Jonker Sailplanes JS3 RES

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JS-MD 3 RES Maintenance Manual

Supplement

MD11-AMM-00-002

Issue: 00

Rev. 00

Rev. Date: 23-May-22

Page 4-11

RES Pylon

The pylon is the main structural component connecting the motor to the fuselage of the aircraft.

The pylon is a dynamic component that is extended and retracted into the fuselage of the

aircraft by the actuator assembly.

Overview

Main Page

Table of Contents8
List of Figures11
General15
Descriptive Data15
Technical Data15
Figure 1-1 JS3 with RES Pylon Extended15
Table 1-1 RES Technical Data15
Description of Systems and Components17
Introduction and Overview17
Figure 2-1 RES System Overview17
RES Kinematics Overview18
Figure 2-2 Kinematics Layout Overview18
Electrical System Overview19
Figure 2-3 Electrical System Overview19
Figure 2-4 Electrical Interaction Overview21
Table 2-1 Electrical Loads21
Airworthiness Limitations and Inspections23
Airworthiness Limitations23
Table 3-1 Life Limits Durations23
Maintenance Schedule25
Annual Inspection25
Table 4-1 Maintenance Requirement Schedule25
RES Actuator Assembly26
Figure 4-1 RES Actuator Assembly26
Figure 4-2 Actuator Assembly28
Table 4-2 Actuator Specifications28
Figure 4-3 Pylon Bell Crank Assembly29
Figure 4-4 Pylon Bell Crank Bracket Assembly31
Figure 4-5 Pylon Driver Arm Assembly33
RES Pylon35
Propeller36
Figure 4-6 Pylon Assembly36
Figure 4-7 Motor Wires Routing38
Figure 4-8 Propeller Assembly39
Electrical Motor43
Figure 4-9 Electrical Motor43
RES Doors46
Front Doors46
Figure 4-10 Doors Assembly46
Figure 4-11 Main Door Bell Crank Assembly48
Figure 4-12 Main Doors Assembly50
Figure 4-13 Front Doors Assembly52
Battery Latches54
Figure 4-14 Battery Latches54
Display and Control Unit (DCU)56
Figure 4-15 DCU56
LXNAV Bridge59
Motor Controller Assembly60
Figure 4-16 Motor Controller Overview61
Figure 4-17 Motor Controller Assembly61
Figure 4-19 Motor Controller Pcbs64
Figure 4-22 HV Wire69
DC-DC Converter81
Figure 4-20 Cooling Fans84
Figure 4-21 Motor Controller HV Wire Sequence84
Table 4-3 DC-DC Converter Specifications94
Retraction and Fuses Unit (RFU)97
Insulation Monitoring Device (IMD)98
HV Connectors99
Avionic Batteries103
Table 4-4 Seatpan Battery Specification103
Fire Warning System104
Calibration & Setup106
Actuator System Setup106
Figure 5-1 Fuselage Clearance107
Figure 5-2 Pylon Driver Arm Extension107
Figure 5-3 B9 Bulkhead108
Actuator Calibration109
Main Door Setup109
Motor Resolver Calibration110
Figure 5-4 Main Door Setup110
Propeller Alignment111
Wiring Loom114
Display and Control Unit (DCU)114
Figure 6-1 DCU Wiring114
RES Control Board (RCB)115
Figure 6-2 RCB Wiring115
Retraction and Fuses Unit (RFU)117
Actuator117
Figure 4-24 RFU118
Figure 6-3 RFU Wiring118
Figure 6-4 Actuator Wiring118
Left Battery Connector119
Figure 6-5 Left Battery Connector Wiring119
Charger Connector120
Right Battery Connector120
Figure 6-6 Charger Connector Wiring120
Figure 6-7 DC-DC Converter121
Figure 6-8 Right Battery Connector Wiring122
Motor, Motor Controller and Resolvers123
Figure 6-9 Motor, Motor Controller, and Resolvers Wiring123
Cooling Fans124
Figure 6-10 Cooling Fans Wiring124
Insulation Monitoring Device (IMD)125
Figure 6-11 IMD Wiring125
Avionic Batteries126
Figure 6-12 Avionics Battery Wiring126
Ground Bus127
Figure 6-13 Ground Bus Wiring127
Supplementary Fire Warning System128
Figure 6-14 Supplementary Fire Warning System Wiring128
LXNAV Bridge129
Complete Schematic130
Supplementary Information and Pictures131
Lubrication133
Introduction133
Lubricants133
Lubrication Plan133
Figure 7-1 Lubrication Points134
System Operation135
Guarded RES Master Switch135
Figure 8-1 Guarded RES Master Switch135
Display and Control Unit Interface136
Battery Selection Switch136
Figure 8-2 DCU Primary Controls136
Operational Mode137
Figure 8-3 Standby Screen137
Figure 8-4 Extension/Retraction Screen138
Figure 8-5 Extended Screen139
Figure 8-6 Propulsion Screen140
Figure 8-7 Battery Charging Screen141
Other Information Screens142
Figure 8-9 Message Screen142
Figure 8-10 System Screen143
Warning Caution and Information Messages144
Figure 8-11 Warning Screen144
Maintenance Mode145
Setup Menu145
Figure 8-12 Service Screen145
Figure 8-13 Setup Screen145
Charge Mode146
Fire Warning System146
Figure 8-14 Fire Warning System146
Software/ Firmware Update147
Requirements for Firmware Updated147
DCU Firmware Update147
RFU Firmware Update148
Accessing the Motor Controller Parameters149
Figure 9-1 Adapter Installation149
10 High Voltage Batteries151
Overview151
Figure 10-1 Battery Overview151
Inspections152
Trailer Considerations152
Battery Status Indicators153
Figure 10-2 Battery Status Indicators153
Battery Handling154
Installing the HV Batteries154
Battery Care155
Long Term Storage155
Figure 10-3 Dual Battery Operation155
Figure 10-4 Single Battery Operation155
Charging157
Figure 10-5 Dual Battery in Aircraft Charging157
Figure 10-6 Single Battery in Aircraft Charging158
Figure 10-7 External Dual Battery Charging158
Figure 10-8 External Single Battery Charging159
11 Placard Booklet160
Figure 11-1 RES Placard Booklet160
13 Service Bulletins163
14 Contact166
APPENDIX A - Annual Inspection Checklist168
APPENDIX B - General Torque Specifications172
APPENDIX C - Stcs and Minor Change Approvals174
Appendix D - List of Warnings/Cautions176

Jonker Sailplanes JS3 RES - RES Pylon

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