ASTM F2563-06(2010)
(Practice)Standard Practice for Kit Assembly Instructions of Aircraft Intended Primarily for Recreation
Standard Practice for Kit Assembly Instructions of Aircraft Intended Primarily for Recreation
ABSTRACT
This practice covers the instructions a kit producer must provide to a consumer in order to assemble and safely flight-test a recreational aircraft to ensure compliance with applicable ASTM standards. The instructions prescribe the necessary mechanical skills or training, or both, required for successful completion of the kit, as well as necessary tooling, fixtures, inspections, measurements, and other pertinent items required for successful completion of the kit. The kit assembly instructions (KAI) shall include at least the following information: (1) Revisions; (2) Introduction and instructions for using the KAI; (3) Table of Contents; (4) Safety Summary; (5) Applicable standards and specifications; (6) Terminology; (7) Required consumer abilities and responsibilities; (8) Required equipment and environmental conditions; (9) Parts list; (10) Assembly operations; (11) Final assembly Inspections; (12) Flight-test procedures; and (13) Additional requirements.
SCOPE
1.1 This practice covers the instructions a kit producer must provide to a consumer in order to assemble and safely flight-test a recreational aircraft to ensure compliance with applicable ASTM standards.
1.2 The instructions prescribe the necessary mechanical skills or training, or both, required for successful completion of the kit, as well as necessary tooling, fixtures, inspections, measurements, and other pertinent items required for successful completion of the kit. Proof of compliance with these instructions may be vital for obtaining flight authorizations from the applicable CAA.
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.
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Standards Content (Sample)
NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
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Designation: F2563 − 06(Reapproved 2010)
Standard Practice for
Kit Assembly Instructions of Aircraft Intended Primarily for
Recreation
This standard is issued under the fixed designation F2563; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope 3. Required Sections
1.1 This practice covers the instructions a kit producer must 3.1 The KAI shall include at least the following information
provide to a consumer in order to assemble and safely (preferably in the same sequence as numbered in 3.1.1):
flight-test a recreational aircraft to ensure compliance with
3.1.1 (1) Revisions; (2) Introduction and instructions for
applicable ASTM standards. using the KAI; (3) Table of Contents; (4) Safety Summary; (5)
Applicable standards and specifications; (6) Terminology; (7)
1.2 The instructions prescribe the necessary mechanical
Required consumer abilities and responsibilities; (8) Required
skillsortraining,orboth,requiredforsuccessfulcompletionof
equipment and environmental conditions; (9) Parts list; (10)
the kit, as well as necessary tooling, fixtures, inspections,
Assembly operations; (11) Final assembly Inspections; (12)
measurements, and other pertinent items required for success-
Flight-test procedures; and (13) Additional requirements.
ful completion of the kit. Proof of compliance with these
instructions may be vital for obtaining flight authorizations
NOTE 1—The required information may be provided in separate books
or volumes.
from the applicable CAA.
1.3 This standard does not purport to address all of the
4. Revisions
safety concerns, if any, associated with its use. It is the
responsibility of the user of this standard to establish appro- 4.1 The kit provider shall update the KAI when changes of
priate safety and health practices and determine the applica- form, fit, or function are identified as needed in the aircraft or
bility of regulatory limitations prior to use. its sub-components via a revision to the KAI.
4.2 KAI revisions shall be uniquely identified by date,
2. Terminology
purpose, and applicable KAI section.
2.1 Definitions:
4.3 The KAI shall include a form to be used to provide
2.1.1 consumer—any person who follows the instructions
feedback on the document to the kit producer on errors,
covered by this practice to assemble the kit.
anomalies, suggestions, or queries. The form shall identify the
2.1.2 operation—process or action that is part of a series in sourcedocument,user,date,subject,discussion,andreturnable
the assembly of a kit. It is identified by the kit producer as a acknowledgement sections for each communication as a mini-
means to partition the aircraft assembly task into subgroups of mum.
tasks or processes that allow the consumer to track progress or
completion of portions of the kit in an orderly manner. 5. Safety Summary
2.1.3 producer—any person or company who fabricates the
5.1 The KAI shall provide a list of potential hazards
kit and authors the instructions covered by this practice.
associated with kit assembly. It is important to note that no list
of potential hazards could ever include every possible hazard.
2.2 Acronyms:
This section is intended to serve as an advisory to all parties to
2.2.1 CAA—Civil Aviation Authority
enhance safety.
2.2.2 CAGE—commercial and government entity
5.1.1 Chemicals—If hazardous chemicals are used in the
2.2.3 KAI—kit assembly instructions
assembly of the kit, it is advised that information such as
MaterialSafetyDataSheets(MSDS)orequivalentbeprovided
in the KAI.
This practice is under the jurisdiction ofASTM Committee F37 on Light Sport
Aircraft and is the direct responsibility of Subcommittee F37.70 on Cross Cutting. 6. Applicable Standards
Current edition approved Dec. 1, 2010. Published March 2011. Originally
6.1 The KAI shall list the title, source, and significance of
approved in 2006. Last previous edition approved in 2006 as F2563 – 06. DOI:
10.1520/F2563-06R10. the aircraft standards applicable to the aircraft.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F2563 − 06 (2010)
7. Required Consumer Abilities and Responsibilities 10.3 Assembly Operations—Each assembly operation sec-
tion shall include information such as text, photos, templates,
7.1 Consumer Skills and Training:
electrical schematic drawings, or technical drawings sufficient
7.1.1 The KAI shall prescribe any specific skills or training
to explain how to perform that operation and ensure compli-
necessary to complete each operation.
ance with the design criteria.
7.1.2 The KAI shall prescribe any specific responsibilities
10.4 Post-Assembly Inspections and Measurements—Each
theproducerexpectstheconsumertoassumeforcompletionof
the kit. assembly operation section shall prescribe any specific
inspections, measurements, or criteria necessary for verifying
7.1.3 The KAI shall prescribe the responsibilities of the
customer for obtaining a flight authorization from the appli- successful completion of that operation.
cable CAA. Deviation from the instructions or unauthorized
11. Final Assembly Inspections
modifications may prohibit the assembled aircraft from obtain-
11.1 Systems Inspections—The KAI shall prescribe specific
ing a flight authorization. Such information shall be provided
systeminspectionsnecessaryforverifyingsuccessfuloperation
in the KAI.
of each system.
8. Required Equipment and Environmental Conditions
11.2 Engine Start-Up and Break-In—The KAI shall pre-
scribe any specific procedures necessary for initial engine
8.1 Required Equipment and Parts:
start-up and break-in.
8.1.1 The KAI shall prescribe any specific equipment nec-
essaryforcompletionofeachoperationsuchas,butnotlimited 11.3 Pre-Flight Tests and Verifications—The KAI shall
to, tooling, jigs, parts, and fixtures. This list should include prescribe any specific tests and verifications required prior to
initial test flights.
specific manufacturers (CAGE codes if applicable), part
numbers, quantity, and description if possible. 11.3.1 The KAI shall include the Production Acceptance
and Quality Assurance procedures that relate to the final
8.1.2 The KAI may prescribe any specific equipment rec-
ommended for completion of each operation. assembly checks required to show compliance with the appli-
cable ASTM standards.
8.2 Required Environmental Conditions—The KAI shall
11.4 CAA Documentation and Authorizations—The KAI
prescribe any specific environmental conditions necessary for
completion of each operation such as, but not limited to, shall provide the manufacturers documentation necessary for
obtaining all required registration, inspections, and authoriza-
temperature range, humidity, wind, dust, and lighting.
tions from the applicable CAA. Check Appendix X2 for
information regarding various countries’ requirements.
9. Parts List
9.1 The KAI shall contain a parts list of all the kit parts (or
12. Flight-Test Procedures
subassemblies) listing a part number or identifier, description,
12.1 Flight-Test Objectives—The KAI shall prescribe any
and quantity.
specific flight-test objectives necessary for verification of
9.2 A unique part number or identifier shall be assigned to successful operation.
each unique assembly, subassembly, detail part, or consumable
12.2 Flight-Test Environmental Conditions—The KAI shall
material provided in the kit.
prescribe the environmental
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