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MVE_CatalinaNG_R582_v3

1. meters feet meters feet meters feet meters feet m Ft m Ft m Ft m Ft 0 305 1 3 281 7 925 85 30 15 54 167 3 23 16 249 3 0 610 2 6 562 8 230 27 88 58 15 85 52 170 6 23 47 77 252 6 0914 3 9 843 8 534 28 91 86 16 15 53 173 9 23 77 78 255 9 1 219 4 13 12 8 839 29 95 14 1646 54 1772 2408 79 2592 1 524 5 16 40 9 144 30 98 43 16 76 55 180 4 24 38 80 262 5 1 829 6 19 69 9 449 31 101 7 17 07 56 183 7 24 69 81 2657 2 134 7 22 97 9754 32 105 0 1737 57 187 0 24 99 382 269 0 2 438 8 26 25 10 06 33 108 3 17 68 58 190 3 25 30 83 2723 2 43 9 29 53 1036 34 111 5 17 98 59 193 6 25 60 84 275 6 3 048 10 32 81 10 67 35 1148 18 29 60 196 9 25 91 85 278 9 3 353 11 36 09 10 97 36 118 1 18 59 61 200 1 2621 86 2822 3 658 12 39 37 11 28 37 121 4 18 90 62 2034 2652 87 285 4 3 962 13 42 65 11 58 38 124 7 1920 63 206 7 26 82 88 288 7 4 267 14 45 93 11 89 39 128 0 19 51 64 210 0 27 13 89 292 0 4 572 15 49 21 12 19 40 131 2 19 81 65 213 3 27 43 90 295 3 4877 16 52 49 12 50 41 134 20 12 66 216 5 2 74 91 298 6 5 182 17 55 77 12 80 42 137 8 2042 67 219 8 28 04 92 301 8 5 486 18 59 06 13 11 43 141 1 20 73 68 223 1 28 35 93 305 1 5 91 19 62 34 1341 44 31444 21 03 69 2264 28 65 94 308 4 6 096 20 65 62 13 72 45 147 6 21 34 70 2297 28 96 95 311 7 6401 21 68 90 14 02 46 150 9 21 64 71 232 9 29 26 96 315 0 6 06 22 72 18 14 33 47 154 2 21 95
2. Wingspan 9 470 Length 6 280 m Height 2 490 DoI aws u 9 Surface 12 70 Chord 1 340 m Wing loading 37 20 kg m2 C Xn Surface each 0 96 Span 3 36 m Chord 0 25 m Run Disc position 6 15 2 Surface 1 650 Span 2 450 m m 0 700 m 1175 12 Surface 1 120 Height 1 280 m Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 2 1 Average run 0 930 m Surface 0 600 m2 Height 1 200 m Average run 0 480 m Run 22 Hui Length 3 400 m Width 1 640 m 2 3 TRITTICO CATALINA NG er it 3600 1640 6280 9470 on 2 4 WEIGHTS Empty weight 315 kg 324 kg with parachutes Kg Maximum permitted baggage weight 12 Kg Maximum take off weight 495 Kg Minimum pilot weight 55 Kg Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 2 2 2 5 ENGINE Model Rotax 582 UL DCDI mod 99 Type two cylinder inline two stroke liquid cooled aspirated dual ignition Displacement 580 7 cc Max power 48KW 64 4Hp SAE at 6800 rpm Max torque 75Nm at 6000 rpm Max rpm 6800 rom For more information about the engine consult the Rotax Owner Operator Manual 2 6 FUEL SYSTEM 2 6 1 TYPE Single line with an auxiliary mechanical and electric fuel pump positioned in series Fuel draining system by means of a gascolat
3. are Retracted flaperons Extended flaperons Maximum positive 4 0 Maximum positive 2 0 Maximum negative 2 0 Maximum negative 0 0 PRUDENCE Exceeding the load factor overloads the aircraft with risks of possible structure damage or yielding Uncoordinated manoeuvres could cause the load factor to be exceeded even if performed at a speed within the permitted limits or within the manoeuvre speed PRUDENCE Due to problems related to damaging the engine all manoeuvres with a load factor lower than 0 5 g may not be performed for a period of time that exceeds 5 seconds see Rotax manual Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 3 3 3 9 CREW The minimum crew is a pilot the maximum number of people on board is two 3 10 PROHIBITED USES The aircraft may not be used in the following weather conditions e Current rain e Current hail e Current snow e Thick fog or haze e Current storm e Wind speed above 28 Km h It is prohibited to take off from or land on runways smaller than 250x30 metres 820x98 ft and or with obstacles at the end with an angle greater than 4 It is prohibited to take off and land on water under conditions f g h in the following table Terms used by US Velocity Estimating Velocities Estimating Velocities on Weather Service mph on land Sea Check your glassy water technique before water A Calm less
4. 1 Master switch Off 2 Voltmeter Check the voltage drop 3 Master switch On 4 Voltmeter Check the voltage increase within the limits If the previous point 4 has a negative outcome proceed as follows 5 Exclude the electric equipment that is not indispensable for the flight 6 Land ASAP The battery allows the actuation of flaps and auxiliary fuel pump for about 10 minutes Are also allowed 2 complete extraction retraction cycles With the Master OFF to use emergency under carriage extraction retraction procedure press and keep hold the emergency button and act on undercarriage switch It is necessary to keep hold the emergency button up to the extraction re traction procedure is completed LOW VOLTAGE IN FLIGHT Excessive consumption Too many electric users 1 Possible causes Alternator failure Fuse interrupted 2 Land ASAP for a detailed control LOW VOLTAGE ON THE GROUND 1 RPM Increase above 4000 min 2 Navigation and landing lights OFF 3 Voltmeter Check if within limits Shutoff the engine and have the electric system che 4 If the checks had a negative outcome cked by specialised personnel Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 5 4 5 3 7 ELECTRIC SYSTEM FIRE ATTENTION An electric system fire can be recognised by white smoke and the characteristic odour of burnt plastic Master Off Electric users Off
5. Engine instruments Within limits for take off Flight instruments Seat belts Check and adjust Fastened and well tightened Parking brake Disengaged N A in water 4 5 2 TAKE OFF Aircraft Aligned with the runway axis and against the wind Throttle Fully forward in 3 4 At 70 km h Turn in take off attitude Accelerate Vx or Vy Flaps fully lowered Trim As necessary Throttle As necessary Electric fuel pump Off at 500 ft 4 5 3 TAKE OFF from WATER The take off procedure is very different than when taking off from the ground Particular attention must be placed on the wavy motion of the water surface the direction of the wind the marine current and look for an area suitably distant from the shore and free of obstacles to perform it in complete safety Catalina NG User Manual Issued 08 07 2011 FlySynthesis S r l Page 4 8 PRUDENCE Before alighting or taking off from water always make sure that the landing gear is retracted An attempt to take off with the landing gear extracted could cause the aircraft to overturn The condition of the water surface can be classified in three ways Flat surface no waves Wavy surface wavy motion with sprays of foam Agitated surface wavy motion with a pronounced surface coverage of white foam PRUDENCE It is prohibited to take off when the water surface is agitated Avoid landing
6. Auxiliary fuel pump Off Battery and magnets Off Seat belts Fastened and tightened Abandon the aircraft after landing 5 2 3 ENGINE FAILURE DURING while climbing If the altitude permits it proceed as follows Maintain a safety speed in relation to the weight and configuration and identify an area suitable for landing on ground or water Best gliding speed 80km h Flaps retracted Auxiliary fuel pump Check that it is on Fuel level Check amount in both tanks Fuel cock Check if the tank with the greater quantity is open Fuel pressure Check that it is within the permitted limits Key with magnets Check they are inserted Engine throttle Hot start position Engine start up as indicated in the engine operating manual e If the engine starts immediately climb to a safety height and land ASAP for a detailed check e Ifthe engine does not start immediately select a suitable area for an emergency lan ding avoiding tight turns and maintaining a suitable safety speed Flap As necessary Fuel cock Close Auxiliary fuel pump Off Key with magnets Both Off ATTENTION Never perform a 180 turn at a low altitude to try to return to the runway 5 3 IN FLIGHT EMERGENCY PROCEDURE 5 3 1 ENGINE SHUTDOWN Engine throttle Check position and clutch Engine instrument check Check parameters Choke control OFF Fuel cock Select the tank with the greater amount of fuel Au
7. otherwise replace it X X OUTER WINGS Check the windbracing conditions check for deformation tightened nuts O O O O Check the condition of the wing s skin check for delamination defective 0000 ness or scratches PILOT COCKPIT Carefully control the conditions of all control levers check for any damage abnormal play and check that the connection is secure X X X Clean and lubricate if necessary Check the wiring and the installation of the electric system components O 00 check the connection conditions Clean inside the hull X X X X Inspect the seats and the seat belts Check the validity of the quick connec tions releases on the seat belts and check the hooking points X X X O visual check only X complete maintenance tools and instruments required Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 9 3 INSPECTION TYPE SCHEDULED INSPECTIONS FOR CATALINA Zone Operations to carry out gt PILOT COCKPIT Control the instrument panel and its connection points Check the instru ment connections and the static and dynamic lines RS Check the instrument s limitation panels X X Drain the instrument tubes to prevent the accumulation of condensation X X X X Check the radio navigation systems and the antenna O O O O Check the integrity and movement of the hatches disassemble them and X X lubricate Check the landing gear movement mechanism lubri
8. 0432 931280 Web site www flysynthesis com e mail technical support flysynthesis com Model FLY SYNTHESIS CATALINA NG Version CATALINA NG Engine model ROTAX 582 DCDI UL Mod 99 Serial number Engine serial number Propeller model Propeller serial number Registration Date Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page l ll III Index Chapter Title Page General information LI 1 Introduction 1 1 2 Technical Card 2 1 3 Restrictions 3 1 4 Operative procedures 4 1 5 Emergency procedures 5 1 6 Performance 6 1 7 Weights and balances 7 1 8 Daily mantenance 8 1 9 Scheduled mantenance 9 1 10 Unscheduled mantenance 10 1 11 Appendix 11 1 Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page l III Introduction 1 1 INTRODUCTION This flight manual was created to provide suitable and clear information for pilots of FLY SYNTHESIS CATALINA NG aircraft in order to guarantee an absolutely safe and efficient use This manual applies only to the aircraft identified on page in the configuration shown on the technical card on page 2 1 In addition to the normal page numbering the manual has been divided into sections chapter and paragraphs which are summarised on the heading of each page which makes searches easier Each page also shows the revision number as the manual pages or individual sections may be fully or parti
9. 08 07 2011 User Manual FlySynthesis S r l Page 8 4 SCHEDULED MAINTENANCE 9 9 SCHEDULED MAINTENANCE 9 1 INSPECTION PLANNING Scheduled maintenance is carried out with planned inspections in cycles of 50 hours of flight The type of inspection is divided into 4 categories which are provided in the table 25 hour inspections 50 hour inspections 100 hour inspections 200 hour of flight inspections continuing every 50 hours The normal cycle is repeated as follows Hours of Inspection Hours of Inspection Hours of Inspection Hours of Inspection flight Type flight Type flight Type flight Type 50 50 300 100 550 50 800 200 75 50 325 50 5 5 50 825 50 100 100 350 50 600 200 850 50 125 50 3 5 50 625 50 875 50 150 50 400 200 650 50 900 100 175 50 425 50 675 50 925 50 200 200 450 50 700 100 950 50 225 50 475 50 25 50 975 50 250 50 500 100 50 50 1000 Overhaul In any case scheduled maintenance must be carried out after one year if the aircraft did not reach the number of hours necessary for the subsequent type of inspection Other overhaul limits for some equipment are pointed out separately 9 2 DESCRIPTION OF THE INSPECTION Each time the table indicates checking nut and bolt tightening check the table in the appendix General rule at each inspection perform a visual check and lubricate all moving parts
10. 1 85 kg mt Screws M10 3 75 kg mt 11 5 1 3 Nuts buried in resin or threaded inserts Screws M5 0 42 kg mt Screws M6 0 75 kg mt Screws M8 1 60 kg mt 11 5 2 Propeller bolts Refer to the propeller manual Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 11 6 Cf FLYSYNTHESIS Strada provinciale nr 78 km 12 150 33050 Mortegliano UD Italy MVE_CatalinaNG582v4 Issued 08 07 2011
11. 72 236 2 2957 97 3182 7 010 23 75 46 1463 48 157 5 22 25 73 239 5 29 87 98 321 5 7 315 24 78 74 14 94 49 160 8 22 56 74 242 8 30 18 99 324 8 7 620 25 82 02 1524 50 164 0 22 86 75 246 1 30 48 100 328 1 Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 11 1 11 1 2 Speed conversion table m s km h kts m s km h kts m s km h kts m s km h kts 0 278 1 0 540 7 222 26 14 04 14 17 51 27 54 21 11 76 41 04 0 556 2 1 080 7 500 27 1458 1444 52 28 08 21 39 77 41 58 0 833 3 1 620 7 78 28 15 12 14 72 53 28 62 21 67 78 42 12 1 111 4 2 160 8 056 29 15 66 1500 54 29 16 21 94 79 42 66 1 389 5 2 700 8 333 30 16 20 1528 55 2970 22222 80 43 20 1 667 6 3 240 8 611 31 16 74 15 56 56 30 24 22 50 81 43 74 1 944 7 3 780 8 889 32 17 28 1583 57 30 78 22 8 82 44 28 2 222 8 4 320 9 167 33 17 82 16 11 58 31 32 23 06 83 4482 2 500 9 4 860 9444 34 18 36 16 39 59 31 86 23 33 84 45 36 2 778 10 5 400 9 722 35 18 90 1667 60 32 40 23 61 85 45 90 3 056 11 5 940 1000 36 19 44 16 94 61 32 94 23 89 86 46 44 3 333 12 6 479 1028 37 19 98 17 22 62 33 48 2417 87 46 98 3 611 13 7 019 10 56 38 20 52 1750 63 34 02 2444 88 47 52 3 889 14 7 559 10 83 39 21 06 17 78 64 34 56 24 72 89 48 06 4167 15 8 099 11 11 40 21 60 1806 65 35 10 25 00 90 48 60 4444 16 8 639
12. 83 26 91 0 722 0 759 1 148 10000 3048 4 81 23 34 0 694 0 736 1 166 11000 3353 6 79 19 78 0 668 0 713 1 184 12000 3658 8 77 16 21 0 642 0 691 1 203 13000 3962 10 75 12 64 0 617 0 669 1 222 14000 4267 12 73 9 079 0 593 0 648 1 242 15000 4572 14 72 5 513 0 570 0 628 1 262 16000 4877 16 70 1 947 0 547 0 608 1 283 17000 5182 18 68 1 619 0 525 0 588 1 304 Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 11 4 11 4 CROSSWIND DIAGRAM The maximum relative crosswind value is 32 km h or 17 kts The following diagram shows the cross component relative to the head and tail wind Lun m o 10 y L Q 30 Wa un N 40 35 L 9 E B as 30 50 5 CH D 25 un _60 E 20 d E o 15 70 t 10 E wL 80 4 5 E e M C i 90 Re E A ngj ui dira bep 100 n d tion Cep Wi Gee Nd pry d way 110 160 140 130 120 0 5 10 15 20 25 30 35 Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 11 5 11 5 BOLT TIGHTENING TORQUE TABLE 11 5 1 Steel steel connection This includes composite coupling with through screws and washers from both sides 11 5 1 1 Screws resistance class 8 8 Screws MA 0 30 kg mt Screws M5 0 55 kg mt Screws M6 0 95 kg mt Screws M8 2 40 kg mt Screws M10 5 0 kg mt 11 5 1 2 Stainless steel screws resistance class A2 70 Screws M5 0 45 kg mt Screws M6 0 78 kg mt e Screws M8
13. Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 9 1 INSPECTION SCHEDULED INSPECTIONS FOR CATALINA TYPE Zone Operations to carry out ann S GENERAL Make sure that the injection switches are OFF and the master switch key is 0000 removed Open all inspection hatches X X X X Remove the seats and seat belts X X X X Check all rivets for any leaks or breaks Replace missing rivets with standard 0000 compliant rivets PROPELLER Inspect the propeller blades for breaks or defects Always refer to the pro 0000 peller manual for any repairs Check bolt tightness consult the propeller manual for the tightening tor X X X que HULL Inspect the fuselage especially the hull and check for any defects Check for skin delamination make sure there are no cracks in the inner structure O O O O Check the gluing of the hull ribs and mobile surfaces Check the landing gear mechanisms There must not be signs of cracks and check the bolt tightening The check can also be performed with the speci X O X X fic video devices such as fibre optic probes only visual check at 50h Check the conditions of the antenna that it is connected correctly and its 0000 bolts are correctly tightened Check the beam outer wing connections the tightening of the respective bolts and the general conditions of the connection flanges only visual X OX X check at 50h Clean the windshield and check its condition
14. Engine throttle At a minimum Flap Retract Rudder pedals End of travel opposite to the rotation direction Control stick Neutral slight nose down When the rotation stops and is under control return to a level flight ATTENTION during the flare after exiting the spin do not exceed the Vne 5 3 5 FLUTTER This phenomenon may involve the ailerons the flying tail the trim tab and the rudder It appears as strong vibration of the control surface during the flight generally at high speeds To contrast this phenomenon reduce the engine and pull up to reduce speed being careful not to exceed the maximum permitted load factors Land ASAP Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 5 3 after a flutter have the entire aircraft inspected by qualified personnel 5 3 6 ELECTRIC SYSTEM FAILURE SWITCHING ON OF THE GENERATOR VOLTAGE LOW LIGHT 1 Voltmeter Check 2 Unnecessary elelctric users Off 3 Land ASAP The battery allows the actuation of flaps and auxiliary fuel pump for about 10 minutes Are also allowed 2 complete extraction retraction cycles With the Master OFF to use emergency under carriage extraction retraction procedure press and keep hold the emergency button and act on undercarriage switch It is necessary to keep hold the emergency button up to the extraction re traction procedure is completed OVERVOLTAGE voltmeter indication above 16 V
15. Land ASAP PRUDENCE With the master OFF use the emergency switch for all the extraction retraction procedure Con figure the aircraft before turning the Master OFF 5 4 EMERGENCY PROCEDURE DURING LANDING 5 4 1 LANDING WITHOUT FLAPS OR WITH FLAPS BLOCKED IN AN INTERMEDIATE POSI TION 1 Check the flap breaker Engaged 2 Visually check the position of both flaps Check notches 3 Try to extract the flaps with the position selector 4 f point 3 is not possible check that there is enough space free of obstacles to be able to land maintaining a final speed that is 10 Kts higher than the standard 5 4 2 LANDING WITH A DEFLATED TYRE Carry out a normal landing if possible select a long and wide runway If the runway dimensions permit it use the centreline of the runway opposite to that of the deflated tire Before touching down on ground turn off the engine and the electric systems Land trying to keep the deflated tyre off the ground Prepare for a swing tendency from the side of the deflated tyre Maintain the direction using the rudder If the front wheel is deflated lighten the front section pulling up on the control stick trying to keep the wheel in a central position 5 4 3 FORCED LANDING After carrying out the instructions in section 5 3 1 engine shutdown without a positive outcome proceed as follows Best gliding speed 80 km h Flaps retracted Seat belts We
16. Maximum speed in turbulent air Vmo 136 Km h 73 KTS Never exceed speed Vne 150 Km h 78 KTS 4 1 4 Landing Landing approach Flaps lowered 75 Km h 41 KTS Pull up Flaps lowered 75 Km h 43 KTS Maximum demonstrated crosswind 28 Km h 15 KTS 4 2 PREPARATION FOR FLIGHT Prior to each fight the pilot much check the aircraft s suitability and also check the fuel level on board All of the checks included in this section must be carried out before every flight even if the last flight was very brief 4 2 1 Remove all protections e pilot cover wheel block mobile surface block windbreaker cover propeller protection 4 2 2 Refuel Check that the quantity of fuel in the tank is sufficient for the scheduled file otherwise refuel Make sure that the fuel pipes are connected safely Unscrew the double tank plugs located to the sides of the hull next to the seats and proceed with refuelling It is recommended to first mix the gasoline Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 1 with the oil suitable for a two stoke engine before adding it to the tank if the aircraft does not have a separate mixer PRUDENCE pay attention during refuelling procedure to not pour fuel on the windscreen this becau se it is not fuel proof This can cause damages to the windscreen and it can be broken PRUDENCE It is strongly advised not to use the two tanks simultaneously PRUDENCE carry o
17. muddy fields it iscompulso ry to wash and clean landing gear vanes This because mud could compromise the correct landing gear retraction extraction procedu re If not done severe damages could occur to the structure Issued 08 07 2011 FlySynthesis S r l Page 8 2 8 4 5 Rudder pedal unit Clean and lubricate the heads of the pedal unit control cable connections 8 4 6 Hull Open all inspection hatches and check for water inside the watertight compartments In the case of a prolonged stop leave the hatches open to permit any condensation to evaporate Also check all the hull outerwing and fuselage beam hull fastening connections Check that all con nections are tight 8 4 7 Engine DISCONNECT THE BATTERY FROM THE AI RCRAFT S ELECTRIC SYSTEM Wash with freshwater and lubricate with a lu bricant spray suitable for marine operations Pay attention not to get the electric connec tions wet Clean and lubricate with a protec tive silicone based spray Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 8 3 8 4 9 Aircraft cleaning IMPORTANT After using the aircraft in the water all external surfaces must be washed with freshwater Do not use high pressure and or high temperature water jets this could damage the aircraft s surfaces 8 4 10 Flight controls After using the aircraft in the water clean and lubricate all articulated joints in the flight control lines Catalina NG Issued
18. play Rudder no delaminations correct fastening check hinges integrity PRUDENCE do not force the rudder Bowden cables correctly fastened Catalina NG User Manual Issued 08 07 2011 FlySynthesis S r l Page 4 4 Flying tail free movement along the entire stroke without buckling Flying tail hinge correct fastening without play no welding cracks Flying tail counterweights correct fastening without play no welding cracks Hinge pin nuts correct fastening Trim tab intact free movement Flying tail trailing edge no buckling or delaminations Stabilator trailing edge no buckling or delaminations 7 Leftwing Wing surface no bulges depressions or delaminations Trailing and leading edges intact no residual deformation Wing fuselage connections fastened correctly without deformations Ailerons upward and downward freedom of movement without excessive play on the hinges no cracks near the connections no lateral movements Control rods integrity and correct fastening smoothness and freedom of oscilla tion Hinge supports firmly fastened to the wing Counterweights fixed without play 8 Cabin controls Instrument panel correctly fastened all plates present Battery ON instruments ON Battery OFF instruments OFF Control stick freedom of movement correct fastening of supports Rudder pedals fastened no distortions functional test Throttl
19. switch until the indicator light of completed extraction retraction will switch on Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 5 7 Using the Emergency switch the plant pressure control system is by passed so to avoid damages of the undercarriage plant it is suggested to activate it for more than 10 consecutive seconds The switch can be used both to lift or lowering the undercarriage If necessary repeat the operation after a 10 seconds stop e After landing check carefully the hydraulic plant and the presence of dirt in the undercar riage vanes to identify the cause of the malfunctioning If itis not possible to completely extract the undercarriage to avoid severe damages to undercarria ge and hull structure retract the undercarriage and land on the hull on a grass runway To reduce the damages to the hull touch ground at 65km h or less If itis not possible retract completely the undercarriage green light off it is strictly forbidden to land on water The risk of overturning is high Extract the undercarriage if possible and land possi bly on a grass runway Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 5 8 Performance 6 6 PERFORMANCE The tables and diagrams on the following pages were prepared to illustrate the performance that can be expected from CATALINA NG in order to more precisely plan the flight The data provided in these tables was obtained from tests
20. than 1 Smoke rises vertically Sea like a mirror flying under these con ditions di cri Ripples with the appearance B Light air 1 3 no us of scales are formed but XX varies unmoved without foam crests Wind fell on face Smalt wavelets still short eontre 4 7 leaves rustle ordireary but more pronounced XX wind vane moves by crests have a glossy appe wind rance and do not breck Leaves and small twigs Bade Wavelets ERI ideal water flying cha to break Foam of glassy ap o d D Genfle Breeze 8 12 in constant motion racteristics in protected pearance perhaps Scattered wind extends light flag water shitewaps Dust and loose paper Small waves becoming E Moderate Breeze 13 18 raised small branches longer fairly frequent whi XX are moved tecaps Small trees in leaf Moderate waves taking This is considered rough D Crabe 19 24 begin to sway crested amore pronounced long water for seaplanes and wavelets form in form many whitecaps are small amphibians espe inland water formed chace of some spray cially in open water Large branches in mo i en Large waves begin to form tion whistling heard white foam crests are more G Strong Breeze 25 31 in telegraph wires XX extensive everywhere pro umbrellas used with sia difficulty gt pray Whaletaes iewmotion Sea heaps up and white This type of water condi ee ters en foam from breaking waves tion is for emergency H Moderate Gale 32 38 begins to be blown in stre only sm
21. 07 2011 002 11 5 21 12 2010 001 4 19 05 07 2011 002 11 6 21 12 2010 001 4 20 05 07 2011 002 Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 1 2 Technical Card 2 2 Technical Card 2 1 Description Catalina NG is a two seater ultralight amphibious aircraft with high counterwind wings and an open cabin The fuselage hull wings and control surfaces are made out of composite material whereas the tail boom is made out of aeronautic aluminium alloy The rectangular plant type wing with la minar profile has Junker ailerons for the entire wingspan used also as flaperons thanks to a suitable kinematic motion The vertical tail surface consists of the fin fixed and the rudder mobile the horizontal surface consists of the flying tail fully mobile plane centrally hinged to the tail boom The trim tab is integrated in the flying tail and also acts as an anti servo tab The fuselage mainly consists of the hull and the tail beam pipe that supports the outer wings the empennage and the engine The hull contains two seats which are protected by a fairing with a windshield The front tricycle type landing gear is retractable and is moved by hydraulic actuators Once retracted the wheels disappear inside the hull and the landing gear compartments are automatically covered by panels The engine is positioned to the front on the fuselage beam and is powered by two tanks positioned symmetri cally in the hull 2 2 Dimensions
22. 11 39 41 22 14 18 33 66 35 64 2528 91 49 14 4722 17 9 179 11 67 42 22 68 18 61 67 36 18 25 56 92 49 68 5 000 18 9719 11 94 43 23 22 18 89 68 36 72 25 83 93 50 22 5 278 19 10 26 12 22 44 23 76 1917 69 37 26 26 11 94 50 76 5 556 20 10 80 12 50 45 24 30 1944 70 37 80 26 39 95 51 30 5 833 21 11 34 12 78 46 24 84 1972 71 38 34 26 67 96 51 84 6 111 22 11 88 13 06 47 25 38 2000 72 38 88 26 94 97 52 38 6389 23 12 42 13 33 48 25 92 2028 73 39 42 2722 98 52 92 6 667 24 12 96 13 61 49 26 46 20 56 74 39 96 27 50 99 53 46 6 944 25 13 50 13 89 50 27 00 20 83 75 40 50 27 78 100 54 00 Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 11 2 11 2 STANDARD ATMOSPHERE CONVERSION TABLE T C T K T To Pz mmHg Pz mbar P Po pz Kg m 1000 3280 84 21 5 29466 1 022 854 475 1139 300 1 124 1 353 1 105 900 2952 76 20 85 29401 1 020 844 609 1126 146 1 111 1 340 1 094 800 2624 67 20 2 293 36 1 018 834 836 1113 115 1 098 1 327 1 083 700 2296 59 19 55 29271 1 015 825 155 1100 206 1 085 1 313 1 072 600 1968 5 18 9 292 06 1 013 815 564 1087 419 1 073 1 300 1 061 500 1640 42 18 25 291 41 1 011 806 069 1074 752 1 060 1 287 1 051 400 1312 34 17 6 290 76 1 009 796 654 1062 206 1 048 1 275 1 040 300 984 252 16 95 290 11 1 006 787 334 1049 778 1 036 1 262 1 030 200 656 168 16 3 289 46 1 004 778 101 1037 468 1 023 1 249 1 020 100 328 084 15 65 288 81 1 002 768 954 10
23. 25 276 1 011 1 237 1 010 0 0 15 288 16 1 759 9 1013 2 1 1 225 1 100 328 084 14 35 287 51 0 997 750 929 1001 239 0 988 1 212 0 990 200 656 168 13 7 286 86 0 995 742 044 989 392 0 976 1 200 0 980 300 984 252 13 05 286 21 0 993 733 245 977 660 0 964 1 188 0 970 400 1312 336 12 4 285 56 0 990 724 530 966 040 0 953 1 176 0 960 500 1640 42 11 75 284 91 0 988 715 899 954 533 0 942 1 165 0 951 600 1968 504 11 1 284 26 0 986 707 352 943 137 0 930 1 153 0 941 700 2296 588 10 45 283 61 0 984 698 888 931 851 0 919 1 142 0 932 800 2624 672 9 8 282 96 0 981 690 506 920 675 0 908 1 130 0 923 900 2952 756 9 15 282 31 0 979 682 205 909 607 0 897 1 119 0 913 1000 3280 84 8 5 281 66 0 977 673 986 898 648 0 886 1 108 0 904 1100 3608 924 7 85 281 01 0 975 665 847 887 796 0 876 1 097 0 895 1200 3937 008 7 2 280 36 0 972 657 787 877 050 0 865 1 086 0 886 1300 4265 092 655 279 71 0 970 649 807 866 410 0 855 1 075 0 877 1400 4593 176 5 9 279 06 0 968 641 905 855 874 0 844 1 064 0 869 1500 4921 26 5 25 27841 0 966 634 082 845 443 0 834 1 054 0 860 1600 5249 344 4 6 277 76 0 963 626 336 835 114 0 824 1 043 0 851 1700 5577 428 3 95 277 11 0 961 618 666 824 889 0 814 1 033 0 843 1800 5905 512 3 3 276 46 0 959 611 073 814 764 0 804 1 022 0 834 1900 6233 596 2 65 275 81 0 957 603 556 804 741 0 794 1 012 0 826 2000 6561 68 2 275 16 0 954 596 113 794 818 0 784 1 002 0 818 2100 6889 764 1 35 274 51 0 952 588 745 784 994 0 774 0 992 0 809 2200 7217 848 0 7 273 86 0 950 581 451 775 268 0
24. 765 0 982 0 801 2300 7545 932 0 05 273 21 0 948 574 231 765 641 0 755 0 972 0 793 2400 7874 016 0 6 272 56 0 945 567 083 756 110 0 746 0 962 0 785 2500 8202 1 1 25 271 91 0 943 560 005 746 676 0 736 0 952 0 777 2600 8530 184 1 9 271 26 0 941 553 003 737 338 0 727 0 943 0 769 2700 8858 268 2 55 270 61 0 939 546 070 728 094 0 718 0 933 0 762 2800 9186 352 3 2 269 96 0 936 539 208 718 944 0 709 0 924 0 754 2900 9514 436 3 85 269 31 0 934 532 416 709 887 0 700 0 914 0 746 Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 11 3 11 3 INDICATED SPEED CONVERSION The speed conversion table which provides the correction factor for obtaining the true speed TAS from the instantaneous speed IAS according to the simplified formula TAS IAS Cor factor ICAN international comitee for air navigation temperatures relative pression relative densit est IAS a IAS correction factor in relation to the alti tude Relative Relative Cor factors 2000 610 18 96 66 1316 1 084 1 063 0 970 1000 305 16 98 62 5658 1 046 1 031 0 985 0 0 15 59 1 1 1 1000 305 13 02 55 43 0 973 0 970 1 015 2000 610 11 04 51 87 0 938 0 941 1 031 3000 914 9 06 48 30 0 905 0 913 1 047 4000 1219 7 08 44 74 0 872 0 885 1 063 5000 1524 5 10 41 17 0 840 0 858 1 079 6000 1829 3 11 37 61 0 809 0 832 1 096 7000 2134 1 13 34 04 0 779 0 807 1 113 8000 2438 0 85 30 47 0 750 0 783 1 130 9000 2743 2
25. Cf FLYSYNTHESIS Catalina NG User Manual valid for versions with a Rotax 582 engine Revision 002 Date 08 07 2011 THIS DOCUMENT MUST ALWAYS BE TRANSPORTED ON BOARD General informations I Foreword This User Manual it is provided with the ultralight aircraft Catalina NG and must be always held on board The pilot must be familiar with all normal and emergency procedures must take cognizance of the limitations mentioned in this User manual All these information are necessary to guarantee to operate in complete safety in particular e Pre flight inspections e Normal procedures e Emergency procedures e Limitations e Performances The strict observance of these limitations and procedures is required for rider safety Flysynthesis srl is not responsible for damages or injuries suffered by partial or total failure to com ply with the requirements contained in this User Manual The data and information contained in this document is the property of FLYSYNTHESIS SRL This document may not be reproduced or transmitted to a third party in any form or by any means Any unauthorised copy or distribution is illegal as per international agreements relating to property rights Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page l l Il IDENTIFICATION DATA Manufacturer FLY SYNTHESIS SRL Strada Provinciale n 78 Km 12 150 33050 Mortegliano UD ITALIA Tel 0432 992482 993557 nage Fax
26. TECHNIQUE FROM THE WATER Align the aircraft against the wind in an area free of obstacles Fully open the throttle in progression within a few seconds During the first phase of the take off run keep the control stick at the belly until the aircraft s nose exits the water and starts the gliding phase While gliding return the control stick to the center and let the aircraft accelerate until you notice a clear sensation of a decrease in friction and the speed stabilises At this point pull up softly until arriving to the end of stroke and wait for the separation from the water In this phase the force on the stick increases considerably Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 9 quickly pulling up on the stick will cause an increase in resistance causing speed to reduce and making the separation more difficult 4 6 CLIMB Engine 6500 rpm Engine parameters within limits of use Trim As necessary 4 7 CRUISING Throttle Max continuous power 6500 rpm Engine parameters Within limits PRUDENCE Frequently check the fuel levels in the tanks selecing the appropriate tank to use It is extremely advisable not to use the two tanks at the same time as if fuel runs out in one of the tanks this could cause the engine to shutdown due to a lack of fuel PRUDENCE Flying during a rain squall reduces the aircraft s flight performance and the stall speed increases in a considerable manner P
27. ace rod connecting point Remove the wing nut paying attention to not lose the nylon washers d Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 19 FlySynthesis S r l Remove the safety pin on the 2 bolt on the lower attachment point of the brace rod and remove the respective nuts Put the nuts and the safety pins in the provided bag or put them temporarily in the fuel cap cover indents in order to not lose them Remove the front root wing attachment point if some difficulties are encounte red in this phase lifting a bit the wing leading edge will help to loosen the pin To ease the pin removal go up the hull and remove the pin from the upper side of the wing Issued 08 07 2011 Page 4 20 Catalina NG User Manual FlySynthesis S r l Go to the wing strut attachment and lifting the wing with one hand remove the threaded pin Lean the wing on the bracing strut so it is between the two plates of the wing attachment points as it is shown in the picture Before proceeding with other opera tions be sure that the bracing strut is perfectly inserted between the two wing plates If not the wing could fall down and damage itself Go back to the wing root and remove the rear attachment point If difficulties are found try to push the wing forward lifting it with one hand Pay attention to not allow it to fall down the bracing strut BAT TENTION When the rear pin is
28. act the manufacturer to identify and solve the balancing problem Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 7 2 DAILY MAINTENANCE 8 8 DAILY MAINTENANCE Daily maintenance must be carried out by visually inspecting the aircraft every day checking the efficiency and functionality of each component The visual and functional inspection is fundamen tal also during fuelling fuel system draining and pre flight inspection phases where any anomaly must be identified and corrected to ensure flight safety 8 1 REFUELLING See section 4 2 2 8 2 TANKDRAINING Seer section 4 2 3 8 3 PRE FLIGHT INSPECTIONS See section 4 3 8 4 DAILY OPERATIONS 8 4 1 Flying tail hinge Clean and lubricate all heads and the hinge of the flying tail as shown in the figure Use a lubricant spray that is suitable for ma rine operations 8 4 20 Trim tab control Clean and lubricate all joints as shown in the figure Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 8 1 8 4 3 Fin and rudder 8 44 Landing gear Catalina NG User Manual Clean and lubricate the heads of the push pull cables on the rudder connection plate Clean and lubricate also the two lower and upper rudder hinges Clean and lubricate the various landing gear and retraction system connection points Use a lubricant spray that is suitable for ma rine operations ATTENTION After landing on
29. all aircraft in walking againstthe wind aks along the direction of the wind inland waters and for the expert pilot Catalina NG User Manual FlySynthesis S r l Issued 08 07 2011 Page 3 4 3 11 RESTRICTION PLATES A4 FLYSYNTHESIS ELYSYNTHESIS Vs Stall speed without flaps 65 Km h 35 KTS BAGGAGE COMPARTMENT Va Design manoeuvring speed 130 Km h 70 KTS MAXIMUM 12 Kgs Vne Never exceeded speed 150Km h 81 KTS l EVENLY DISTRUBUITED Vmo Maximum operative speed 130Km h 70 KTS Centre of Gravity possible range 28 37 MTOW Maximum Take Off Weight 495 Kgs All aerobatic manoeuvres including intentional spin are prohibited see Flight Manual for other limitations Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 3 5 OPERATIVE PROCEDURES 4 4 OPERATIVE PROCEDURES 4 1 NORMAL OPERATING SPEED Unless otherwise indicated the following speeds refer to the maximum take off speed equal to 472 5 Kg and can be used for any lower weight These speeds are approximate and can change if the ai rcraft configuration changes 4 1 1 Take off Flap pos 1 Rotation 70 Km h 38 KTS Speed over a 50 ft obstacle 15 m 80 Km h 43 KTS 4 1 2 Climb Flaps retracted Best angle of climb speed Vx 78 Km h 42 KTS Best rate of climb speed Vy 90 Km h 48 KTS Best gliding speed Ve 80 Km h 43 KTS 4 1 3 Cruising Cruising speed 120 Km h 65 KTS
30. ally replaced in the future Any updates must be printed and inserted in the manual as soon as possible to guarantee maximum safety when using the aircraft The owner or the person using the aircraft must register the revisions in the following table 1 1 Revision registration Description Signature 000 First issue 02 08 2010 Cosatto C 001 Complete revision 21 12 2010 Paulin C 002 Some data update added folding sysytem 08 07 2011 Paulin C As in this paragraph the revised parts of the text will be marked by a black vertical line on the left side If the manual has been fully revised the line will not be necessary This manual uses various key words defined below PRUDENCE Procedures or instructions that if not correctly observed could cause an accident or death Procedures or instructions that if not correctly observed could damage aircraft parts Procedures or instructions that require particular attention This manual must be complied with in order to use the aircraft Furthermore a copy of this manual must always be transported on board FLYSYNTHESIS S r l declines all liability for any damage to people or property resulting from failure to observe or the partial observance of the instructions contained in this manual FLYSYNTHESIS S r l holds the copyright for this Flight Manual and it is prohibited to reproduce it par tially or completely or to provide it to competitors without prevous written authoris
31. and or with common sense The following section contains the operations to carry out to the letter in the case of emergency situations The latter are divided by type ATTENTION the multifunction instrument indicates if parameter threshold has been exceeded completely tur ning the indicator bar black If the parameter is within the limits the indicator bar is dotted 5 1 EMERGENCY PROCEDURE ON THE GROUND 5 1 1 ENGINE FIRE Fuel cocks Closed Auxiliary fuel pump Off Engine throttle Stop Key with magnets OFF Master switch OFF Engage the parking brake if on the ground Abandon the aircraft as soon as possible If available use a fire extinguisher to put out the fire 5 2 EMERGENCY PROCEDURE DURING TAKE OFF 5 2 1 TAKE OFF INTERRUPTION before lifting off from the ground water Engine throttle Fully back Brakes Brake without locking the wheel on the ground Pull up the aircraft on water Flap Retract Magnets Off Master Off Fuelselectors Off 5 2 2 ENGINE FAILURE DURING TAKE OFF immediately after takeoff altitude below 50 mt Maintain a safety speed in relation to take off weight Select a location to land in the area in front of you alter course max 45 with respect to the origi nal path fly in a coordinated manner DO NOT TRY TO TURN 180 TO RETURN TO THE RUNWAY Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 5 1 Fuel cock Closed
32. ane has low fuel quantity less _ than total fuel tanks capacity anchor the plane on ground using the steel hook located on the hull s bow Position the wings supporting device on the tail beam and lock it with the proper ratchet Tighten the ratchet as needed without overdo Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 16 FlySynthesis S r l Position the strap which keeps the sta bilator in right position as shown in the pictures The anchor of the strap on the stabilator mass balance must be at the middle of the mass balance Remove covering between the wings on the tail beam To do it remove the 2 lo cking screws using a Phillips screwdriver Slip off the covering rearward till all the holes are free as shown in the picture Put the screws in a secure place Lift the covering and remove it Issued 08 07 2011 Page 4 17 Using the 2 provided size 10mm span ners remove the bolt which connects the control rod and the aileron bellcrank Put the nut to the screw on the alumi num bellcrank This is needed to main tain the aileron in the right position ATTENTION In this phase do not lose nuts or wa shers Remove all the safety locking pins to the wing tail beam attaching point joints Front connecting point Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 18 Rear connecting point Remove the safety pins on the upper br
33. applies to all types of una voidable impacts also on the ground 5 6 PARACHUTE OPENING PROCEDURE IF INSTALLED The emergency parachute is located in the rear part of the hull The parachute is fixed to the aircraft by two kevlar straps passing in the external part of the fuselage to the front and rear wing bayonet connections The emergency parachute must only be used in the case of losing complete control of the aircraft If activated 1 Turn off the engine magnets OFF 2 Pull out the red parachute strap postioned above the instrument panel at least 20 cm 3 Close the tank cocks 4 Tighten the seat belts 5 Turn off all users Master OFF 6 Crouch down and protect your face with your hands For more information and notes regarding maintenance refer to the enclosed parachute manual Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 5 6 5 7 OTHER EMERGENCIES 5 7 1 LOW FUEL PRESSURE if the optional fuel pressure indicator is installed Auxiliary fuel pump ON Fuel cocks Open alternately for a flow rate check Fuel pressure Check limits If the fuel pressure has not stabilised land as soon as possible 5 7 2 UNEXPECTED CONDITIONS OF ICE It is prohibited to fly in conditions with ice snow and rain If weather conditions are encountered that favour the formation of ice reduce altitude immediately If ice forms on the bearing surfaces and planes keep in mind the increase in th
34. ation Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 1 1 1 2 ENREGISTREMENT DES PAGES EFFECTIVE Page Date Revision Date Revision l l 21 12 2010 001 4 21 05 07 2011 002 Al 21 12 2010 001 4 22 05 07 2011 002 BI 21 12 2010 001 4 23 05 07 2011 002 1 1 21 12 2010 001 4 24 05 07 2011 002 1 2 21 12 2010 001 5 1 08 07 2011 003 2 1 21 12 2010 001 5 2 21 12 2010 001 2 2 05 07 2011 002 5 3 21 12 2010 001 2 3 05 07 2011 002 5 4 08 07 2011 003 2 4 21 12 2010 001 5 5 08 07 2011 003 3 1 21 12 2010 001 5 6 21 12 2010 001 3 2 21 12 2010 001 5 7 08 07 2011 003 3 3 21 12 2010 001 5 8 08 07 2011 002 3 4 21 12 2010 001 6 1 21 12 2010 001 3 5 21 12 2010 001 6 2 21 12 2010 001 4 1 21 12 2010 001 7 1 21 12 2010 001 4 2 05 07 2011 002 7 2 21 12 2010 001 4 3 21 12 2010 001 8 1 21 12 2010 001 4 4 05 07 2011 002 8 2 05 07 2011 002 4 5 21 12 2010 001 8 3 21 12 2010 001 4 6 21 12 2010 001 8 4 05 07 2011 002 4 7 21 12 2010 001 9 1 21 12 2010 001 4 8 21 12 2010 001 9 2 21 12 2010 001 4 9 21 12 2010 001 9 3 21 12 2010 001 4 10 21 12 2010 001 9 4 21 12 2010 001 4 11 05 07 2011 002 9 5 21 12 2010 001 4 12 21 12 2010 001 9 6 21 12 2010 001 4 13 08 07 2011 003 10 1 21 12 2010 001 4 14 21 12 2010 001 11 1 21 12 2010 001 4 15 05 07 2011 002 11 2 21 12 2010 001 4 16 05 07 2011 002 11 3 21 12 2010 001 4 17 05 07 2011 002 11 4 21 12 2010 001 4 18 05
35. carried out on a standard aircraft in optimal conditions and were adjusted to standard atmospheric conditions at sea level The performance tables do not account for pilot ability or the maintenance conditions of the aircraft The performance indicated in the tables can only be obtained if the indicated procedures are followed scrupulously and if the aircraft is in a good efficient condition Many variables such as the engine s operative conditions or turbulence could have an impact on performance with particular reference to take off runs clim bing rates and in general to characteristic speeds 6 1 TAKE OFF RUN ON GROUND DIAGRAM 15m TAKE OFF RUN DISTANCE TO SUPERATE AN OBSTACLE OF 15m _ TAKE OFF DISTANCE Take off run Take off distance Take off speed 130m 350 80 Km h The specified distance and speed values are approximate and may vary with the various configura tions of the aircraft or different atmospheric conditions 6 2 LANDING RUN LAND DIAGRAM 15m DISTANCE TO OBSTACLE OF 15m LANDING RUN ES e LANDING DISTANCE Landing distance Landing run Landing speed 295m 150m 75 Km h Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 6 1 The specified distance and speed values are approximate and may vary with the various configura tions of the aircraft or different atmospheric conditions 6 3 TAKE OFF RUN ON WATER DIAGRAM Water run take off run Take off distance Take off spee
36. cate the hinges and XOXX replace the electric actuator if necessary Check the front landing wheel check for misalignments and breakage X X X check bolt tightening Disassemble the front wheel landing gear check the anchoring points of the moving part to the hull structure check the steering plate reassemble X X and check bolt tightening Check the conditions of the front landing wheel and the respective tyre 0000 Inflate to 1 2 bar 17 2 psi Check the brake s hydraulic system in its entirety Replace any damaged O 00 parts Drain the hydraulic system Top up with new fluid Check the conditions of the hydroconic brake replace if necessary Check X X X the tightening of the self locking nuts Remove the rear landing gear Clean the movement parts and lubricate correctly Make sure all the components are efficient and reinstall them X X checking bolt tightening Check the conditions of the wheels and the respective tyres Inflate to a 00 pressure of 2 2 2 4 bar 32 35 psi Reinstall the wheels and check bolt tightening Make sure that the wheel bearings move in a regular and agile manner check for play Check wheel alignment X X X O X O X xXx O X O Check the steering mechanism replacing the cords if ruined ALL ENGINE MAINTENANCE MUST BE PERFORMED IN COMPLIANCE WITH THE ENGINE MANUAL This part of the manual only covers the checks for the engine s instal
37. check that the area near the propeller is clear and never abandon the aircraft with the engine on Remember that when in water and once the engine has started even if at reduced power the aircraft tends to float YELL KEEP AWAY FROM THE PROPELLER Press the START button Max 20 sec followed by a cooling period of 1 minute for each attempt Throttle with the engine started position 2500 rpm Generator indicator light Off 4 44 3 PRE TAXIING Avionic devices On Navigation instruments Checked Flaps Take off position Parking brake Disengaged Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 6 444 TAXIING FLOATING a Taxiing Brake Check efficiency Mobile surfaces Check complete excursion Flight instruments Check operation and coherence Throttle As necessary to maintain a taxiing speed no greater than 5 km h b Floating Floating refers to all aircraft movements in the water Once in the water remember that if the ai rcraft is not tied up it is at the mercy of the forces exercised by the wind waves marine current and inertia which must be managed and corrected with the traction generated by the propeller and the use of the marine and or aerodynamic rudder Furthermore amphibious aircraft are optimal weathervanes in fact if left free to move they position themselves spontaneously with their nose to the wind During manoeuvres always remember that the turn
38. d 300m 400 85 km h The specified distance and speed values are approximate and may vary with the various configura tions of the aircraft or different atmospheric conditions 6 4 LANDING RUN ON WATER DIAGRAM Landing distance Landing run Landing speed 265m 120m 70 km h The specified distance and speed values are approximate and may vary with the various configura tions of the aircraft or different atmospheric conditions Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 6 2 WEIGHTS AND BALANCES 7 7 WEIGHTS AND BALANCES This section includes the information needed to correctly balance and centre the aircraft PRUDENCE If the gravity centre limits are not taken into account problems regarding aircraft stability and con trollability can occur with serious safety risks 7 1 WEIGHING CONDITIONS The following conditions must be satisfied to weigh the aircraft The equipment must be those foreseen in the list related to the aircraft in question This must include brake fluid engine oil antifreeze and unused fuel A scale with three independent sensors must be used placed on the same horizontal plane as well as a plumb line 7 2 CALCULATING THE CENTRE OF GRAVITY As a reference for the subsequent measurements the projection of the wings leading edge will be adopted marked using a plumb line With respect to this reference distances X1 and X2 are measu red X1 is the distance between the centre o
39. d in this section 3 1 SPEED RESTRICTIONS Speed Notes Never exceed this speed in any Vne Never exceed speed 150 km h condition or configuration Never exceed this speed in turbulent Vmo Maximum operating limit speed 130 km h d E The maximum speed at which the Va Manoeuvring speed 130km h abrupt use of the complete run of the flight controls is permitted Never exceed this speed with the Vfe Maximum flap extended speed 105 km h flaps extended Vs Stall speed without flaps 65 km h Never go below this speed without flaps to avoid undesired stalling Never go below this speed with the flaps in the landing position to avoid VsO Stall speed in landing configuration 55 km h flaps extended undesired stalling Permitted speed with the landing Never exceed this speed with the Vig gear extended 120 km h landing gear extended 3 2 MARQUAGE ANEMOMETRE Marking Speed range IAS Definition White arc VsO Vfe 55 105 km h Speed range where the flaps can be extended Green arc Vs Vmo 65 130 km h Speed range for normal operations Yellow arc Vmo Vne 130 150 km h Manoeuvre the aircraft with great caution Red line Vne 150 km h Maximum permitted speed Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 3 1 3 3 ENGINE LIMITATIONS Refer to the Rotax operative manual Engine manufacturer Rotax Bombardier Engine model 582 UL Maximum tak
40. d out to restore safe aircraft conditions If the aircraft has not reached the 200 hours of flight within the first 24 months the 200 hours of flight maintenance operations must be carried out to restore safe aircraft conditions 9 3 EXPIRATION LIMITS FOR SOME COMPONENTS The following components must be removed for inspection and complete overhaul respecting the defined deadlines 300 hours whichever of the two conditions occurs first refer to the Engine ROTAX 582 DCDI UL ROTAX manual Propeller refer to the propeller manual Silent block replace after 150 hours or every 2 years whichever occurs first Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 9 6 UNSCHEDULED MAINTENANCE 1 0 10 UNSCHEDULED MAINTENANCE 10 1 HARD LANDING A hard landing must be recorded in the flight log by the pilot or a technician after observing the conditions of the landing gear The following inspection must be carried out 1 Disassemble all landing gear check for breaks in the wheels and in the kinematic motion components Check for misalignments check the connection and tightening of the bolts Check for leaks or breaks in the step and check the welds Replaced the damaged components 2 Check for any leaks or abrasions on the hull Check for distortion of the engine mount or tail boom 4 Check for distortion of the wing struts and the front struts where the instrument panel is fixed 5 Check for distortion
41. e freedom of movement correct fastening of supports Brake functional test Manual trim position function check Seat belts function and anchoring check Seats correct fastening 9 a BATTERY Clamp tightened Cables connected and screws tightened No oxidation or electrolytic phenomenon For acid batteries level of the liquid within the toleran ce A MOTOR CONNEC T dertad Coil and spark plug cables dry and without evident damage Spark plug pipes tightened Spark plug base thermocouple cable tightened Starter motor cables connected and tightened Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 5 4 4 BEFORE TAKE OFF During flight and when moving the aircraft the use of a helmet is mandatory and the seat belts must always be used and fastened 44 1 PRE STARTUP CHECKS Pre flight inspections Completed Seats Adjusted Seat belts Fastened and well tightened Parking brake Engaged Controls Free Fuel tank selector The fullest is open the other closed Trim Neutral position Retractable landing gear selector position DOWN on the ground UP in water 4 4 2 STARTING Master ON Generator indicator light ON Parking brake Engaged if on the ground Throttle choke engine cold ON fully back engine hot OFF fully forward Electric fuel pump ON for 15 sec then OFF Throttle Minimum Magnets Both ON PRUDENCE
42. e off power 64 4 HP Maximum continuous power 58 HP Maximum take off RPM 6800 rpm Maximum continuous RPM 6500 rpm Maximum cylinder head temperature 150 C Type of usable fuel min 95 RON unleaded Type of usable oil see Rotax manuals 3 4 ENGINE INSTRUMENTS MARKING Red line pone Green arc Normal Upper yellow arc Red line Instrument 4 yellow arc i Lower limit Cauti operations Caution Upper limit aution RPM indicator nd nd 2000 6500 rpm 6500 6800 rpm 6800 rpm Fuel pressure 0 15 bar nd 0 15 0 4 bar nd 0 4 bar Water temperature 65 nd 65 75 C 75 80 C 80 C 3 5 WEIGHT RESTRICTIONS Empty weight 315 kg 324 kg with parachutes Maximum fuel weight 38 Kg Maximum weight in baggage compartment 12 Kg Maximum take off weight 495 kg 495 kg with parachutes PRUDENCE never exceed the maximum take off weight 3 6 LIMITATIONS OF THE CENTRE OF GRAVITY In order to obtain the best flight and operating performance in complete safety the aircraft must be used in compliance with the loading and balancing schemes indicated on the fol lowing pages It is the task and responsibility of the pilot to take these load parameters and limits into account Before delivering any aircraft the empty weight and the position of the centre of gravity are measured The empty weight and the centre of gravity must always be measured after replacing modifying integrating repairing or painting any
43. e paragraph 4 10 OPERATIONS AFTER LANDING ALIGHTING ON WATER 4 10 1 AFTER LANDING Throttle gas To minimum Flaps UP Taxiing Free the runway as soon as possible Electric pump OFF Brakes Check hot brake efficiency Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 11 4 10 2 AFTER ALIGHTING ON WATER Throttle gas To minimum Flaps UP Floating Float at a moderate speed Electric pump OFF 4 10 3 SHUTTING OFF THE ENGINE on the ground water Throttle gas To minimum Parking brake Engaged if on ground Electric equipment OFF Magnets OFF one at a time Master OFF Fuel tank selectors both OFF 4 10 4 MANUAL MOVEMENTS ON THE GROUND Instructions for moving the aircraft on the ground with the engine off e Disengage the parking brakes if engaged e Tale the aircraft by the tail boom and press downward to raise up the front wheel e Make sure there are no obstacles animals or people nearby e Push or pull the aircraft making it rest only on the main landing gear Engage the parking brakes once the target destination has been reached A pin system on the front wheel is also availalbe for the tow hook when moving the aircraft on ground optional 4 10 5 MANUAL MOVEMENTS IN WATER When it is necessary to dock in an area that is crowded or that has obstacles it is best to make mo vements manually Instructions for moving the aircraft in the wate
44. e seats ina central position Keep the lever pulled back the entire time the rudder is used When the lever is released a return spring will return the rudder to the flight position retracted position Rudder activation lever Throttle brakes lever Rudder extracted 50 Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 14 4 12 LIFTING POINTS The Catalina airframe and hull are designed for distributed loads so lifting it in wrong points could damage it It is necessary to always use some polystyrene blocks or similar to distribute the loads The lifting points for the Catalina are 4 12 1 Ontheairframe e The connecting point between wing and bracing struts e The wing tip in the correspondence of the last rib located in correspondence of the last flapperon pylon distributing the load 412 2 On the hull e ln correspondence of the wing bracing strut attachment e ln correspondence of the main wheels supporting boxes Fly Synthesis will not take any responsibility from damages occurred by lifting the aircraft in points different from the ones reported above Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 15 4 13 WINGS FOLDING PROCEDURE Optional ATTENTION The wings folding operations must be done only on ground in a suitable place sufficiently bro ad The folding on water It is strictly forbidden because of the risk of overturning ATTENTION If the pl
45. e stalling speed as well as the increase in power necessa ry to maintain speed and a level flight Aircraft manoeuvrability reduces drastically and in extreme cases control of the craft can be fully lost Rpm Maintain the highest engine power possible Move the various control surfaces to prevent the formation of ice on the drive chain 5 7 3 FORMATION OF ICE ON THE CARBURETORS This is recognised by a decrease in engine revolutions with the throttle motionless This may also occur on a humid day at low rpms Throttle Fully forward to increase rpms Restore normal flight conditions 5 7 4 ABNORMAL ENGINE VIBRATIONS Check that vibrations decrease by reducing rpms Land as soon as possible Prepare for engine failure and a forced landing 5 7 5 LANDING WITHOUT BRAKES Look for a runway as long and grassy as possible grass brakes Land with the flaps fully out at the minimum support speed After contact with the ground Battery and magnets OFF 5 7 6 UNDERCARRIAGE SYSTEM MALFUNCTION In case that the completed extraction retraction indicator lights will not switch on it is possible to by pass the pressure control and regulation system of the hydraulic plant and force within certain limits the extraction or retraction of the undercarriage To do this see the following instructions e Position if not already done the undercarriage switch in wanted position extract re tract e move up down and hold the Emergency
46. eck the entire gas exhaust system check for leaks breaks and the hold of the springs installed to hold the muffler x O X X x O XX X x O IX IX X Check the secure connection of the cooling radiator Check or replace all cooling system ducts x Check the terminal conditions O O O Check all electric system wires that concern the engine gt lt gt lt gt lt Check the level of the coolant top up if necessary Replace the coolant Check the engine casing and check for leaks or problems Check all fuel system connection pipes Check the cooling system connection pipes and expansion tanks Check all engine probes Check the battery electrolyte top up if necessary Check the battery support its anchoring check for any leaks in the battery casing and the electrolyte properties must always be clean O O oo 0 0 O O O O O 000 OO O O 000 OO X Check the battery cables Check that the tools have been removed from the aircraft Close all inspection holes Clean the cabin XK XXX Reinstall the seats and safety belts O visual check only X complete maintenance tools and instruments required Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 9 5 If the aircraft has not reached the 100 hours of flight within the first 12 months the 100 hours of flight maintenance operations must be carrie
47. f the front wheel and the reference X2 is the distance between the rear wheel axle and the reference The position of the centre of gravity in mm in reference to the chord is Xt ML PT Where ML is the moment of the empty weight calculated as P2 X2 P1 X1 With P1 Weight measured under the nose wheel P2 Sum of the weights measured under the rear wheels P2lh P2rh PT Total weight sum of the three measurements P1 P2 The position of the centre of gravity can be expressed as a chord percentage Xt Xt M A C x 100 where M A C is the length of the chord Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 7 1 7 3 CHECKING THE RESULTS For proper balancing the centre of gravity must lie within the two limits shown in the following table Maximum limit Chord percentage Xt Position on the chord Xt Front 2896 M A C 375 mm Rear 3796 M A C 496 mm The first recording of the aircraft weighing report is carried out by the manufacturer FlySynthesis before delivering the aircraft The factory Weighing and centring report is delivered together with the aircraft Any variation due to the installation of new components repairs or painting implies the obli gation to remeasure the empty weight and calculate the relative position of the centre of gra vity All of these updates must be entered in the Weighing and centring report If the centre of gravity does not lie within the limits cont
48. g the control sticks to the seat belts It is always best to pull the aircraft onto the shore rather than anchor it in water as strong wind or strong waves could cause the hull to collide with surrounding objects which may not be seen because submerged damaging it If it must be anchored in water for example to a pier in adverse weather conditions it is advised to place polystyrene blocks or other materials that absorb impacts around the perimeter of the hull or on the pier 4 11 LANDING GEAR AND RUDDER EXTRACTION AND RETRACTION PROCEDURE 4 11 1 LANDING GEAR EXTRACTION AND RETRACTION Use the specific switch on the control panel to extract or retract the landing gear To extract the landing gear push downards the switch lever The redlight turn on only if all three wheels are completely extracted To retract the landing gear pull the switch lever upwards when all the three wheels are completely retracted the greenlight will turn on The luminous landing gear position indicators are inverted in comparison to traditional ground type aircraft with retracting landing gear as the most dangerous phase is to alight or try to take off from the water with the landing gear extracted Landing gear indica tor light Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 13 4 11 2 RUDDER EXTRACTION RETRACTION AND USE FOR WATER OPERATIONS To extract the marine rudder pull back the left lever located on the floor in front of th
49. lation on the fuselage X X X X Check the part of the fuel system connected to the engine Check that the O 00 connections are secure and replace if necessary Check the electric fuel pump Remove it to clean the filter 0000 O visual check only X complete maintenance tools and instruments required Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 9 4 INSPECTION SCHEDULED INSPECTIONS FOR CATALINA TYPE i In Zone Operations to carry out N N ENGINE Check the cables controlled by the choke and gas throttle check their volta ge and any interference with other parts The movement must be free and O O O agile Clean and lubricate the cables Check the carburettors check for any problems and adjust if necessary X Clean if necessary SA Clean the carburettors refer to the ROTAX manual X X Clean or replace the air filters refer to the ROTAX manual O O O Inspect the carburettor installation flanges X X X Replace the carburettor installation flanges X Check the integrity of the silent blocks and replace them if necessary X X X Replace the silent blocks X Check the tightening torque of the bolts connecting the engine to the engi X X X ne mount Refer to the ROTAX manual Check the tightening of the self tightening nuts that connect the fuselage to the engine mount Check the radiator tightening Check the exhaust manifold tightening Ch
50. ler hub bolts locked 3 Right side of the fuselage Hull nose fairing and windshield intact and without microfractures or delaminations Wing strut nuts locked Fuselage and wing struts intact without inflections Fuselage rivets intact Front and rear landing gear Mechanism operating without distortion or play clean free of foreign objects Wheel rota tion pin nut locked Landing gear compartment intact and clean Tyre intact and at a correct pressure Hub and brake intact Nylon brake control tube intact and without bends Brake no oil leaks 4 Right wing Wing surface no bulges depressions or delaminations Trailing and leading edges intact no residual deformation Wing fuselage connections fastened correctly without deformations Ailerons upward and downward freedom of movement without excessive play on the hinges no cracks near the connections no lateral movements Control rods integrity and correct fastening smoothness and freedom of oscilla tion Hinge supports firmly fastened to the wing Counterweights fixed without play Anemometer probe intact aligned with the aircraft axis no obstructions 5 Rear fuselage section Fuselage beam fastening rivets intact Hull rudder intact and functioning Vertical fin no buckling or delaminations fastening rivets without
51. ll tightened Engine throttle Fully back Fuel cocks Closed Auxiliary fuel pump Off Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 5 5 Select the landing area evaluating the origin and intensity of the wind and the absence of obsta cles Flap As necessary Trim As necessary If possible fly over the selected area making sure that it is free of obstacles and safe for landing Final Check the speed Landing Check the speed minimum 85 Km h with flaps Key with magnets and battery Off When coming into contact with the ground keep the front wheel lifted as long as possible 5 5 EMERGENCY PROCEDURE IN WATER 5 5 1 WATERINFILTRATIONS IN THE HULL As soon as you notice water infiltrations activate the bilge pump and try to plug the leak and go to the nearest mooring point If you are in open sea or far from land request help immediately from the Coast Guard and put on the lifejackets do not try to take off with a leak in the hull maintain position and request help The aircraft could sink Considering that the outer wings are semi waterproof the craft should generally float In the case of sinking abandon the aircraft cockpit and position yourself on the outer wings while waiting for help 5 5 2 INCORRECT MANOEUVRES If due to an incorrect floating maneouvre it is impossible to avoid an impact the engine must be turned off close the fuel cocks and set the master to OFF This procedure
52. lus visibility is reduced It is prohibited to fly when it is raining 4 7 1 FLIGHT WITH TURBULENT AIR CONDITIONS PRUDENCE In conditions of turbulence and or wind gusts reduce the speed by keeping the flaps in the crui sing position and adjust speed below the normal manoeuvering speed 4 8 DESCENT Altimeter Check the QNH value Throttle As necessary Trim As necessary Engine parameters Within the limits 4 9 LANDING AND ALIGHTING ON WATER 4 9 1 LANDING With regard to the typical landing and alighting on water distances see section 6 Performance Speed 80 km h Flaps fully extended Trim As necessary Throttle As necessary Landing gear Extended for operations on the Ground Retracted for operations on the water Auxiliary fuel pump ON Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 10 Hydraulic brake test Carry it out keeping the system pressurised Final approach speed 70 km h Landing speed 65 km h a In conditions with strong cross wind or gusts or in the case of wind shear increase the final speed by at least 10 km h b Brakes perform a system pressurisation test pulling the brake lever to the end of stroke position a few times to check its correct operation the lever must encounter resistance a sign of a pressure increase in normal operation 4 9 2 ALIGHTING ON WATER The alighting on water procedure is similar to landi
53. ng Apply maximum power pulling up on the control stick as when taking off and when the aircraft reaches the gliding speed keep only a minimum part of the hull in contact with the water reducing the power to a value that makes it possible to maintain the obtai ned speed When using this techngiue retract the hull rudder to prevent it from being damaged also because it is not of much use at high speeds Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 7 PRUDENCE In the case of strong side winds float at a low speed using the power cautiously as the aircraft could capsize Always turn at a low speed max 3km h 4 4 5 ENGINE TEST on ground and in water Parking brakes Engaged on ground N A in water Fuel tank selector The fullest is open Temperature and pressures In the green arc or within the limits Trim Neutral position Controls Free Magnets at 4000 rpm removing them one at a time there must be a maxi mum decrease of 300 rpm per magnet Throttle Fully forward maintain 6000 rpm 150 for 5 Minimum RPM 2000 rpm check minimum PRUDENCE in the water the engine test causes significant acceleration Always carry it out in an area free of obstacles and upwind 4 5 TAKE OFF 4 5 1 BEFORE TAKE OFF Flight controls Free Trim Neutral Electric fuel pump ON Flaps Fuel tank selector Take off position The fullest is open
54. ng on the ground Pay particular attention however to the wavy motion of the water surface the wind direction and look for an area suitably distant from the shore and free of obstacles PRUDENCE Before alighting on water also make sure the landing gear is retracted Alighting on water with the landing gear extracted could cause the aircraft to overturn or hull yielding Alighting on water is carried out with the flaps completely lowered decreasing the engine and pul ling up slightly in a ground effect in order to come into contact with the water with the hull s tail without risking bouncing or even worse overturning forward Alighting on a flat surface is a very deceptive and dangerous situation The physiology of the hu man eye also prevents the most expert pilots from correctly perceiving the depth without signifi cant projections on the water surface In these conditions it is easy to perform an incorrect appro ach risking a stall at an altitude of a few metres resulting in a belly flop and probable overturning In these conditions monitor the altimeter often or orient yourself using the shores using elements on the ground such as trees buildings high ground etc as a reference Also prior to alighting on water the landing area should be flown over in order to view any obstan ces or possible landing problems In the case of TOUCH amp GO Flaps completely lowered Then repeat the take off procedure see relativ
55. of the flanges and the wing connections DI 10 2 DAMAGE TO THE COMPOSITE STRUCTURE For problems of this type contact Fly Synthesis s r l as in order to guarantee completely safe use of the aircraft the nature and seriousness of the structural damage must be carefully examined Yiel ding of the composite structure during flight could have catastrophic outcomes 10 2 1 EXCEEDING ENGINE LIMITS If the restrictions concerning rotation speed time pressure or temperature limits have been excee ded record the event in the aircraft s log and refer to the ROTAX maintenance manual 10 2 2 EXCEEDING LOAD LIMITS AND AIRCRAFT SPEED If the load coefficient limits or the VNE have been exceeded the aircraft is no longer approved for flight Therefore to restore airworthiness the aircraft must be checked following the 200 hour inspection program 10 2 3 AIRCRAFT PAINTING The aircraft is delivered white It is prohibited to paint the upper surfaces of the wings and fuselage with dark paint as the increase in absorption of the sun s heat could damage the composite struc ture After any painting operation the aircraft s weight and centring must be verified see flight manual Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 10 1 APPENDIX 11 11 APPENDIX 11 1 UNIT OF MEASURE CONVERSION TABLES Distance conversion table 11 1 1
56. on is free to rotate around its axis The balancing masses may hit or hook on the other wing during the wing s positioning on the supporting device Link the rear root attachment points with the provided device and tighten the related nuts Issued 08 07 2011 Page 4 23 Remove the bracing struts and place them into the hull as it shown in the picture ATTENTION Pay attention that in the left bracing strut is present the pitot tube line So sli de off the bracing strut without forcing and then disconnect the rilsan tube ATTENTION Cover the rilsan tube of the pitot in order to avoid that foreign object could ob struct it or water could enter into it 4 14 Toresetthe plane in flight configuration follow the instructions above in reversal order 4 15 While moving the plane with folded wings pay attention that the load on the front wheel is very low Keep firmly the plane during ground movements to avoid that because of even small subsidence the plane could fall down with rear part and damage the hull s tail Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 24 EMERGENCY PROCEDURE 5 5 Emergency Procedure Emergency situtations are very rare if the pilot carries out the pre flight aircraft checks very care fully also carrying out ordinary and if necessary extraordinary maintenance Emergencies due to poor weather conditions may be minimised or eliminated by carefully planning the flight
57. on water when the surface is agitated Maximum wave height permitted 35 cm Always take off against the wind if possible If the water surface does not have a wind sock the wind s direction can be assessed by observing flags boat sails smoke tree leaves and the streaks on the water surface Before taking off foat along the section to be used to make sure that there are no obstacles and that it is free until the end of the takeoff PRUDENCE Please remember that when taking off from a flat water surface the aircraft needs a longer take off area as the adhesion forces of the water on the hull increase arriving to extreme cases in which taking off it not possible Both when taking off or when alighting pay attention to the possibility of porpoising which is a type of dynamic instability caused by wavy motion where the hull first bounces forward and then backward on the water The frequency of this oscillation depends on the speed of the aircraft there fore at high aircraft speeds it becomes difficult to control with serious risks of overturning and hull yielding To prevent this from occuring move the control stick slowly avoiding pulling up or diving suddenly If the porpoising phenomenon is not corrected in time it will continue to increase There fore as soon as the pilot notices that the oscillation cannot be controlled power must be reduced pulling up slightly until returning to the initial floating position 4 5 4 TAKE OFF
58. or located on the right side of the hull under the instruments panel 2 6 2 TANKS Two removable tanks in the hull located symmetrically to the side of the pilots with 25 litre capacity each Fuel tanks with breather pipe 2 6 3 UNUSABLE FUEL 2 litres per tank 2 6 4 FUELFILTER Located inside the Gascolator 2 7 PROPELLER Type Helix two blade composite fixed propellere 2 8 LANDING GEAR Type Hydraulic retractable front tricycle landing gear Front steering wheel controlled by rud der pedals Track 1 380 m Pitch 1 750m Tyres Rear 5 00x6 Front 4 00x6 Tyre pressure Rear 2 2 2 4 bar Front 1 8 bar Brakes Hydroconic on the front wheel controlled by a centrally positioned lever 30 cm in front of the seats Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 2 3 2 9 ELECTRIC SYSTEM Type Electric 12 V DC system with a buffer battery protected with fuses rectifier external governor 2 10 STANDARD INSTRUMENTS Anemometer altimeter rate of climb indicator magnetic compass turn coordination indicator CHT EGT RPM manual trim on the pitch axis luminous landing gear position indicator Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 2 4 RESTRICTIONS 3 3 Restrictions Aircraft use must be compliant with the laws of the state in which it is used It is the task and responsibility of the commanding pilot to take this into account and respect the restrictions describe
59. r with the engine off e Tiearope the the front connection on the hull e Goon shore or on the pier and move the aircraft by pulling the rope being careful not to make it collide with obstacles of any type e Throw the anchor tie the rope used previously to any solid and resistant object or pull the aircraft ashore 4 10 6 ANCHORING ON THE GROUND The aircraft is anchored first by positioning the parking brake to ON then tying the cords to the up per connections of the struts on the outer wings A third anchoring point may be the flying tail hin ge or the steel ring located on the nose of the hull When tying the rope on the ground make sure not to tension it too much A little force is sufficient for secure anchoring and will not risk damaging the aircraft especially in conditions with strong wind CAUTION It is a good habit to tie the control stick to the seat belts when the aircraft is left in windy condi tions which prevents the mobile surfaces from violently impacting against the stops Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 12 4 10 7 ANCHORING IN WATER In water the aircraft can be temporarily anchored by throwing the anchor However it is advised not to abandon the aircraft in conditions of strong wind or wavy motion if anchored only with the anchor In these cases it would be better to secure the aircraft with the lines on the hull connec tions blocking the mobile surfaces also by only tyin
60. radius increases as speed increases At a high speed the aircraft s inertia makes it tend to maintain the same direction Unfortunately there are no brakes in water therefore near to shore or obstacles of various types it is always best to proceed with caution at a low speed when floating try to avoid water sprays from hitting the propeller when moving reducing the movement speed as the sprays are not only harmful to the blades if launched from the propel ler flow at a high speed they could cause damage to the aircraft There are three types of movement in the water Engine at a low speed therefore low speed direction set mainly by the hull rudder which must be lowered by keeping the lever located between the seats pulled back near the brake lever and by pulling up on the control stick keeping the nose lowered At a low speed the tail rudder is ineffi cient This technique is particularly recommended when moving in small and crowded spaces in fact it reduces the risk of hitting obstacles as the aircraft accumulates little inertia To increase speed increase the power with the control stick always pulled up which causes the hull to lift up the nose and the aircraft will be unbalanced towards the back This technique is used when moving in wavy water as it keeps the propeller away from the sprays When the water conditions permit it and the aircraft must be moved for a long distance that is not crowded it is best to float glidi
61. removed the wing tend to rotated and fall down Support it firmly to avoid damages Keeping the wing in equilibrium go to the wing s tip Supporting the wing with one hand lift it a bit and unlock the folding system pulling the cable on the wing tip Issued 08 07 2011 Page 4 21 Pull the wing outwards up to the stop helping if it is necessary pulling the un locking cable ATTENTION During the wing extraction and rotation process the wing must be kept lifted in order to avoid collisions with the upper part of the bracing strut If not severe damages will occur to the wing Rotate a bit the wing on its axis with the leading edge downwards Drive the wing to the tail paying the maximum attention to pass over the bracing strut Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 22 FlySynthesis S r l Rotate completely the wing with the leading edge downwards so it is vertical Rotate it toward the tail and place it on the supporting device putting the lea ding edge into it ATTENTION To avoid that the mass balances will interfere during the folding operations of the other wing push the folded wing forward up to the stop In this way the two wings will be not aligned Put the provided cable to keep the aile ron in the neutral position as shown in the picture Fold the other wing following the same procedure ATTENTION During the folding of the wing the aile r
62. ry TN Check the correct operation of the trim and regularity of its surface condi O 00 tions Check the trim cable check its regular and agile movement check the O 00 clamps and check the irreversibility of the uncontrolled movement Check the flap movement mechanism check for distortions check its cor rect movement along the entire extension Check the hinge pins Check the trim surface its correct installation and for kinks in the hinges Check the angular extension of the ailerons up 2 down 15 Check the angular extension of the flying tail up 17 down 1 2 Check the angular extension of the rudder 22 with 09 1 per side Check the trim movement from neutral the trailing edge must diverge from the flying tail movement by 5 Check the angular extension of the trim with the flying tail neutral the trailing edge must be 3 with a deviation of 1 O OOO O O OO OO O O O O 0 0 O O O O Slightly lubricate all moving parts and the respective hinges Check the tightening of the hinge safety bolts of the ailerons fastened on X X X the outer wings Check the tightening of the self locking safety nuts of the ailerons and the rods that connect the spherical head of the control flap inner part betwe X X X en the outer wing and the fuselage Check the movement of the hull rudder replacing the cords if necessary X X X X Check bilge pump operation
63. s Check its connection to the O O O O structure FLIGHT CONTROLS Check the surface of the ailerons check their regular and agile movement 0000 check for play the lateral movement on the hinge must be minimum Check the tightening of the bolts that connect the hinge Check the hinge pins and their hold use Loctite Check the surface of the flying tail check its regular and agile movement check for play the lateral Movement on the hinge must be minimum Check the bolts that connect the hinge to the flying tail check for play Check the surface of the rudder check its regular and agile Movement check for play the vertical movement on the hinge must be minimum Check the bolts that connect the hinge to the hull check for play O O0 Note The maximum permissible play on the control surface lateral for the ailerons and verti cal for the rudder is 0 6 mm Check the kinematic motion of the ailerons and its clamps check for distor tion check the correct movement when fully extended X X x X X O O X X O O O O O O OO X Key O visual check only X complete maintenance tools and instruments required Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 9 2 INSPECTION SCHEDULED INSPECTIONS FOR CATALINA TYPE uo Zone Operations to carry out N FLIGHT CONTROLS Check the Bowden cables and their clamps check the tension and replace if necessa
64. ties at risk The pilot is responsible for the pre flight inspection This procedure does not require any particular equipment a flashlight may be useful for the dark corners Carry out the checks listed below with maximum ac curacy and exactness Hull nose fairing and windshield Wing strut nuts Left side of the fuselage intact and without microfractures or delaminations locked Fuselage and wing struts intact without inflections Fuselage rivets intact Front and rear landing gear Mechanism operating without distortion or play clean and free of foreign objects Wheel rotation pin nut locked Landing gear compartment intact and clean Tyre intact and at a correct pressure Hub and brake Nylon brake control tube intact intact and without bends Catalina NG User Manual Issued 08 07 2011 FlySynthesis S r l Page 4 3 Brake no oil leaks 2 Engine and propeller Engine clean without signs of liquid leaks or blow bys Coolant tank and pipes intact level control no leaks Radiator no leaks or obstructions Muffler and manifold intact well coupled no cracks clean undamaged correctly fastened to the engine choke and throt Carburetors tle cables not worn and correctly positioned Silent block intact rubber section and correctly fastened Propeller clean without delaminations or breaks Propel
65. ut the refuelling operations by first establishing an earth connection to the aircraft using the engine as an earthing point Check the quantity of fuel on board carefully fol low the refuelling operations checking the increase of the fuel level in the tanks in order to avoid fuel from escaping with the related risk of fire or environmental pollution 4 2 3 Drainthe tank The draining procedure must be performed before the first flight of the day 10 minutes after refuelling and between two flights if the aircraft remains parked for a period of time that exceeds 3 hours Simply let 80 100 cc of fuel exit the specific cock under the gascolator filter located in the hull right side under the instruments panel turning the latter forward To perform the operation use a transparent container for hydrocarbons If you note the presence of water repeat the opera tion multiple times until all of the water has been discharged Dispose of the drained fuel without causing harm to the environment PRUDENCE It is recommended to perform this operation before moving the aircraft to prevent the condensation water present on the botton of the tanks to emusify with the fuel Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 4 2 4 3 Inspecttheaircraft The purpose of the pre flight inspection is to identify instrument damage or any type of anomalies none excluded that could place the flight the pilot the passenger or third par
66. vehicle component or installed acces sory The empty weight and the corresponding positioning of the Centre of Gravity must be reported after each measurement on the weight and centring report only by people authorised to carry out this measurement Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 3 2 The position of the centre of gravity can refer to the mean geometric chord M A C Front limit 32 M A C corresponding to 428 mm Rear limit 37 M A C corresponding to 496 mm See section 7 for the weighing test methodology and conditions PRUDENCE if the barycentre is located outside these limits both aircraft manoeuvrability and stability are jeopardised with serious risks to pilot safety The aircraft may not fly 3 7 MANOEUVRE RESTRICTIONS All acrobatic manoeuvres are prohibited including intentional spins Only manoeuvres connected to normal flight conditions are permitted Manoeuvres with a bank angle no greater than 60 and a pitch angle no greater than 30 are permitted In any case the maximum permitted load factor is 4 2g Any type of voluntary stall is prohibited Night time flights flights in icy conditions snow and rain are prohibited during the flight with a single pilot on board the seat belts of the passenger seat must be fastened and well tightened 3 8 LOAD FACTOR RESTRICTIONS The load factor limits used for the structure calculation comply with LTF UL standards and
67. xiliary fuel pump ON Fuel pressure Check that the values are within the limits Key with magnets Both Check Master Check ON Throttle Hot start position Engine start Proceed Catalina NG Issued 08 07 2011 User Manual FlySynthesis S r l Page 5 2 If the engine restarts check all engine parameters and land ASAP for a detailed check Keep in mind that the engine could fail again therefore maintain a suitable flight profile preferring a route that has free space if an emergency landing must be performed ATTENTION If the engine does not restart prepare for an emergencing landing on the ground water 5 3 2 ENGINE FIRE Fuel cock Closed Auxiliary fuel pump Off Engine throttle Fully forward Key with magnets Off when the engine turns off Best gliding speed 80 km h Flaps retracted Land immediately and do not try to restart the engine even if the fire is put out After landing exit the aircraft immediately If available use a fire extinguisher to put out the fire ATTENTION Do not try to restart the engine after a fire started but prepare for an emergency landing 5 3 3 RECOVERING FROM STALL e Gently push the stick forward to eliminate the stall condition e Apply full power to minimise loss of altitude e Return to a level flight 5 3 4 RESTART from an involuntary SPIN ATTENTION NEVER try to stop the rotation by opposing the rotation direction with the ailerons

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