Test Flying should only be performed by a pilot who is licensed, rated and experienced on the aircraft type.

Transcription

1 Test Flying Procedure: Test Flying should only be performed by a pilot who is licensed, rated and experienced on the aircraft type. In particular, the test pilot should have recently demonstrated an ability to: Deal with an engine failure at low altitude (200 ) after Take Off. Recover from stalls in level flight and in banked turns Recover from a spin. Recover from unusual attitudes (including a spiral dive). Carry out a flapless landing Carry out a glide approach and landing The Australian CASA (formerly CAA) produces a Flight Test Guide for Certification of CAO Category Airplanes. As part of the approval process, this document is required to be completed. In countries other than Australia, the amateur builder should seek advice from the appropriate Airworthiness Authority and/or the relevant amateur building association (EAA Chapter or equivalent). A copy of the Jabiru Aircraft Pty. Ltd. Flight Test Procedures and Report Form are included for your reference. Test Flying Page 1 10/04/02

2 Production Flight Test Report Procedures 1. Aircraft Identification Production Serial No: Record the aircraft production serial number from the aircraft identification plate located behind the hinge on the left hand side door. Registration: Record the aircraft registration number from the aircraft identification plate located behind the hinge on the left hand side door. Engine: Record the engine serial number from the engine data plate on the crankcase. Propeller: Record the propeller serial number from the propeller hub. Airframe Hours: Record the total number of hours on the airframe. Engine Hours: Record the number of engine hours on the engine. 2. Compass Check that the compass has been swung and that the calibration table is in place. Complete the certification details. 3. Conformity Check that the final inspection checklist has been completed and certified. Equipment correctly installed and functioning: Check that all instruments, radios and avionics are installed and the instruments, radios and avionics checklist has been completed and certified. Control Ranges: Check that all controls have full and free movement with the control moving fully to the stop. Control Markings: Check that all of the secondary controls are labelled. Instrument Range Markings: Check that the instrument ranges are shown or labelled. Harnesses: Check that the harness are present, on the correct side, adjustable, and release buckle working. Doors: Check the door operation and that the latches are working. Test Flying Page 2 10/04/02

3 4. Engine Run Locate the aircraft on a well grassed area, point into the wind and chock the wheels. Turn the Fuel Tap ON, the Master Switch ON, pull the Choke ON and turn the ignition Switch ON. Do not wear headsets for this test. Auxiliary Fuel Pump Functioning: Turn the Fuel Pump ON and listen for its operation. Starter Function: Depress the starter button, listen for the click of the solenoid, and the winding of the starter motor. Listen for the sound of the starter motor disengaging. Engine Oil Pressure after starting: Watch the engine oil pressure if it does not rise in the first 10 seconds shut the engine down and call the mechanic. The Oil Pressure Range should be from 175 to 500 kpa. Idle Condition: The idle should be smooth and up to 1400 rpm, with the choke on, and up to 1100 rpm without the choke. Check the Oil temperature, it should rise slowly and steadily to C, and the Cylinder Head Temperature should rise to C. The Exhaust Temperature Gauge (if fitted) should read between C. Turn the Auxiliary Fuel Pump OFF. Once the engine has warmed (EOT 50 C) proceed, if there is any doubt regarding the idle figures do not proceed. Ignition Drop at 2000 RPM: Increase the engine speed to 2000 rpm and check the ignitions individually. If a rpm drop of more than 200 rpm occurs shutdown the engine and call the mechanic. Maximum Power (not more and 2 mins): Open the throttle slowly until it is fully open, the engine should not falter or surge during this operation. Record the maximum static speed ( rpm) achieved; wait for 60 sec and then record the Oil Pressure, Oil Temperature, Cylinder Head Temperature and Exhaust Gas Temperature (if fitted). Carburettor heat Function: While at maximum Power apply the Carby Heat, a drop in speed should be noticeable (max to 200 rpm). VHF Functioning (BN 124.1) Readability: Call Brisbane for a radio check the result should be readability 4-5. If not, note for the Radio Technician. Engine Shutdown: Check the idle with the warm engine, it should be smooth 800 rpm. Turn both of the Ignition OFF and the engine should stop smoothly. Test Flying Page 3 10/04/02

4 5. Flight Test #1 Funcation Loading: Load the aircraft with only one pilot and a maximum of 20 L of fuel. Engine Start and Run-up: Start the engine normally and perform an engine run-up. Taxi: Taxi along the normal route to the fuel depot with the headsets removed. Listen for and note: Airframe sound Fuel Pump Functioning Strobe Flashing (if fitted) Suspension Movement Doors and Windscreen Structure Movement Wheel Bearings Tyres Rubbing on the Wheel Spats (if fitted) End Float, Front Steering Pivot Check and SEE the control movements Brake Tracking Approaching the fuel depot cut the engine. Check that the aircraft rolls freely without brake drag. At a slow speed without feet on the rudder pedals apply the brakes firmly, the brakes should pull straight and stop abruptly. On the movement area near the terminal building check the turning circle (left and right turns). The radius of the left and right turns should be the same. Face into and taxi into the wind. The aircraft should track straight with feet off the rudder pedals. Pre-take off Checks Listen for traffic and where possible wait for traffic to clear for fist flight. Carry out pre-take off checks as per operations manual. Advise traffic that a first flight is to be conducted. Record OAT, Wind Velocity, Wind Direction and Runway. Check controls for full and free movement. Takeoff: After lift off check instruments and LISTEN, FEEL and SMELL if in doubt abort. Climb to 300 ft reduce power to 2800 rpm and cruise climb at 80 kts over the airport. Monitor engine gauges. At 2000 ft trim for straight and level at 2800 rpm. Stability and Control Directional, Lateral and Longitudinal: If the rudder pedals are level and the aircraft flies straight with the bal in the centre the rigging is correct. If the ball is centred but the rudder pedals are displaced the rudder needs adjusting. If the ball is centred and the rudder pedals are level, and the aircraft still turns then the ailerons need adjustment. All of the corrections required should be recorded in the comments section at the end of this section. Landing: Test Flying Page 4 10/04/02

5 When landing check that the undercarriage does not have any usual noises, that the aircraft is easily controlled and that the brakes work. After Landing: Report all defects, rectify and re-test. 6. Flight Test # 2 Loading: This Flight Test is performed at MTOW. Two crew and enough fuel to bring the weight to 430 kgs and calculate CG position and check limits. Timed Climb - Performance: At the start of the climb record the Mean Pressure Altitude and the outside Air Temperature. Climb at 65 KIAS. From the start height, record the time taken to climb 1000 ft and the indicated rate of climb. Timed Climb Engine Parameters: With the engine at wide open throttle and the aircraft trimmed to 65 KIAS record the engine speed, Oil Pressure, Oil Temperature, Cylinder Head Temperature and Exhaust Gas Temperature (if fitted). Maximum Power Flight Performance: Record the mean pressure altitude, the outside air temperature, the maximum IAS in level flight with 3100 rpm. Maximum Power Flight Engine parameters: With the engine at wide open throttle and the aircraft in straight and level flight record the engine speed (RPM), Oil Pressure, Oil Temperature, Cylinder Head Temperature and Exhaust Gas Temperature (if fitted). Trim Speed Range (3100 rpm): In the cruise configuration record the trim speeds achieved. Trim speed limitations are for the forward trim position and in the aft trim position. Trim Speed Range (Idle 1300 to 1500 rpm): In the approach configuration record the trim speeds achieved. Trim speed limitations are for the forward trim position and in the aft trim position. Stalls: The stalls are performed in all configurations as per the table in the Production Flight Test Report. Record the speeds at which the stalls occur. If anything out of the normal occurs record it in the comments at the bottom of the section. V NE 116 KIAS: At V NE note the amount of buffeting and vibration as well as the controllability of the aircraft. 62 KIAS (Idle power): Reduce the power to idle and trim the aircraft for a 62 kt glide. Note the controllability and if the controls are rigged properly. Landings: Test Flying Page 5 10/04/02

6 When landing check that the undercarriage does not have any unusual noises, that the aircraft is easily controlled and that the brakes work. Taxi: During the taxi check the controllability, steering and brakes. Engine Shutdown: The engine should stop smoothly without back fire etc. 7. Post Flight Fuel Used: Record the fuel used in litres and calculate the weight of the fuel in kilograms. Climb Performance: Define the weight and calculate the rate of climb during the timed climb. Predicted Performance: Compare the rate of climb with the rate of climb listed on the Type Certification Data Sheet. The limits for climb performance are 425 to 545 fpm. Results (comment on the following): Engine Operation Throughout Avionics and Systems Operation Flight Performance Controllability Control Rigging Stability Trim and Handling Characteristics 8. Record of Aircraft Time in Service Flight No: Date Time in Service Test Flying Page 6 10/04/02

7 9. Record of Aircraft Defect Date Defect Corrected By 10. Certification I hereby certify that this aircraft complies with the certification flight test data and is fit for sale. Signed: Date: Jabiru Aircraft Pty Ltd Test Flying Page 7 10/04/02

8 JABIRU AIRCRAFT Pty Ltd For all models Production Flight Test Report Production Serial No. Aircraft Serial No. 1. Aircraft Identification Production Serial No. Registration Engine Propeller Airframe Hours Engine Hours 2. Compass Compass Deviation Swung In Place 3. Conformity Equipment correctly installed and functioning Control Ranges Control Markings Instrument Range Markings Harness Doors 4. Engine Run Starter Functioning Auxiliary Fuel Pump Functioning Engine Oil Pressure after Starting ( kpa) Idle Condition RPM ( RPM) EOP ( kpa) EOT ( <50-60C) CHT ( C) EGT ( C) If Fitted. Test Flying Page 8 10/04/02

9 Ignition Drop at 200 RPM Ign 1 (max 200) Ign 2 (max 200) Max Power RPM ( RPM) EOP ( kpa) EOT ( <50-118C) CHT ( C) EGT ( C) Carb. heat ( RPM) VHF Functioning - Readability Engine Shutdown Comments: Signed: Date: Jabiru Aircraft Pty Ltd Certificate of Approval # Test Flying Page 9 10/04/02

10 First Flight Form Registration No: Production Serial No: Date: Time: VDO Fuel Quantity Start RPM T/O PRM S&L ASI ALT IAS CHT OT OP EGT S&L Full Power RPM IAS ALT Stalls Stall S&L Idle Clean Stall S&L Idle Full Flap Suction Voltage Things To Do Incoming and Outgoing Time Finished VDO Fuel Quantity Finish Transfer information onto next page. Test Flying Page 10 10/04/02

11 5. Flight Test #1 Function Loading Basic Equipment Crew 1 only Fuel (max 20L) L Engine Start and Run-up Taxi Brakes (Pull straight, release 0 no drag) Steering (Runs straight feet off, radius left and right equal) Pre-Takeoff Checks Pressure Alt (1014 Hpa) OAT Wind Velocity Wind Direction Runway Controls Check Take-off Controllability Control Rigging Engine RPM ( KIAS Cruise Configuration Lateral and Directional Control Rigging Lateral and Directional Stability and Control Longitudinal Control Rigging and Trim Longitudinal Static Stability Flap Functions (2 stages at 70 KIAS) Performance Climb Cruise Descent Landing Comments: Signed: Production Test Pilot Date: Test Flying Page 11 10/04/02

12 6. Flight Test #2 Performance Loading Calculations CG Position Empty Position Arm [mm] Weight [kg] Index [kg.mm] Left Main Wheel Right Main Wheel Nose Wheel Total CG ============================== CG Position Loaded Position ARM[mm] Weight [kg] Index [kg.mm] Aircraft Empty Pilot Observer Fuel Total 1 Ballast (430 Total 1) Total CG ================================ Equations 1. Index = Weight x Arm [kg.mm] 2. CG = Ó Indexes AUW [mm] Test Flying Page 12 10/04/02

13 Stalls Straight and Level No Flap Idle Full Flap Idle 1 kt/sec Start from 60 kts (45 50 KIAS) (40 45 KIAS) Power Setting Flap Setting Condition KIAS Idle No Flap Straight 30 Bank to Left 30 Bank to Right 1 Stage Flap Straight 30 Bank to Left 30 Bank to Right 2 Stage Flap Straight 30 Bank to Left 30 Bank to Right Max Power No Flap Straight 30 Bank to Left 30 Bank to Right 1 Stage Flap Straight 30 Bank to Left 30 Bank to Right 2 Stage Flap Straight 30 Bank to Left 30 Bank to Right Trim Speed Range (3050 rpm) KIAS From to Clean (68 72 KIAS) (88 95 KIAS) Trim Speed Range (Idle 1300 to 1500 rpm) KIAS From to Full Flap (53 58 KIAS) (68 70 KIAS) Result 62 KIAS (Idle Power) Controllability 1 Control Rigging 1 Engine RPM ( RPM) rpm V NE 116 KIAS Vibration 1 Buffeting 1 Controllability 1 ( rpm) Test Flying Page 13 10/04/02

14 Max Power Level Flight Performance (3050 rpm) Pressure Alt. (1013 hpa) ft OAT C Level Flt IAS (95-99 KIAS) KIAS Max Power Level Flight Engine Parameters EOP ( kpa) kpa EOT ( C) C CHT ( C) C EGT ( C) C RPM ( rpm) rpm Timed Climb Performance Pressure Alt (1013 hpa) ft OAT C Start Height ft Finish Height ft Time to Climb 1000 ft secs Rate of Climb (indicated) fmp Prop RPM on Climb ( ) rpm Timed Climb Engine Parameters EOP ( k/pa) k/pa EOT ( C) C CHT ( C) C EGT ( C) C Jabiru Aircraft General Lateral and Directional Control Rigging Lateral and Directional Stability and Control Longitudinal Control Rigging and Trim Longitudinal Static Stability Landing Undercarriage Brakes Control Taxi Brakes Steering Controllability Engine Shutdown Comments: Signed: Date: Production Test Pilot Test Flying Page 14 10/04/02

15 7. Post Flight Fuel Used Climb Performance at Weight L x 0.72 kg / L kg kg Is the climb performance within or exceed the 10% climb gradient band YES/NO * *- if not; climb tests and data reduction must be performed Engine Operation Throughout Avionics and Systems Operation Flight Performance Controllability Control Rigging Stability Trim and Handling Characteristics Signed: Production Test Pilot Date: Test Flying Page 15 10/04/02

16 8. Record of Time in Service Flight No: Date: Time in Service 9. Record of Defects Date Defect Corrected By 10. Certification I hereby certify that this aircraft complies with the certification flight test data and is fit for sale. Signed: Date: For Jabiru Aircraft Pty Ltd Certificate of Approval # Test Flying Page 16 10/04/02