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 ii

Intentionally left blank

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 - Page 4

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