Door
12
Nut: Hex: M4
5
Jet Right Door Control Horn
13
M4FCSC20
6
Main Dorr Hinge 2
14
M4FCSC25
7
Main Door Hinge 1
15
Nut: Nylock: M5
8
Main Door Hinge Shaft
16
Nut: Hex: M5
Figure 2.3.6-1: Main Door Assembly

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2.3.7 Front Cover plate Assembly
The Front Cover plate assembly is installed over the front area of the jet box. The rear of the
plate is held in place with 2 x 2.9mm countersink screws and the front with an attachment
bracket. The assembly is illustrated in Fig 2.3.7-1
NO
DESCRIPTION
NO
DESCRIPTION
1
Nut: Nylock: M3
10
Screw: Self Tap: CS: 2.9x10
2
Front Coverplate
11
Nut: Hex: M4
3
Jet Front Door
12
Screw: Self Tap :CS: 2.9 x 10
4
Front Door Pushrod Attachment
13
6-32 Monster Ball Link
5
Front Door Pushrod Assembly
6
Jet Front Door Hinge
7
Washer: Plain: M3
8
Spring: Pressure: OD5x55x0.65
9
Front Cover Attachment Bracket
Figure 2.3.7-1: Front Door Assembly
The front door is actuated by the front door pushrod connected to the jet pylon cam. Once
the cam rotates the front door is pulled open until the fully open position is reached.
Compression springs allows the movement of the cam to continue once the door has
reached the open position.

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2.4 Fuel System
Fuel is contained in three interconnected composite tanks situated inside the fuselage. The
tanks are connected in such a way that switching between the tanks is not possible. Fuel
management is provided by the fuel panel situated on the left hand side of the engine box.
All tubing is manufactured from aluminium pipes except for the tubing installed inside the
engine box. These tubes are made from flexible hoses allowing for the retraction of the
engine.
Three independent fuel filters are installed in the system. The first filter is situated before the
fuel panel and uses a 20 μ brass sintered element to filter. The two remaining filters (44 μ)
are installed on the rubber tubing inside the engine box.
The fuel system is vented by means of a single vent tube running from the rear of the top
tank straight down and through the bottom of the fuselage.
In case of an emergency the pilot can shut off the fuel by means of the emergency fuel
shutoff valve.
A graphical description of the fuel system is illustrated in Fig 2.4-1
Figure 2.4-1: Fuel System Layout