MAINTENANCE MANUAL - Stemme AG

A4010022_B12_97.doc-0/04.12.07 16:33/05.12.07 08:57
Stemme AG – Flugplatzstrasse F2 Nr. 7 - Germany-15344 Strausberg
MAINTENANCE MANUAL
for the powered sailplane STEMME S 10
Document No. A40-10-022
Date of Issue: October 1, 1990
The pages forming the Airworthiness Limitations Section have been approved by the
Luftfahrt-Bundesamt, FRG. They are marked "LBA approved" and held in yellow colour.
................................................ (Signature)
(Stamp)
................................................ (Original date of approval)
This Maintenance Manual is based on the original in the German language. It comprises
some deviations due to specific FAA requirements and unique U.S. aircraft specification.
Model: STEMME S 10 Serial number: 10-
Type Certificate: EASA.A.054 (former LBA 846) / FAA No. G 58 EU Registration: N-
Non-standard equipment or systems with effect to the contents of this manual, if installed, are entered in the table on page 1.
Druck-Info: Datei enthält 68 Seiten gesamt

Maintenance Manual STEMME S 10 Date of Issue Oct. 1, 1990 page: 2-1
0.1 Record of Amendments
Amendment No.: 12 Date: Nov. 30. 2007
Any amendment of the present manual must be recorded in the following table. Exempted are:
Data relating to the installation of alternative equipment (page 1)
Data relating to the installation of supplemental or additional equipment (page 51)
Deletion of inapplicable text passages pursuant to the Service Bulletin A31-10-008.
The list of amendments on this page and the list of effective pages on the next page are assigned to the
serial number. The indicated revision no. in the headline of these pages does not change with later entries
in the lists.
Information as to which amendments must be included in the present Manual can be seen from the current
"Record of Airworthiness Directives and Service Bulletins" (see Annex B, doc. no. A08-10-000).
The new or amended text of the latest amendment will be marked on the revised page by a black vertical line
on the right hand margin. Any Amendment Numbers applied to the specific page and the date of the most
recent amendment is indicated on the right hand side in the headline of each page. In text passages
concerned by the installation of alternative equipment, the text for both versions is included in [ ]; the text not
applicable to the serial number concerned must be crossed out. For further information please refer to
Section 9.3 or to the Service Bulletin A31-10-008.
The inspector certifies by his signature at the same time the correct transfer of the information specific to the
serial number (deletion of inapplicable text passages).
Am.
No.
Affected
Sections
Removed Pages included Pages
Amendment
Date
Date of
inclusion
Signature
1 0, 4 4, 21 4, 21 Aug. 15, 1991 Aug. 15, 1991 ex works
2 0, 4 4, 21, 22 4, 21, 22 March 1, 1993 March 1, 1993 ex works
3 0, 9, 10, 11, 12,
13
1, 2, 3, 5, 51, 53,
54, 55, 56
4 3, 12 14, 15, 47*,
Fig. 3.3.2.a * ,
Fig. 3.6.b*
Title p., 1, 2, 3, 5,
51, 53 to 56,
Cover p. Annex A,
B, and C
14, 15, 47*,
Fig. 3.3.2.a*,
Fig. 3.6.b*
5 not issued
6 3, 4, 10, 12 13, 25, 55,
Fig. 3.2.b
7 3, 5, 12 4, 13, 14, 24 ··· 26,
Fig. 3.2.a ··· g,
Fig. 6.4.1.a
13, 25, 55,
Fig. 3.2.b
4, 13, 14, 24 ··· 26,
Fig. 3.2.a ··· g,
Fig. 6.4.1.a
July 1, 1993 July 1, 1993 ex works
May 26, 1993 May 26, 1993 ex works
Feb. 10, 1994 Feb. 10, 1994 ex works
Dec. 05, 1994 Dec. 05, 1994 ex works
8 0, 5 2 ··· 5, 26 ··· 30 2 ··· 5, 26 ··· 30 Aug. 8, 1996 Aug. 8, 1996 ex works
9 3, 5, 6, 7, 8 2...5, 19 ,28, 29, 33,
42, 44, 45, 48
2...5, 19 ,28, 29, 33,
42, 44, 45, 48
10 0,4 2, 3, 21, 22 2, 3, 21, 22-1, 22-2 March 16, 2005
11 0,3,4,5,7,9 2..5, 18, 21, 22-1,
22-2, 27...30, 36,
38, 51..54
2..5, 18, 21, 22-1,
22-2, 27...30, 36,
38, 51..53, 54-1,
54-2
April 19, 1999 April 19, 1999
May 25. 2005
*
These pages may only be incorporated with the quoted amendment number if the alternative equipment
item requiring the amendment is installed in the individual aircraft - please check the entries on page 1 for
the corresponding SB. Amendment no. 4 is mandatory for U.S.A.
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Maintenance Manual STEMME S 10 Date of Issue Oct. 1, 1990 page: 2-2
Am.
No.
Affected
Sections
12 0, 7, 4, 12 Title, 2, 3, 21, 22-1,
22-1, 38, Fig. 6.3.a,
Removed Pages included Pages
Title, 2-1, 2-2, 3, 21,
22-1, 22-1, 38, Fig.
6.3.a-1, Fig. 6.3.a-2
Amendment No.: 12 Date: Nov 30. 2007
Amendment
Date
Nov 30. 2007
Date of
inclusion
Signature
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Maintenance Manual STEMME S 10 Date of Issue Oct. 1, 1990 page: 3
0.2 List of effective pages
Amendment No.: 12 Date: Nov. 30. 2007
This record is valid only for the Serial No. specified on the title page. Any amendment is contained ex works
that is effective for this Maintenance Manual at Aug. 08, 1996 (amendment status 08). Related to alternative
equipment, only those amendments is provided for that correspond to the entries on page 1, amendments
that are included later must be entered by hand.
Section Page Am. No. Date
-- Title 12 Nov. 30, 07
-- 1 3 July 1, 93
0.1 2-1 12 Nov. 30, 07
0.1 2-2 12 Nov. 30, 07
0.2 3 12 Nov. 30, 07
0.3 4 11 May 25. 05
0.3 5 11 May 25. 05
res. 6 Oct. 1, 90
1 7 Oct. 1, 90
res. 8 Oct. 1, 90
2 9 Oct. 1, 90
2 10 Oct. 1, 90
res. 11 Oct. 1, 90
3.1 12 Oct. 1, 90
3.1/3.2 13 6, 7 Dec. 5, 94
3.3 14 4, 7 Dec. 5, 94
3.3 15 4 May 26, 93
3.3 16 Oct. 1, 90
3.4 17 Oct. 1, 90
3.5/3.6 18 11 May 25. 05
3.7/3.8 19 9 Apr. 19, 99
res. 20 Oct. 1, 90
4 21 12 Nov. 30, 07
4 22-1 12 Nov. 30, 07
4 22-2 12 Nov. 30, 07
5.1/5.2 23 Oct. 1, 90
5.2 24 7 Dec. 5, 94
5.2 25 6, 7 Dec. 5, 94
5.2 26 7, 8 Aug. 8, 96
5.2 27 11 May 25. 05
5.2 28 11 May 25. 05
5.2 29 11 May 25. 05
Section Page Am. No. Date
5.3 30 11 May 25. 05
6.1/6.3 31 Oct. 1, 90
6.4/6.5 32 Oct. 1, 90
6.6 33 9 Apr. 19, 99
res. 34 Oct. 1, 90
7.1/7.3 35 Oct. 1, 90
7.3 36 11 May 25. 05
7.3 37 Oct. 1, 90
7.3/7.4 38 12 Nov. 30, 07
7.4 39 Oct. 1, 90
7.4 40 Oct. 1, 90
7.4/7.6 41 Oct. 1, 90
7.7/7.8 42 9 Apr. 19, 99
res. 43 Oct. 1, 90
8 44 9 Apr. 19, 99
8 45 9 Apr. 19, 99
8 46 Oct. 1, 90
8 47 4 May 26, 93
8 48 9 Apr. 19, 99
8 49 Oct. 1, 90
res. 50 Oct. 1, 90
9.1 51 11 May 25. 05
9.2, 9.3 52 11 May 25. 05
9.3 53 11 May 25. 05
9.3 54-1 11 May 25. 05
9.3 54-2 11 May 25. 05
10, 11 55 3, 6 Feb.10, 94
12 56 3 July 1, 93
Figure to
Section
Am. No. Am. Date
2.a Oct. 1, 90
3.2.a 7 Dec. 5, 94
3.2.b 7 Dec. 5, 94
3.2.c 7 Dec. 5, 94
3.2.d 7 Dec. 5, 94
3.2.e 7 Dec. 5, 94
3.2.f 7 Dec. 5, 94
3.2.g 7 Dec. 5, 94
3.3.a Oct. 1, 90
3.3.2.a 4 May 26, 93
3.4.1.a Oct. 1, 90
3.5.a Oct. 1, 90
3.5.b Oct. 1, 90
3.6 Oct. 1, 90
3.6.a-1 12 Nov. 30, 07
3.6.a-2 12 Nov. 30, 07
3.6.b Oct. 1, 90
3.6.c Oct. 1, 90
3.6.d Oct. 1, 90
3.6.e Oct. 1, 90
3.6.f Oct. 1, 90
6.3.a Oct. 1, 90
6.3.b Oct. 1, 90
6.4.1.a 7 Dec. 5, 94
6.4.2.a Oct. 1, 90
7.4.1.a Oct. 1, 90
Annex A
(Cover Page)
Annex B
(Cover Page)
Annex C
(Cover Page)
3 July 1,1993
3 July 1,1993
3 July 1,1993
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Maintenance Manual STEMME S10 Date of Issue: Oct. 1, 1990 page: 21
4. Airworthiness Limitations Section
Amendment No.: 12 Date: Nov 30. 2007
LBA approved
This section is FAA-approved for U.S. registered powered sailplanes in accordance with the provisions of
14 CFR Section 21.29. In addition, this section is required by FAA Type Certificate No. G 58 EU and it
specifies maintenance required under 14 CFR Sections 43.16 and 91.163 unless an alternative program has
been FAA-approved.
The permissible operating times of all parts, components and assemblies assigned for installation - in series
or optional - in the powered sailplane STEMME S10 and subject to service life limitations, are notified by the
Service Bulletin no. A31-10-001. When the limitation of at least one item changes, this SB will be reissued in
a revised version. The document no. will be maintained in this case, the amendment no. will be advanced
(the letter in the amendment index is for internal use only).
The pages of this section are printed on yellow paper for better discernment. They may not be revised without
FAA engineering approval. Regulations upon keeping of service records must be observed.
Excerpt of Service Bulletin A31-10-001 Amendment-No: 12.a: Review of permissible operating times:
No.
S10
Model Permissible op. time by
S10-V
S10-VT
Part/Assembly/
Equipment
1 X X X Airframe
(Composite structure)
2 X X Limbach Engine
Manufacturer,
Type
Part No.
(STEMME)
Overhaul
(TBO)
Replaceme
nt
NOTES
STEMME sundry 6000 h 6000 h (1)
Limbach
L 2400 EB 1.D
L 2400 EB 1.AD
10AM-MOL (2)
3 X X Magneto for Limbach Slick 4230 (from Limbach) (2)
4 X Rotax Engine
5 X
Propeller
(fixed pitch)
ROTAX 914
F2/S1
11AM-M
1200 h
(12 years)
(5)(8)
STEMME 10AP-N 400 h (3)(4)
6 X Lateral parts STEMME
10AP-N01
10AP-N11
1000h (4)
7 X Fix-Pitch Propeller STEMME 10AP-F 400 h (3) (4)
8 X Centre Part STEMME 10AP-F01 2000 h (4)
9 X Variable pitch propeller STEMME 10AP-V
200 h
(5 years)
(3)(4)(10)
10 X Variable pitch propeller STEMME 11AP-V
200 h
(5 years)
(3)(4)(10)
11 X X Propeller hub STEMME 10AP-V01 2000h (4)
12 X
Propeller fork and
X
its fastening
STEMME
10AP-V88,
-V77, -V78, -VU
400h (3)(4)
13 X X
Reduction Gear
(vee-belts)
STEMME 10AG 400 h (3)(4)
14
Reduction Gear
X
(cog wheels)
STEMME 11AG 1000 h (3)(4)
15 X Gear suspension STEMME 10AA
1000 h
(12 years)
(4)(11)
16 X Gear suspension STEMME 14AA
1000 h
(12 years)
(4)(11)
17 X Gear suspension STEMME 11AA
1000 h
(12 years)
(4)(11)
18 X X
Flywheel clutch
(2 flyweights)
STEMME 10AK 400 h (3)(4)
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Maintenance Manual STEMME S10 Date of Issue: Oct. 1, 1990 page: 22-1
No.
S10
Amendment No.: 12 Date: Nov 30. 2007
LBA approved
Model Permissible op. time by
S10-V
S10-VT
Part/Assembly/
Equipment
Manufacturer,
Type
Part No.
(STEMME)
Overhaul
(TBO)
Replaceme
nt
NOTES
19
Flywheel clutch
X
(3 flyweights)
STEMME 11AK 400 h (3)(4)
20 X X Driveshaft
Ciba-Geigy
(without P/N ref.)
10AS-07 800 h (3)(4)(9)
21 X X X Driveshaft
Glaenzer-Spicer
19.01.01.xxx
10AS-07 800 h (3)(4)(9)
22 X X X Driveshaft
MAN Techn. AG
95.0700.00.000
10AS-W 800 h (3)(4)(9)
23 X X X Driveshaft STEMME 10AS-F 800 h (3)(4)(9)
24
rubber parts of the
X
engine
Rotax sundry 5 years (7)
25 X X
Rubber parts of the
clutch
STEMME
10AK-43
10AK-48
12 years
26 X X
flexible disk of the drive
shaft system
STEMME 10AS-09 12 years
27
flexible disk of the drive
X
shaft system
STEMME 11AS-09 12 years
28 X X Fuel Hoses STEMME 10AB-... - 5 years
29 X X Fuel hoses STEMME HZ-KSL014 - 5 years
30 X X X Fuel Hoses STEMME HZ-KSL010 - 5 years
31 X X Lubrication Hoses STEMME 10AM-KÖS / ~T - 5 years
32 X Lubrication Hoses STEMME 11AM-O... - 5 years
33 X Coolant Hoses STEMME 11AM-W... - 5 years
34 X X X Brake Hoses sundry 10FO-B06 - 10 years
35 X X X Safety Harnesses sundry 10C-08/-09 - 12 years (6)
36 X X
Control Rod
X
Connectors
L'Hotellier 10M-098/-099 (2)
37 X fuel check valve Stemme 11AB-M03 5 years 10 years (12)
On expiry of a part’s permissible operating times the affected part has to be sent to the manufacturer or to a
from the manufacturer approved repair/overhaul workshop for inspection. The organisation has to decide if
further use is possible after the inspection, or if an replacement or overhaul or repair is necessary.
If the limitation is given in operating hours and in a calendar period (year), the first occurring case applies.
If further equipment subject to service life limitations is installed, the overhaul intervals and service life limits
prescribed by the respective manufacturer must be observed. The item has to be entered in the form Review
of Operating times.
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Maintenance Manual STEMME S10 Date of Issue: Oct. 1, 1990 page: 22-2
NOTES:
Amendment No.: 12 Date: Nov 30. 2007
LBA approved
(1) Extension of service life exceeding 6000 h can be achieved only for individual airplanes after a comprehensive
inspection of the airframe carried out by the manufacturer according to an approved program.
(2) Please refer to the actual issue of the appropriate manufacturer's Service Bulletin. Maintenance Manuals
or Instructions of the manufacturer must be strictly adhered to (for L'Hotellier Ball and Swivel Joints contained
in the Annex to the Maintenance Manual).
(3) The stated times are provisional within the TBO development programs. Based on sufficient operating
experience they may be further raised or reduced if necessary (extension of TBO and/or service life is
intended) and will be notified by a new issue of this Service Bulletin.
(4) The TBO expires in each case of:
• impact stop (possible ground touch of the propeller);
• Non-observance of the periodical inspections as they are fixed in the Maintenance Manual;
• replacement of essential parts.
Damaging by ground contact, bird strike, stone strike or similar which require a „large repair“, the
manufacturer decides which parts of the complete drive system are affected and if a repair may be
practicable or if an overhaul or replacement have to be performed.
(5) see also ROTAX SB 914-027 “Extension of the Time Between Overhaul (TBO)“.
For Engines ROTAX 914F2/S1 up to S/N: 4.420.313 after performing of the ROTAX SB 914-027, for all other
engines from S/N: 4.420.314 without any more actions.
(6) Replacement required after heavy overloadings (e.g. due to an accident); hereto refer also to the
operating instructions of the manufacturer.
(7) All rubber parts of the engine Rotax 914 F2/S1 must be renewed. Subject to this action are: the
carburetor venting hoses (between airbox-carburetor float chambers-fuel pressure control and pressure
sensor), the air hoses between Turbo Charger-Intercooler-Airbox, the connecting hoses on the compensating
tube, the V-belt, all rubber hoses of the cooling system, and the rubber diaphragms and the rubber flange on
both carburetors.
(8) For the STEMME supported model of the engine type Rotax 914, the TBO is established by this SB on
the basis of that published by Rotax, and in general it will not differ. Overhaul of engines model
Rotax 914 F2/S1 must be carried out by a workshop that is authorized by STEMME in accordance with
Rotax.
(9) The drive shaft cannot be overhauled. Instead of an overhaul it will be checked by a load test at
STEMME.
(10) After 5 years the variable pitch propellers 10AP-V and 11AP-V will not be overhauled. The propeller will
be inspected only. During the inspection the propeller will be disassembled, inspected and reassembled.
(11) During the overhaul of the gear suspensions 10AA, 14AA and 11AA all rubber parts are replaced
(overhaul program: D40-10AA; D40-14AA or D40-11AA). The metal parts will be used again.
(12) The fuel check valves can not be overhauled. The check valves will be checked visually after 5 years.
Indications of a brittleness or change of the original colour must be specially observed. The parts must be
untimely replaced if such a indication were found.
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Maintenance Manual STEMME S10 Date of Issue: Oct. 1, 1990 page: 38
7.3.10 Drivetrain System
Adjustment of the Belts on the Transmission Gear:
Amendment No.: 12 Date: Nov 07. 2007
Loosen the clamping screw on the left lower side of the transmission gear. Adjust the belt tension (per belt)
by means of the setting screw on the left transmission gear side to 0.15 in. (3.7 mm) press-down depth
halfway between the axes exerting a press-down force of 11.2 lbf. (50 N). Tighten the clamping screws.
Insufficient belt tension is indicated by slipping together with "squeaking" at full power or when the power
lever is pushed forward suddenly.
Removal:
The propeller shaft can be removed together with transmission gear and the propeller in one step:
− Remove the propeller dome: lift off left and right leg room coverings in the cockpit, Loosen clamping screw
on the stay tube of the propeller dome, pull out locking screw, disconnect flexible hoses, disconnect the
antenna connection to transponder/GPS, withdraw the dome to the front.
− Disconnect the control cable of the propeller brake on the transmission gear.
− Loosen four fastening screws on the transmission gear supports, loosen balancing spring on top of the
transmission gear.
− Pull out transmission gear with propeller shaft.
− The engine side clutch remains on the engine. Removal by loosening of the attachment screws on the
engine flange.
Installation:
− In the opposite order as removal. Attention: Clean and regrease splined sliding joint.
− For tightening moments please refer to section.6.6, page 33.
7.4 Landing Gear
7.4.1 Main Landing Gear
Check the main landing gear legs and the trailing arms for deformation and possible cracks as an result of
overloads.
Adjustment Data: see fig. 3.4.1.a
Functional Check:
Support the aircraft (clearance between the main wheels and the ground must be approximately 1.6 in. / 40
mm), remove upper cowling of the central fuselage.
Checking procedure:
− Inspect screw joints (torque paint);
− check wheels for smooth turning;
− joint heads of the operating arms may not be jammed;
− the articulations of the spindles and the operating arms must have play;
− installation of the landing gear emergency release system without kinks/collisions;
− landing gear stop switches on the operating arms: check for halfway position and proper functioning,
inspect wiring / connection;
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Maintenance Manual STEMME S 10 Date of Issue Oct. 01, 1990 fig. 6.3.a-1
Serial Number:
-
Registration:
-
Amendment No.: 12 Date: Nov. 30. 2007
Relevant Equipment List:
Order No.:
This Weight and Balance Report was drawn up without weighing. Any weighing data have been taken from the
Weight and Balance Report dated and if need be corrected according to point 4.2.
Drawing Up Reason: Conformity Inspection
Changes of Equipment
Repair. Date of Findings Report:
Other:
1. Preparation and Conditions
1.1 The fuselage weight must be determined including rudder, back rests with cushions or equivalent upholstery, seat cushions,
canopy, standard tool kit in baggage compartment behind backrest, Logbook and Flight Manual. Replenish oil if necessary.
Fixed ballast must be installed, loose ballast must be removed.
1.2 Wing weight must be determined with bolts and 3 l / 0.66 imp. gal. fuel (unusable volume).
1.3 Fixed supplementary equipment must be installed.
1.4 Points 1.2 through 1.4 must be observed if an overall weighing of the powered glider is performed. The canopy has to be
closed during weighing.
1.5 If weight and moment arm of additionally installed or removed items is known exactly, the new CG may be determined
numerically (see point 4.2)
2. Overview of Component Weights and Weight Limits
Component Weights from Separate
Weighing
[kg]
[lbs] ***
[kg]
[lbs] ***
Weight Limits [kg]
Fig. 6.3.a Mass and Balance Sheet (Pattern; the complete form can be obtained from the
manufacturer)
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[lbs] ***
Central Wing Maximum All Up Weight (incl. Fuel) 850 (1874)
Right Hand Outer Wing
Left Hand Outer Wing
Maximum Weight of Non-Lifting Parts
GNTmax (incl. Load in Cockpit)
Of that: Maximum Weight of Equipment on
Instrument Panel, without engine instruments
Fuselage Maximum Load (Max AUW - Empty Weight)
Horizontal Tail
Component Weight Sum
Empty
Weight*
LNT**
Max. Load in Cockpit
(GNTmax - LNT**; maximum 202 kg / 445 lbs,
of that max. 180 kg / 397 lbs in seats, max.
110 kg / 243 lbs in each seat and max. 22 kg
/ 48.5 lbs in baggage compartments)
Cockpit load must be at least 7 kg / 15,43
lbs less than maximum load!
* cross-check: compare with empty weight from 3.; Divergence of 2 kg / 4.4 lbs due to measure error is allowable.
** LNT: Empty weight of "Non Lifting Parts"
*** Units: cross out if not applicable
3. Determining of Empty Weight and Moment Arms
Weights and Moment Arms ***:
forward RH mr kg / lbs
forward LH ml kg / lbs
Tail Wheel ms kg / lbs
Σ=Empty Weight me kg / lbs
Moment Arm a mm / in.
Moment Arm b mm / in.
Datum level: Leading Edge of
Central wing, vertical plane
Pitch: wedge 1000:84 (4°50') on tail
cone, upper edge horizontal
570 (1257)
10
(22)

Maintenance Manual STEMME S 10 Date of Issue Oct. 01, 1990 fig. 6.3.a-2
4. Determining of Empty Weight Center of Gravity
4.1 After Weighing:
x
S
mSb =
m
⋅
+ [mm / in.]*** ⇒ x S =
e
a
4.2 After Changes, without Weighing:
Following changes have been made on the powered glider:
Install. /
Removal
Amendment No.: 12 Date: Nov. 30. 2007
Fig. 6.3.a Mass and Balance Sheet (Pattern; the complete form can be obtained from the
manufacturer)
A4010022_B12_97.doc-0/05.12.07/08:43
Item
⋅
+
Weight ( + /-)
m = [kg / lbs]***
Moment Arm ( + /-)
x = [mm / in.]***
Sum mzus= Sum Mzus=
NOTE: Count weight installed positive, weights removed negative.
Count moment arms aft of datum positive, in front of datum negative.
x
Sneu ,
m ⋅ x + M
=
m
alt alt zus
neu
[mm / in.] ⇒ x S , neu =
5. Definition of Minimum Load Required
⋅ +
With Empty Weight determined: kg / lbs***
and the empty weight CG aft of datum: mm / in. ***
the Minimum Load Required is ****: kg / lbs***
*** Units: cross out if not applicable
****According to Maintenance Manual, Section 6.3
= [mm / in.]***
= mm / in. ***
Site, Date Stamp Sign Job Leader
Moment ( + /-)
M =[mm kg / in. lbs]***
Inspector Statement: All measured data are within the allowable ranges and correspond to the production and
maintenance instructions of the type.
Site, Date Stamp Sign Inspector