1、Designation: F 2563 06Standard Practice forKit Assembly Instructions of Aircraft Intended Primarily forRecreation1This standard is issued under the fixed designation F 2563; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year
2、of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This practice covers the instructions a kit producer mustprovide to a consumer in order to assemble and safelyflig
3、ht-test a recreational aircraft to ensure compliance withapplicable ASTM standards.1.2 The instructions prescribe the necessary mechanicalskills or training, or both, required for successful completion ofthe kit, as well as necessary tooling, fixtures, inspections,measurements, and other pertinent i
4、tems required for success-ful completion of the kit. Proof of compliance with theseinstructions may be vital for obtaining flight authorizationsfrom the applicable CAA.1.3 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of
5、 the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2. Terminology2.1 Definitions:2.1.1 consumerany person who follows the instructionscovered by this practice to assemble the kit.2.1.2 operationproc
6、ess or action that is part of a series inthe assembly of a kit. It is identified by the kit producer as ameans to partition the aircraft assembly task into subgroups oftasks or processes that allow the consumer to track progress orcompletion of portions of the kit in an orderly manner.2.1.3 producer
7、any person or company who fabricates thekit and authors the instructions covered by this practice.2.2 Acronyms:2.2.1 CAACivil Aviation Authority2.2.2 CAGEcommercial and government entity2.2.3 KAIkit assembly instructions3. Required Sections3.1 The KAI shall include at least the following information
8、(preferably in the same sequence as numbered in 3.1.1):3.1.1 (1) Revisions; (2) Introduction and instructions forusing the KAI; (3) Table of Contents; (4) Safety Summary; (5)Applicable standards and specifications; (6) Terminology; (7)Required consumer abilities and responsibilities; (8) Requiredequ
9、ipment and environmental conditions; (9) Parts list; (10)Assembly operations; (11) Final assembly Inspections; (12)Flight-test procedures; and (13) Additional requirements.NOTE 1The required information may be provided in separate booksor volumes.4. Revisions4.1 The kit provider shall update the KAI
10、 when changes ofform, fit, or function are identified as needed in the aircraft orits sub-components via a revision to the KAI.4.2 KAI revisions shall be uniquely identified by date,purpose, and applicable KAI section.4.3 The KAI shall include a form to be used to providefeedback on the document to
11、the kit producer on errors,anomalies, suggestions, or queries. The form shall identify thesource document, user, date, subject, discussion, and returnableacknowledgement sections for each communication as a mini-mum.5. Safety Summary5.1 The KAI shall provide a list of potential hazardsassociated wit
12、h kit assembly. It is important to note that no listof potential hazards could ever include every possible hazard.This section is intended to serve as an advisory to all parties toenhance safety.5.1.1 ChemicalsIf hazardous chemicals are used in theassembly of the kit, it is advised that information
13、such asMaterial Safety Data Sheets (MSDS) or equivalent be providedin the KAI.6. Applicable Standards6.1 The KAI shall list the title, source, and significance ofthe aircraft standards applicable to the aircraft.7. Required Consumer Abilities and Responsibilities7.1 Consumer Skills and Training:7.1.
14、1 The KAI shall prescribe any specific skills or trainingnecessary to complete each operation.1This practice is under the jurisdiction of ASTM Committee F37 on Light SportAircraft and is the direct responsibility of Subcommittee F37.70 on Cross Cutting.Current edition approved Aug. 1, 2006. Publishe
15、d August 2006.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.7.1.2 The KAI shall prescribe any specific responsibilitiesthe producer expects the consumer to assume for completion ofthe kit.7.1.3 The KAI shall prescribe the responsib
16、ilities of thecustomer for obtaining a flight authorization from the appli-cable CAA. Deviation from the instructions or unauthorizedmodifications may prohibit the assembled aircraft from obtain-ing a flight authorization. Such information shall be providedin the KAI.8. Required Equipment and Enviro
17、nmental Conditions8.1 Required Equipment and Parts:8.1.1 The KAI shall prescribe any specific equipment nec-essary for completion of each operation such as, but not limitedto, tooling, jigs, parts, and fixtures. This list should includespecific manufacturers (CAGE codes if applicable), part num-bers
18、, quantity, and description if possible.8.1.2 The KAI may prescribe any specific equipment rec-ommended for completion of each operation.8.2 Required Environmental ConditionsThe KAI shallprescribe any specific environmental conditions necessary forcompletion of each operation such as, but not limite
19、d to,temperature range, humidity, wind, dust, and lighting.9. Parts List9.1 The KAI shall contain a parts list of all the kit parts (orsubassemblies) listing a part number or identifier, description,and quantity.9.2 A unique part number or identifier shall be assigned toeach unique assembly, subasse
20、mbly, detail part, or consumablematerial provided in the kit.9.2.1 Adescription shall be provided with each identifier foreach unique part.10. Assembly Operations10.1 This section shall specify the order in which assemblyoperations should be completed. If operations can be done inrandom order, this
21、shall also be specified.10.1.1 Each KAI assembly operation section shall include aspace for the builder to log completion date and participation.It is recommended that there be a place for the builder todocument time spent performing each operation as well.10.2 Pre-Assembly Operations and Checklists
22、The KAIshall prescribe any specific pre-assembly operations and check-lists necessary for the completion of each operation. At aminimum, it is recommended that the instructions for eachoperation provide a checklist for the skills, tools, parts, andconditions required to complete that operation.10.3
23、Assembly OperationsEach assembly operation sec-tion shall include information such as text, photos, templates,electrical schematic drawings, or technical drawings sufficientto explain how to perform that operation and ensure compli-ance with the design criteria.10.4 Post-Assembly Inspections and Mea
24、surementsEachassembly operation section shall prescribe any specific inspec-tions, measurements, or criteria necessary for verifying suc-cessful completion of that operation.11. Final Assembly Inspections11.1 Systems InspectionsThe KAI shall prescribe specificsystem inspections necessary for verifyi
25、ng successful operationof each system.11.2 Engine Start-Up and Break-InThe KAI shall pre-scribe any specific procedures necessary for initial enginestart-up and break-in.11.3 Pre-Flight Tests and VerificationsThe KAI shallprescribe any specific tests and verifications required prior toinitial test f
26、lights.11.3.1 The KAI shall include the Production Acceptanceand Quality Assurance procedures that relate to the finalassembly checks required to show compliance with the appli-cable ASTM standards.11.4 CAA Documentation and AuthorizationsThe KAIshall provide the manufacturers documentation necessar
27、y forobtaining all required registration, inspections, and authoriza-tions from the applicable CAA. Check Appendix X2 forinformation regarding various countries requirements.12. Flight-Test Procedures12.1 Flight-Test ObjectivesThe KAI shall prescribe anyspecific flight-test objectives necessary for
28、verification ofsuccessful operation.12.2 Flight-Test Environmental ConditionsThe KAI shallprescribe the environmental conditions for conducting initialflight-tests.12.3 Flight-Test Procedures and ManeuversThe KAIshall prescribe any specific flight-test procedures and maneu-vers necessary for verific
29、ation that the controls and systemsoperate within the limits established in the manufacturerspublished aircraft operating instructions.12.3.1 The KAI shall include the Production Acceptanceprocedures that relate to the flight test procedures required toshow compliance with applicable ASTM standards.
30、12.4 Post Flight-Test Documentation and NotificationsThe KAI shall prescribe any specific flight-test documentationor notifications required for verification of successful opera-tion.13. Keywords13.1 assembly; authorization; flight test; instructions; modi-fications; operation; parts list; registrat
31、ion; verificationF2563062APPENDIXES(Nonmandatory Information)X1. METHODS OF COMMUNICATIONX1.1 Formats:X1.1.1 Electronic documents are acceptable so long as theyare viewable on freely distributed software, such as Acrobatviewer, or other no-cost format, such as HTML, or be viewedwithout purchasing ad
32、ditional software. If electronic data isprovided in a proprietary format, the kit producer shall provideviewing software.X1.2 Illustrations:X1.2.1 Illustrations provided in the KAI should be suffi-ciently large and clear enough so that they accurately depict theoperation to a person with reasonable
33、vision. Black and whitephotocopies of photographs seldom contain sufficient clarityand definition to be useful. If such reproduction methods are tobe used, it is highly suggested that technical line drawings beused. Such drawings should be large enough in size so that theyare useful and clear. Photo
34、graphs are useful if the printingquality is high enough to preserve the clarity of the image.X1.3 It is recommended that kit providers and buildersshare information between and among themselves using E-mailand Web sites. The intent is to enhance the building experienceand improve dissemination of be
35、st practices and safety infor-mation within the community.X1.4 It is recommended that documentation provided to theconsumer in English be written as ASD SIMPLIFIED TECH-NICAL ENGLISH. Information on this is available at this Website: http:/www.simplifiedenglish-aecma.org/. Doing so willenhance the c
36、larity of the documents. It will also createdocuments that may be easily translated into other languages.X2. REQUIREMENTS FOR OBTAINING A FLIGHT AUTHORIZATION IN VARIOUS COUNTRIESX2.1 Australia:X2.1.1 Manufacturers Required Documents:X2.1.1.1 A statement of compliance by the manufacturerthat indicat
37、es:(1) The aircrafts make, model, serial number, and date ofmanufacture;(2) The design of the aircraft complies with the LSAstandards;(3) The manufacturers quality assurance system complieswith the LSA standards and based on that system, the aircraftconforms to the manufacturers design data;(4) The
38、manufacturer will make available to any interestedperson the aircrafts operating instructions, the aircrafts main-tenance and inspection procedures, and the aircrafts flighttraining supplement that complies with the LSA standards; and(5) The manufacturer will monitor the continuing airwor-thiness of
39、 the aircraft and will issue directions or requirementsthat comply with the LSA standards to correct any unsafecondition.X2.1.1.2 A copy of the manufacturers assembly instruc-tions.X2.1.1.3 Copies of the aircraft operating instructions, theaircraft maintenance and inspection procedures, and the air-
40、craft flight-training supplement.X2.1.2 Consumer Information for Application of an Experi-mental Certificate for a Kit Built Light Sports Aircraft:X2.1.2.1 When applying for an experimental certificate fora kit built LSA, the applicant should provide the following:(1) Manufacturers statement of comp
41、liance (see above);(2) Written information that a production aircraft of thesame make and model has been issued a special certificate ofairworthiness for LSA or a similar document from a contract-ing state;(3) The aircraft operating instructions, the aircraft mainte-nance and inspection procedures,
42、and the aircraft flight-trainingsupplement;(4) Evidence that repairs and modifications are eithermanufacturer approved or fit the LSA definition;(5) For imported aircraft, evidence that the aircraft wasmanufactured in a contracting state and the aircraft is eligiblefor a certificate of airworthiness
43、 or similar document in thecountry of manufacture;(6) Evidence that any certificated engine/equipment com-plies with all associated Australian ADs; and(7) A placard installed in the aircraft as per CAR 262 AP.X2.1.2.2 CASA or the authorized person shall inspect theaircraft to determine if it is in a
44、 safe condition. The assemblyof the aircraft in accordance with the manufacturers kitassembly instructions, completion of the inspection and main-tenance records, and a manufacturers compliance statement isa sound basis for establishing whether the aircraft is incondition for safe operation.X2.1.2.3
45、 CASAor the authorized person may take a copy ofthe manufacturers statement of compliance and other relevantdocumentations for its records. However, the aircraft operatinginstructions, the aircraft maintenance and inspection proce-dures, and the aircraft flight-training supplement are requiredto be
46、returned to the applicant.F2563063ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentionedin this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the risko
47、f infringement of such rights, are entirely their own responsibility.This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years andif not revised, either reapproved or withdrawn. Your comments are invited either for revision of this
48、standard or for additional standardsand should be addressed to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of theresponsible technical committee, which you may attend. If you feel that your comments have not received a fair hearing you shouldmake yo
49、ur views known to the ASTM Committee on Standards, at the address shown below.This standard is copyrighted by ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959,United States. Individual reprints (single or multiple copies) of this standard may be obtained by contacting ASTM at the aboveaddress or at 610-832-9585 (phone), 610-832-9555 (fax), or serviceastm.org (e-mail); or through the ASTM website(www.astm.org).F2563064
