HANDLING, MAINTENANCE AND PERIODIC INSPECTIONS MANUAL AIRCRAFT KR-030 TOPAZ

Transcription

1 HANDLING, MAINTENANCE AND PERIODIC INSPECTIONS MANUAL AIRCRAFT KR-030 TOPAZ SERIAL NUMBER:

2 CONTENTS PAGE 1 SMALL REPAIRS 2 2 PREPARATION OF THE AIRCRAFT FOR LONG-TERM 4 SUSPENSION OF OPERATION 3 WORKS TO BE DONE AFTER THE LONG-TERM 5 SUSPENSION OF OPERATION 4 ROUTINE MAINTENANCE LIST 5 5 PERIODICAL INSPECTION SCHEDULE 6 6 LIFE CYCLE OF ASSEMBLIES 6 7 ASSEMBLY AND DISASSEMBLY OF THE AIRCRAFT 7 8 ADJUSTMENT POINTS OF THE CONTROL SYSTEM FRONT UNDERCARRIAGE MAIN UNDERCARRIAGE CONTROL SYSTEMS RUDDER CONTROL SYSTEM ELEVATOR AND AILERONS CONTROL SYSTEM FLAPS DRIVE SYSTEM POWER PLANT ENGINE MOUNTING SYSTEM ENGINE CONTROL SYSTEM FUEL SYSTEM ENGINE LUBRICATION SYSTEM ENGINE COOLING SYSTEM AIRFRAME STRUCTURE DOORS REPLACEMENT OF GLAZING 153 2

3 1. SMALL REPAIRS NOTICE: In case of any damage to the propeller, please read the instructions placed in the Operation for AS Type Propellers. NOTICE: All damages to the fuselage composite structure and methods of repair must be consulted with the aircraft manufacturer. a) Small cracks and painting imperfections are to be removed by means of a paintbrush. b) Cracks in the windshield and side windows can be stopped from spreading by drilling a 2 hole at the end of crack. c) During the painting works on control surfaces, such as flaps, ailerons, rudder or elevator, the component must be weighed with the original factory coating. After removing the old coating and applying a new coating, the component should not be heavier than before the repair. After repainting, ailerons' centre of gravity must be verified in the following way: Aileron is to be fixed with two hinges (number 1 and 3, counting along the span) in upside down position. The suspended aileron must be free to swing. If the aileron nose has a tendency to go down or the aileron stays in horizontal position it can be presumed that it is correctly balanced. If the aileron nose has a tendency to go up, a measurement must be performed as per the following drawing. zawieszenie SUSPENSION POINT P Aileron balance measurement diagram 3

4 Value of the P force required to maintain horizontal position of the aileron must not be greater than 0,02 kg. Force P must be applied in the symmetry plane of one of the fastening point. To eliminate influence of friction during measurement of P force, the measurement must be executed by deflecting the aileron s end up and down and then arithmetic mean for calculation must be applied. d) When removing the old coating, special consideration must be given to avoid destruction of the composite structure (see: point a) 2. PREPARATION OF THE AIRCRAFT FOR LONG-TERM SUSPENSION OF OPERATION - Disconnect and remove the battery. - Secure the engine according to the engine Operation and Maintenance. - Empty fuel tanks through the fuselage belly drain valve. Set the CUT- OFF valve to OPEN position. - Dismantle the aircraft (see: point 8.9). Place the wings and control surfaces on special props, ideally in vertical position, aileron and control surfaces to the top. - Attachment points, pins and bolts are to be cleaned with naphtha and covered with Vaseline or thick grease. - Cover the components with protective covers. - Fuselage is to be propped in such a way the tires do not have contact with the ground. - Attachment points, control system, pins and bolts are to be covered with Vaseline and wrapped in greased clothes. - Let air out of tires to 0,5 Bar. - Rear part of the fuselage (the tail seat) is to be properly covered. - Bolts for mounting wings are to be covered with a thin layer of Vaseline, and then put into a plastic bag with nuts and washers, which is in turn to be placed in the luggage compartment. - Mounting bolts seats in wings and fuselage are to be cleaned, covered with a thin layer of Vaseline and plugged with pieces of cloth soaked in grease. - Close and secure the door. - Put a protective cover on all elements. 3. WORKS TO BE DONE AFTER TEMPORARY SUSPENSION OF OPERATION 4

5 - All parts preserved with grease are to be washed and cleaned. - Put air in tires to the level of 1,8-2,0 Bar. - Carry out activities 1, 2, 3, 4, 5, 6, in the procedure Install and connect the battery ( +" terminal to the "+" cable and "-" terminal to the "-" cable). - Remove all preservation from power plant, according to the power plant manual. - Carry out activities 7,8,9, in the procedure Assemble the aircraft (see: point 8.9). - Carry out activities 10, 11, 12, in the procedure ROUTINE MAINTENANCE LIST Pos. Inspection/ check 1 Inspection of airframe structure, giving special consideration to all elements that are heavily loaded during take-off and landing. Control of quality of glue connection of the wing shell with internal wing structure by means of tapping, according to the scheme attached. 2 Inspection of all metal joints pins and bolts. Check for clearances in all critical joints of the airframe. 3 Inspection of all safety elements in particular elements of airframe, power plant and control system. 4 Check of friction in control system, control system fair-leads check. Flaps and ailerons check: external surfaces, hinges, drive system elements.. 5 Inspection and check of undercarriage. 6 Inspection and check of instruments. Checking air tightness of pneumatic systems. 7 Inspection and check of fuel and oil systems(band clips on pipes). All cracked or scratched fuel pipes must be replaced. 8 Inspection of wiring system, check security of cable connections. 9 Inspection of external metal surfaces and protective coatings. 10 Inspection and check of brake system. 11 Inspection of control surfaces displacement. 12 Inspection and check of propeller according to the manual for AS propellers. 13 Lubrication according to procedure Flaps and ailerons suspension position Lamination scheme of the KR-030 wing 5

6 5. PERIODICAL INSPECTION SCHEDULE The following schedule shows inspections that must be carried out after specified periods of time or after incidents mentioned: Period of time Perform inspection/check position: After first 2 hours of flight 1, 2, 3, 4, 5, 6, 7, 8, 12 After first 5 hours of flight 1, 2, 3, 4, 5, 6, 7, 8, 12 After 100 hours of flight or annually 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,13 After hard landing 1, 2, 3, 5, 6 Safe and correct operation of the plane may be assured by systematic maintenance and inspections of the airframe and power plant. The activities must be performed after periods specified in Flight and Maintenance of the Plane, and power plant and propeller manuals. 6. LIFE CYCLE OF ASSEMBLIES Item Assembly Life cycle 1 Airframe - composite structure - metal components of the Depending on technical condition structure - control system components 2 Engine ROTAX 912 UL According to updated technical bulletins issued by the manufacturer. 3 Propeller AS 1700/1950 Depending on technical condition; see manual for the AS type propellers 4 Cockpit instruments (pneumatic Depending on technical condition and electric) 5 Radio and other electronic equipment 6 Rubber pipes for fuel and oil 7 Rubber shock absorbers of the front wheel 8 Tires and inner tubes 9 Rubber dampers in the engine frame According to the updated manuals and instructions of respective manufacturers. Depending on technical condition but no longer than 6 years counted from the year of production 6

7 7. ASSEMBLY AND DISASSEMBLY OF THE AIRCRAFT At least two persons are necessary to perform the assembly described below: a) All parts and elements that are to be assembled must be checked for any visible damages. b) Before commencing assembly, examine general condition of the wings and fuselage structure. If necessary, clean all bolts, pins and holes and cover them with thin layer of Vaseline. Check fuel tank breather for any obstruction (a hole close to the flap drive lever, on the left side of fuselage). c) Put the wing on the fuselage in such a way that its central part slips into the gap over the cockpit. Flaps must be displaced up in such a way that they are above the flaps drive lever (picture 8-1). d) Put pins into the mounting seats ( 2 in front and 2 in back) Front pins are to be inserted after removing top windscreen panel, back pins are to be inserted in the compartment area. The pins are to be secured with bolts. Bolts are to be secured with cotter pins (picture 8-2). e) Flaps drive is to be connected by a clamping ring, secured with bolts. Bolts are to be screwed into using LOCTITE 262 fluid. They must be secured with cotter pins from the bottom (picture 8-3). f) Ailerons drive is to be connected in the cockpit through placing rods eyes on drive lever pins in the bottom part of the wing. Tighten the castellated nuts and secure with cotter pins (picture 8-4). g) Fix the control drive cover and the panel in front of the windshield. h) Insert the pin located in the front part of horizontal stabilizer, to the hole in the fuselage and tighten two bolts to fix the stabilizer to the fuselage (pictures 8-6 and 8-7) i) Put elevator rod eye on the fork in elevator control lever. Secure it with the pin, screw the bolt in and put the cotter pin (picture 8-8) j) Check performance of all control systems, including flaps control system. k) Connect pneumatic pipes with the Pitot pipe. Disassembly of the plane is to be done in reverse order. 7

8 Pic. 8-1 Placing the wing on the fuselage Pic. 8-2 Installation of mounting pins to the fuselage 8

9 Pic. 8-3 Flaps drive connection Pic. 8-4 Ailerons drive connection to the fuselage 9

10 2 1 3 Pic. 8-5 Tail without elevator unit 1 - front seat for mounting the elevator unit 2 - rear seat for mounting the elevator unit 3 - elevator rod eye Pic 8-6 Insertion of elevator unit pin to the seat in the fuselage 10

11 Pic. 8-7 Bolts for fixing elevator unit to the fuselage Pic. 8-8 Connecting of elevator rod to the elevator lever 11

12 8 ADJUSTMENT POINTS OF THE CONTROL SYSTEM 8.1 Adjustment of elevator can be done through screwing in or out the elevator rod eye. See: 8-5, pos. 3. Locknut must be loosened prior to this activity. When the adjustment is finished, the push-pull rod eye must be secured with a locknut and Loctite Ailerons control system is adjustable by changing length of push rods (recommended to be carried out in Ekolot workshop) 8.3 Rudder control system is equipped with neutral position adjustment system with pedals in neutral position, (see Pic. 8 10), as well as adjustment of deflection, by means of changing positions of limiters mounted on the push-pull rod. Middle lever Adjustable tip of the rudder push-pull rod View of the central tunnel from then right side of the cockpit 9 Pic Rudder neutral position adjustment point 1. Setting the neutral position of the ruder. 2. Remove the adjustment tip of the rudder push rod from the bolt on the middle lever. 3. Position pedal in neutral position and immobilize. 4. Prior to screwing the adjusting tip in or out (see: 8-10) neutral position of rudder must be maintained. Secure the end applying the same method as used for rudder assembly components. 12

13 5. Place a lock washer on the middle lever, screw in a crown nut and secure it with a pin. 6. Free the rudder pedal. Push-pull rod movement limiters Rudder push-pull rod Bumper plate Pic Adjustment point of rudder push-pull rod movement limiters (armrest removed from the channel) 7. Identification of rudder deflection (front wheel does not touch the ground). 8. Loosen the limiter bolts. 9. Deflect the rudder to the left to the full possible deflection. 10. Push the front limiter to the retaining plate and clamp the limiter on the push rod by means of tightening the clamp bolt. 11. Deflect the rudder to the right and set the position of the rear limiter similarly to point 3. 13

14 8.4 Elevator trimmer adjustment J T a a 1. Using press buttons on the control stick set the trimmer motor slider in the central position (dimensions a should be identical) 2. Loosen the bolt in the clamp J (blue arrow in the above photograph) 3. Move the clamp along the rod T to the point elevator is in neutral position. 4. Tighten the bolt on the clamp J (blue arrow in the above photograph) in order to fix the clamp J on the rod T

15 PARTS AND SUBASSEMBLIES TO BE REPLACED OUTSIDE THE MANUFACTURER S FACTORY 9.1 FRONT UNDERCARRIAGE Shock absorber assembly J J J pcs. J Pic pcs. AP.PF 126P 1. Washer Ø5 16 1,5 2. Nut M5 DIN 982 Use LOCTITE 262 J J Axle, rocker and hub assembly Pic

16 Pic J Bearing 6004 ZZ zzz Bearing 6004 ZZ J P J J J L J J J J Bolt M6x50 gat. 8,8 DIN Washer Ø6 DIN Nut M6 DIN Fork assembly J with shock absorbers J Pic J J J

17 9.1.4 Complete assembly: hub, rims, tire, inner tube Tyre 4.00x6 6 ply Pic Inner tube 4.00x6 J J pcs. Washer Ø6 6 pcs. Nut M6 DIN Part no Part no pcs. Bolt M6x50, 8,8 DIN Complete wheel assembly with axle and rockers Pic

18 9.1.6 Wheel mounted on the fork Pic Bolt M8 Washer Ø8 Nut M8 DIN 982 Bolt M5 Washer Ø5 DIN 1440 Nut M5 DIN 982 The other side of the wheel is identical Front undercarriage control lever with the pole (removed from the airplane) Pic J T Clamp bolt J

19 (installed in the airplane) J Pic J T Bolt M5x10, 8,8 DIN Removal of wheel from fork 1. Remove the fairing retaining bolts. Pic Bolt M5x10, 8,8 DIN 912 Washer Ø5 DIN

20 2. Move the fairing upward, along the pole. Pic Unscrew the shock absorbers mounting bolts. Pic

21 4. Unscrew the rocker mounting bolts. Pic Remove the wheel and the rocker. Pic

22 9.1.9 Wheel removal 1. Unscrew the valve and release air from the inner tube. 2. Remove the 6 bolts that attach the rim to the hub. 3. Remove the rim and the tyre Pic Removal of the front undercarriage pole 1. Unscrew the bolt Mx10, 8,8 DIN 912 (Pic at the page 18) 2. Start the clamp bolt (Pic at the page 17) 3. Move the lever J from the pole J upward. 4. Remove the pole from the fuselage bushing Installation of the front undercarriage 1. After reassembly the front undercarriage (Pic page 17), install the fairing and fix it to the fork with the bolts (Pic. on the page18) 2. Lubricate top of the pole and slide it into the bushing in the fuselage. 3. Install the control lever J (Pic , page 17) with the bar assembled J (Pic , page18) 22

23 4. The lever must be fixed in a position allowing to screw in the locking bolt (Pic , page 18 Bolt M5x10, 8,8 DIN 912). The bolt must be secured with LOCTITE Tighten the clamp bolt (Pic , page17) When installing front undercarriage with a new pole: 1. Match new slide bearing in the guiding bushing to the new pole. 2. Install and adjust the rudder control system (point 9.3.1) 3. Carry out activities no. 1, 2, 3 of the front undercarriage installation (Pic , page 21). 4. Check if the pole turns without frictional resistance (should be turned easily with one hand) in the slide bearing within the angle range ±30º. 5. Set and lock the rudder in the neutral position. 6. Set the front wheel in parallel to the axis of the airplane. 7. Maintaining this position tighten the clamp bolt on the control lever J (Pic , page 17) in order to fix its position in relation to the pole. 8. Drill a hole Ø4 through the hole Ø5 in the pole s wall and cut M5 thread. 9. Screw in the locking bolt (Pic , page 18 Bolt M5x10, 8,8 DIN 912). Secure the bolt with LOCTITE Replacement of tyre 1. Perform the procedure Take the assembly shown in 9.1.5, perform the procedure 9.1.9, but do not dismantle the assembly shown in the point Rub the inner surface with talcum or other substance used for preservation of rubber. 4. Put a new inner tube inside the tyre. 5. Put the tyre with the tube on the rim (Pic , page 16). Put the wheel valve into the hole located in the rim. 6. Put the rim and tyre on the hub J in assembly (see point 5), and the rim and the clamp ring J Screw the bolts as shown in the point Pump the wheel to the required pressure. 9. Install the wheel on the front fork (reverse order of procedure described in point 9.1.8). 23

24 9.2 MAIN UNDERCARRIAGE Suspension spring with the wheel axle Use LOCTITE 262 J Pic J J J Use epoxy glue for metal surfaces Pic

25 Pic J J Axis of the joint is parallel to the wall of the spring J Pic

26 Pic J J Heat shrink sleeve AP.PF 126P Nut M8 DIN 982 Use LOCTITE 262 J J J Disk brake assembly Pic Part no Part no DOT 3. J (left - right) 3 Bushing J Bolt M5x30 DIN 912 Nut M5 DIN 1587 Washer Ø5 DIN 9021 Bolt M6x50 DIN 912 Washer Ø6 DIN 9021 Nut M6 DIN

27 Pic Part no Wheel - rim and hub assembly Pic J pcs. Nut M6 DIN pcs. Washer Ø 6 DIN Part no Part no Part no pcs. Bolt M6x25 DIN 931 gat.8,8 27

28 9.2.4 Removal of wheel from the axle 1. Remove the fairing - unscrew the retaining bolts - remove the fairing 2. Remove the 4 bolts (2) that fix the brake disc to the rim Pic

29 3. Remove the cotter pin (1) and the circlip (2) Pic Remove the wheel from the axle Removal of the wheel As in the procedure Tire replacement 1. Perform procedure Perform procedure Rub the inner surface with talcum or other substance used for preservation of rubber. 4. Put a new inner tube inside the tire. 5. Put a new tire with tube on the rim (see point 9.2.3). Put the wheel valve into the hole located in the rim. 29

30 6. Put the rim and the rim with tire (see point 5) on the hub J in the assembly and the clamp ring Screw all the elements with bolts. 8. Pump the wheel to the required pressure Removal of the disc brake from the spring 1. Perform procedure Remove the disc from the caliper. 3. Disconnect the brake hose from the caliper: press the fitting ring (A) and pull the hose (B) Pic A B 4. Undo the nut and replace the bolt that attach the brake plate to the spring (3) shown in the picture Remove the caliper assembly from the spring axle. 30

31 9.2.8 Removal of the spring 1. Perform point 3 of the procedure Detach the brake hose from the spring remove the mounting clamps00. Pic

32 3. Remove the spring retaining nut (inside the cockpit), remove the washers and the rubber damper AP.PF126P. Pic J AP.PF 126P Nut M8 DIN 982 J J Pull out the spring from the fuselage seat (see the Pic ). 32

33 9.3 CONTROL SYSTEM Rudder control system Dwg F D 1 4 E C 3 A B Diagram of the rudder control system 1. Main rod T Front rod J Intermediate lever J Drive arm J Pedals J Rudder J

34 Pedals, front rods and the intermediate lever (items A, B and C in the Dwg ) Pic J J J J J J Pic Bolt M6x15 DIN 912 Shaft Ø6H7-22 Nut M6 DIN 937 Washer Ø6 DIN 1440 Cotter pin Ø1.6 DIN 94 34

35 Pic J Washer Ø6 DIN 1440 Use LOCTITE 262 Nut M6 DIN 934 Bearing RS Use LOCTITE 603 Nut M6 DIN 934 J Bearing RS Washer Ø6 DIN 1440 Use LOCTITE 603 J Use LOCTITE 262 Pic Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94 J J J pcs. Bolt M6x25 DIN

36 Pic J J J Pic J J J J X (do not remove this bolt from any of the three pedal slide bearings.) 36

37 Pic T J J Nut M6 DIN 937 Washer Ø6 DIN 9021 Cotter pin Ø1.6 DIN 94 Pic The left side view 37

38 Pic J J J J T Washer Ø6 DIN 9021 Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94 The right side view Rudder travel limiters. Item D (Dwg ) Pic J T Bolt M6x20 DIN 912 J

39 Rudder drive arm. Item E (Dwg ) J Pic J J J J use LOCTITE 262 J Nut M6 DIN 934 Pic J J J J Steel pin Ø5x20 use LOCTITE

40 Pic T Pic

41 Top hinge of the rudder. Item F (Dwg ) Pic J J Removal of pedals 1. Disconnect the rods J from the pedals lever J (Pic , & 9.3.8) 2. Remove the top parts of the slide bearings J Pic (remove the bolts M6x15 DIN 912 Pic ) Attention! Do not remove the bolt X shown in the picture Pic Remove the pedals. 41

42 Removal of the main rod T (can be performed only after removal of the elevator unit) Pic J T K.0 J front Nut M6 DIN 934 rod T tył 1. Disconnect the rod T from the intermediate lever Pic (remove the cotter pin, undo the nut and remove the eye J from the pin). 2. Replace the plastic that covers the inspection hole in the rear part of the fuselage, under the elevator unit. Pic Pic Loosen the limiter bolts J (Pic ) 4. Through the inspection hole disconnect the rod T joint eye J from the ball J (Pic , & ) As shown in the Pic : - put the locking wedge under the spring (1) - lift the spring (2) - move the head J of the rod from the ball (3) 42

43 5. Unscrew the eye nut J from the front part of the rod T Remove the rod in the backward direction, holding the limiters cubes J down not to lose them (Pic ) Installation of the main rod T of the rudder control system (can be carried out after removal of the elevator unit). Left side of the rear part of the fuselage must be visible from the cockpit. 1. The rod J without the eye nut J is to be moved to the fuselage and entered into the guiding eye. Guiding eyes of the elevator system are located on the formers of right wall of the fuselage. 2. When the tip of the rod reaches the front guiding eye it must be put by hand to the eye from the cockpit. 3. When the tip of the rod reaches the limiter J (Pic ) the limiter cube must be put on it J and drive the rod through the limiter J Put the second cube on the tip of the rod J and push the rod in a way the joint head J (Dwg ) is located close to the ball J (Dwg ). 5. The head J should be pressed on the ball J until a clicking sound is made. 6. Check if the rod is free to move in the eyes and rotation of the lever J in the bushing J Screw the eye nut on the front tip of the rod J Adjustment of the rudder control system, according to the section 8, (after installing all elements of the control system, according to the Dwg , except the connection of the main rod (1) with the intermediate lever (3)). 43

44 Rys J Rudder J J J T J J Removal of the rudder 1. Displace the rudder in one direction as much as possible (Pic ). 2. Remove the retaining bolts of the top hinge from the stabilizer (Pic ). 3. Repeat points 1 and 2 for the other side of the rudder. 4. Pull out the top hinge from the seat in the stabilizer (Pic ). 5. Remove the rudder by lifting it up along the axis of rotation (Pic ) Installation of the rudder (Pic to reverse order) 1. Put the rudder on the pins J of the bottom seat (Pic ). 2. Insert the top hinge into the seat in the stabilizer (Pic ). 3. Displace the rudder in both directions as much as possible (to make access to the bolts) insert and tight the top hinge mounting bolts (Pic ). The bolts must be secured by covering thread with epoxy glue for metal-to-metal connections. 44

45 Pic Pic

46 Pic Pic J

47 9.3.2 ELEVATOR AND AILERONS CONTROL SYSTEM Dwg D 2 C A B Elevator and ailerons control system diagram 1. controls T Main rod T Vertical rod of the ailerons T Elevator J controls T , Item A Pic T J J J J

48 Pic brake hoses Nut M6 DIN 982 Washer Ø 6 DIN X controls J , Item B Pic T T T T

49 Pic Pic T J Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94 J T J Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94 49

50 Pic T J use LOCTITE 262 J J Bolt M6x22 DIN 912 J J J J Fill up with grease Nut M6 DIN 982 Washer Ø 6 DIN 1440 Pic J T Blind rivet Ø4 with steel stem 2 pcs. Cotter pin Ø2 DIN 94 T

51 Pic T J Cotter pin Ø2 DIN 94 T hole Ø4 T Pic use LOCTITE 262 T Pic Both tips of the rod T are identical 51

52 Dwg J Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94 J T T Top connection of vertical rods with the ailerons control system in the wing Elevator drive system (Item C, Dwg ) Elevator Pic Nut M6 DIN 937 Washer Ø 6 DIN 1440 Cotter pin Ø1.6 DIN 94 J rod T

53 Dwg. T K.0 J Front Rod T Nut M6 DIN 934 Aft Elevator trimmer (Item D, Dwg ) Pic B J J T A J

54 Pic J Bolt M4x18 DIN 965 Nut M4 DIN 982 Washer Ø 4 DIN x J Pic J J T

55 J Pic J J J J T Bolt M5x22 DIN pcs. Pic J J Nut M5 DIN 982 Washer Ø5 DIN x Bolt M5x22 DIN 912 J J T Bolt M6x30 DIN 912 Nut M6 DIN 982 Washer Ø 6 DIN

56 Removal of the manual controls 1. Remove the central tunnel cover 2. Remove the back wall of the cockpit 3. Disconnect the electric cables of the controls from the main cluster (connector) 4. Disconnect the vertical rods T from the controls T (Pic remove the cotter pins, remove the nuts, remove joints heads from the pins J (Pic ) 5. Disconnect the main rod T from the controls (Pic remove the cotter pin. Put a pin into the hole Ø4 in the ball J (Pic ) and unscrew the rod T from the thread in the ball J ) 6. Detach the hose from the brake master cylinder (Pic ) as in procedure (page 29) 7. Undo 4 nuts M6 (Pic ). 8. Pull the controls upward to remove Installation of the manual controls Activities of the procedure but in reverse order Removal of the main rod T Carry out activities 1, 2 and 4 of procedure Disconnect the joint head of the rod T from the elevator lever (Pic remove the cotter pin, remove the nut and take out the pin J Remove the elevator trimmer spring J (procedure ) 4. Loosen the clamp J by unscrewing the bolt. 5. Remove the clamp J from the rod T pulling forward. 6. Remove the rod T in backward direction through the rear inspection hole in the fuselage Installation of the main rod T Access from the cockpit to the internal left rear area of the fuselage. 1. The rod T is to be slipped into the fuselage through the hole in the rear part of the fuselage and through the eyes located on the internal; formers of the fuselage. 2. Put the clamp J on the rod. 3. Front tip of the rod T should be screwed onto the thread in the ball J (Pic ) and secured with the cotter pin. 56

57 Removal of the elevator trimmer spring J Disconnect the trimmer spring J from the trimmer actuator slider J (Pic , arrow A ) 2. Unscrew the 4 bolts that fix the clamps J to the structure. (Pic , and ) 3. Pull upward and remove the spring with the cubes Installation of the elevator trimmer spring J Put the clamps J on the spring J Put the complete assembly into the hole in the rear plate of the central tunnel, (arrow B in the Pic ) and put into the clamp J (Pic , and ). 3. Fix the clamps with mounting bolts M5 (Pic ) to the plate (Pic ) 4. Connect the trimmer spring J with the trimmer actuator slider J (Pic , arrow A ) with a bolt M5x22, a nut and a washer (Pic ) FLAPS DRIVE SYSTEM Electric actuator of the flap drive system and the torsion pipes Pic T T Bolt M6x15 DIN 912 Washer Ø 6 DIN x use LOCTITE 262 T

58 Pic

59 Pic T T Pic Blind rivet Ø4 with steel stem 3 pcs. use LOCTITE 603 T T

60 Pic T Bolt M6x15 DIN 912 Washer Ø 6 DIN 1440 Pic T T

61 Removal of the torsion pipe T (can be performed after removal of the wing) Through the inspection holes in the fuselage (Pic ) remove bolts M6x15 that fix the torsion pipe to the actuator lever T Take the pipe out of the fuselage through the side hole. 1Pic Blind rivet Ø4 with steel stem 3 pcs. Pic

62 Installation and adjustment of the torsion pipe T i T (it refers to a new pipe). Fuselage without the wing. 1. The pipe T is to be fixed with bolts M6x15 to the actuator lever T without LOCTITE 262 (Pic ). 2. Mount the wing. 3. Set the flaps actuator in the position flaps closed by means of the push buttons located on the control stick. 4. Rise the flap from the side the pipe is to be mounted to such extend to provide access to the side hole in the fuselage (Pic ) 5. Cover the unpainted tip of the part T (Pic ) with a thin layer of LOCTITE 603 and insert it into the hole in the part T (Pic , and ) Attention! LOCTITE 603 dries within a couple of minutes after the assembly. 6. Drop the flap and connect it to the drive, according to the Pic 8-3. Then fix the flap in the retracted position. 7. Wait until the LOCTITE 603 dries completely. (about 2 hours) 8. Disconnect the flap drive and remove the wing. 9. Perform procedure The connection between T and T should be reinforced with three rivets located evenly along the perimeter. (Pic , and ) 11. Attach the pipe to the flap actuator lever T by means of bolts M6x15 and LOCTITE 262 (Pic and ). 9.4 POWER PLANT ENGINE MOUNTING SYSTEM Removal of the power plant 1. Propeller assembly 62

63 Pic M8x100, 8.8 DIN pcs. J Nut M8 DIN 982 6pcs. J Propeller AS 1650/1900 J M4x16 ISO pcs. 2. Remove the engine cowling. Using a flat head screwdriver turn all cam locks of the upper cowling by 90º angle. Pic Upper cowling Bottom cowling Remove the upper cowling. 63

64 Pic Disconnect the landing lamp connector. Pic Connector 64

65 Using a flat head screwdriver turn all cam locks of the bottom cowling by 90º angle. Pic Remove the bottom cowling Pic

66 3. Remove the spinner J Remove the spinner mounting bolts M4x16 (6 pcs.). Pic Remove the spinner J Pic J

67 4. Remove the propeller. Using a box-end wrench 13 mm and Allen wrench 6mm unscrew the hub mounting bolts M8x100 (6 pcs. shown in the below picture). Pic Pic

68 Remove the propeller and the bolts, remove the disc J and the ring J off of the engine reduction gear. Pic Propeller 5. Disconnect the engine controls a. Throttle control cable Remove the securing cap from the tip of the cable Pic Securing cap 68

69 - Using a wrench 8 mm and Allen wrench 4 mm unscrew the clamping bolt and pull out the rope from the clamp Pic b. Choke control cable Straighten the choke control cable fixed in the assembly J , which is located on the engine body Pic J Linka ssania 69

70 Using a wrench 10 mm and Allen wrench 4 mm unscrew the clamping bolt and pull out the rope from the clamp Pic c. Carburetors heating control Using an Allen wrench 2.5 mm remove the bolt M5 from the bushing J , then slide the control rod a J to the cockpit direction J Pic J Bolt M5 70

71 6. Disconnect the electrical connector Remove the safety wire from the connector Pic Undo the nut in the bottom part of the connector and disconnect the connector. 71

72 Pic Pic Disconnect the hot air hose. Using a socket wrench 7 mm, with a flexible extension if available, loosen the steel hose clamp and remove the corrugated hot air hose 72

73 Pic clamp MIKALOR W Hot air hose GATES Nr Disconnect the right hose of the engine coolant and empty the engine coolant circuit. Using a socket wrench 7 mm loosen the clamps on the coolant hose Pic Hose clamps Place a clean pan under the hose and drain the coolant 73

74 Pic Disconnect the fuel pipe from the fuel pump and the overflow pipe from the four-way manifold. Using a socket wrench 7 mm loosen the clamp and disconnect the fuel pipe J from the pump Pic J Using a socket wrench 7 mm loosen the clamp and disconnect the fuel pipe from the four-way manifold J

75 Pic J J Disconnect oil hoses from the oil tank. Remove the plastic clamp that supports the choke cable Using a wrench 22 mm unscrew the barb fitting fitting from oil tank (oil hose J ) Pic J Using a wrench 7 mm loosen the clamp and disconnect the breather pipe from the oil tank 75

76 Pic Breather pipe Using fork wrench 19 mm and 22 mm replace the hose barb fitting fitting from the oil tank (oil pipe J ) Pic J Drain oil from the engine Put a clean pan under the oil hose J and drain the oil from the engine 76

77 Pic Pic Put a clean pan under the surge tank. Using a socket wrench 7 mm loosen the hose clamp and disconnect the coolant hose from the surge tank, draining the coolant from the tank simultaneously. 77

78 Pic Surge tank 13. Remove the plastic clamps of pipes and control cables. Pic

79 14. Sling the engine on a crane of safe working load 200 kg, as shown in the below picture. Pic Using a box-end wrench 13 mm undo the nut and disconnect the electrical bonding cable between the fuselage and the engine frame. J Pic Bonding cable 79

80 16. Using an open-end wrench 10 mm disconnect the cable from the starter contactor. Pic Starter contactor Starter cable 17. Disconnect the magneto cables Disconnect the magneto cables connector that is connected to the dashboard wiring. The connector is located to the left hand behind the dashboard Pic

81 Pull the connector through the hole in the diagonal former after removal of the rubber ring J (the below picture shows the area after removal of the dashboard) Rubber ring J Pic Pic Do the same on the firewall 81

82 Pic Magneto cables Rubber ring J Remove the safety wire, and using a box-end wrench 13 mm remove the lower bolts M8 that attach the engine frame to the fuselage. Do the same on the left and the right side of the engine frame. Pic Safety wire 82

83 Pic Bolt M8x In similar way as in the point 17, remove the upper bolts that attach the engine frame to the fuselage. Observe the position of the engine on the sling and correct the position if necessary. Pic

84 Installation of the power plant in the airplane 1. Lift the power plant on a sling of SWL 200 kg (see: point 13 of procedure 9.4.4). Move the engine to the fuselage firewall direction. 2. Install and tighten the upper bolts J that mount the engine frame to the fuselage. Use the glue for threaded connections and secure additionally with 1.2 mm safety wire (see the picture ) 3. Install and tighten the lower bolts J that mount the engine frame to the fuselage. Use the glue for threaded connections and secure additionally with 1.2 mm safety wire (see the picture ). 4. Connect the electrical bonding cable between the fuselage and the engine frame (compare to the picture ). 5. Connect the starter cable (compare to the picture ). 6. Connect the magneto cables (compare to the picture ) Pull the magneto cables through the eyes in the diagonal former and the firewall and secure the edges J with the rubber rings Connect the magneto connectors with the instrument panel socket 7. Connect the coolant hose to the surge tank (compare to the picture ). 8. Connect the oil hose to the surge tank (compare to the picture ). Tight the barb fitting fitting J to the oil tank Put the breather pipe on the barb fitting and secure with a hose clamp Tighten the barb fitting nut J to the oil tank 9. Connect the fuel pipe to the fuel pump and the overflow pipe to the four-way manifold (compare to the picture and ). 10. Connect the right hose of the engine coolant to the radiator (compare to the picture ). Put the hose on the radiator barb fitting Tighten the hose clamps 11. Connect the hot air hose (compare to the picture ). Put a hose clamp Mikalor W on the corrugated hose (see the below picture, elements outside the airplane) 84

85 Pic Corrugated hose GATES Nr MIKALOR W Put the hose on the air butterfly valve (J ) located on the firewall Tighten the clamp 12. Connect the electrical connector (compare to the picture , and ). Twist the connector s nut Secure with safety wire 1.2 mm 13. Connect the engine controls (compare to the picture , , , , ). a. Throttle control Pull the control cable through the hole in the throttle lever bolt Tighten the bolt Put the safety cap on the end of the cable b. Choke control Pull the choke cable through the clamping element on the engine Tighten the bolt J Bend the tip of the cable by 90º c. Carburetors heating control 85

86 Put the cap J together with the control rod into the bushing J Install the bolt M5x5 DIN Fill the lubrication system with engine oil according to the Rotax Engine Operation. 15. Fill the cooling system with coolant according to the Rotax Engine Operation. 16. Install the propeller. Install the distance ring J on the reduction gear shaft Install the spinner disc J on the distance ring Install the propeller and tighten using bolts bolts M8x100 DIN 912, Install the spinner on the disc using bolts M4x16 (eg. ISO 7380). 18. Install both engine cowlings 1. Install the lower cowling and secure with cam locks in such way the score on the cam lock was aligned with line on the cowling 2. Connect the landing lamp cable (compare to the picture ). 3. Install the lower cowling and secure with cam locks in such way the score on the cam lock was aligned with line on the cowling 86

87 9.4.2 ENGINE CONTROL SYSTEM Throttle control diagram in the cockpit Dwg Throttle control diagram in the cockpit - carburetors cables 4 J J J J L 2 J P 3 J Dwg B Z K A Z K Z Z C Diagram of the cables travel J & J between the levers J L & J P and the intermediate bracket J A left lever J L, B right lever J P, C intermediate bracket J K tip and seat J , Z adjustable clamp 87

88 Throttle control levers J L & J P J L J L Pic J Bolt M5x5 DIN 913 J The lever on the left side Bolt M5X10 DIN 912 Pic Bolt M6x15 DIN pcs. J J L (J P) use LOCTITE 262 J J J Bolt M5x5 DIN 913 Bolt M5X10 DIN

89 Intermediate bracket Pic J J Nut M6 DIN 934 J J Bolt M5x5 DIN 913 J J N J J Pic J J J J use LOCTITE 262 J Nut M6 DIN x Nut M6 DIN

90 Pic J J Removal of the throttle control system 1. Disconnect the cables J from the carburetors clamps. 2. Remove the cover J of the intermediate bracket. Pic J Bolt Ø4.2 x 15 DIN7981C 3. Disconnect the cable J from the intermediate bracket. 90

91 Pic J Bolt M4x12 DIN 7985 Washer Ø4 DIN 1440 Nut M4 DIN 985 J Bolt M5x5 DIN Pull out the cable J from the Bowden conduit. 5. Loosen the bolts M5x5 in the cables clamps J in the intermediate brackets and in the levers (Pic & ). 6. In the intermediate bracket (Pic ) loosen the tension regulatorj so the Bowden conduit could be pulled out from the seats. 7. Install the bolt M5x10 (Pic ) and remove the lever arms (left and right). 8. Remove the cables from the lever arms and the intermediate brackets. 9. Undo the nut (Pic white arrow with N description) and remove the bracket J from the axle J (Pic ). 10. Take out the cable tips from the catches in the bracket J Installation of throttle control in the cockpit Install the throttle lever brackets J and the intermediate body bracket J on the fuselage structure. 91

92 1. The regulatorj on the bracket J must be screwed in (Pic ) 2. Put the distance element J (Pic ) on the axlej Put the cables J to the bracket J with the tip and the seat J (Pic ) thread through all regulators J in the body. 4. The bracket J is to be installed on the bracket J Then install the disc J and tighten the nut (Pic ) 5. Put the conduits J (Pic , arrow 1 ), on the cables J , thread the cables through the clamps J (Pic ) located in the levers J assemble the levers according to the Pic & Secure the bolts M5x10 with LOCTITE 262. Pic Put conduits J (Pic , arrow 2 ), on the cables J thread the cables through the regulators and clamps J in the bracket (Pic & ). 7. Lay the conduits J in the levers seats J and regulators seats J of the intermediate bracket 92

93 J , eliminate play and secure the cables with clamping bolts M5x5 in clamps J (Pic ). Secure the bolts with LOCTITE The regulators J on the intermediate bracket J should be screwed in gradually until the cables are properly tightened and then secured with nuts. 9. Turn the bracketj to the left in the end stops direction. Set the levers in the aft position (to the end stops). Clamp the cables in the lever with bolts M5x5 (Pic ). The bolts should be secured with LOCTITE 262. J Pic J J J

94 Pic Perform operation test of the system: - The throttle levers should move smoothly, without unnecessary play. - There should not be excessive friction in the Bowden cables. - The cables should not come loose during the operation of levers. 11. Secure the cables tips with heat shrink sleeves (Pic ) 12. Put the conduits J (Pic white arrow), into the bracket seats J (Pic ), insert the cable J and fix as shown in the Pic Tips of the cable J should be pulled through the rubber eyes in the former and the firewall to the engine compartment (Pic red arrow) 14. Install the cover J of the intermediate bracket (Pic ) Adjustment of the intermediate bracket clamp J (Pic ). After connecting the cables J to the carburetors levers and adjustment of the engine control. The clamp of the bracket is adjusted with the nut N in the Pic The nut should be tightened in such way, the carburetors throttles springs do not cause self-acting reversion of the levers, and at the same time the operation of the levers was smooth. The nut's thread should be covered with LOCTITE 262. Perform the check as described in procedure , point

95 9.4.3 FUEL SYSTEM 1. Fuel system diagram Dwg Tanks in wings Tanks in the fuselage 1. Tank in left wing 1.a Additional tank - left 2. Tank in right wing 1.a Additional tank - right 3. Filler caps 4. Breather pipe 5. Settling tank 6. Drain 7. Fuel valve 8. mechanical fuel pump 9. Carburetors 10. Electric fuel pump 11. Fuel filter 12. Fuel pressure sensor 13. Reserve sensor d. Choke 2. Replacement of the reserve sensor Remove the upper and the lower fuel hose clamps 95

96 Handling, maintenance and periodic inspections manual Pic Pic Pic Hose clamp W Hose clampw1 Cut out the sensor cable Uninstall the fuel pipes and remove the reserve sensor assembly 96

97 Handling, maintenance and periodic inspections manual Pic Removal of the left additional fuel tank Loosen the hose clamp on the fuel pipe and remove the pipe Hose clamp W1 Pic

98 Handling, maintenance and periodic inspections manual Pic Loosen the clamp on the outlet hose from the settling tank side J , located in the central tunnel Pic Hose clamp W1 98

99 Handling, maintenance and periodic inspections manual Remove the bolts that mount the tank to the brackets in fuselage Pic Lift the additional tank and remove the hose clamp from the overflow hose 99

100 Handling, maintenance and periodic inspections manual Pic Overflow hose Hose clamp W1 Remove the additional fuel tank Pic Overflow hose 100

101 Handling, maintenance and periodic inspections manual 4. Removal of the right additional fuel tank Loosen the hose clamps on the fuel pipe Pic Opaska W Move the rubber part upward and remove it from the fuel tank barb fitting connector Pic

102 Handling, maintenance and periodic inspections manual Remove the hose clamp on the drain pipe from the side of the sediment bowl J , located in the central tunnel Pic Hose clamp W1 Remove the mounting bolts of the fuel tank bracket Pic

103 Handling, maintenance and periodic inspections manual Lift the additional tank, loosen the hose clamp of the overflow pipe and cut the no fuel sensor electric cable Pic Opaska W Pic Electric cable Remove the additional tank 103

104 Handling, maintenance and periodic inspections manual 5. Removal of the sediment bowl Remove the hose clamps from the drain pipes of the additional tanks and remove the pipes from the tanks Pic J Clamp W Pic Clamp W

105 Handling, maintenance and periodic inspections manual Loosen the clamp on the fuel pipe J and remove the pipe from the barb fitting Pic Fuel pipe J Clamp W J Remove the drain valve (see the point 6 below) Using a wrench 20 mm remove the nut (J ) that fixes the sediment bowl to the fuselage structure Fuselage belly Pic J Remove the sediment tank from the fuselage 105

106 Handling, maintenance and periodic inspections manual Pic J Replacement of the drain valve Using an open-end wrench 11 mm unscrew the fuel drain valve (ULM 70569) from the sediment tank J Pic part no

107 Handling, maintenance and periodic inspections manual Clean the bottom hole of the bowl if needed Screw in a new drain valve (ULM 70569) using a Teflon tape to make the connection tight Pic Replacement of the fuel filter Remove the tunnel cover Remove the clamp on the fuel pipe between the filter and the sediment bowl and remove the pipe from the filter barb fitting Pic Filter bracket Clamp W Release the filter from the bracket 107

108 Handling, maintenance and periodic inspections manual Pic Remove the clamp on the fuel pipe between the filter and the valve and take the filter out Pic Filtr paliwa FILTRON PS 878 Installation of a new filter it to be carried out in reverse order, paying special attention the fuel flow direction is according to the arrow on the filter 8. Removal of the fuel filter Remove the cover of the tunnel Loosen the clamps on the pipes connected to the fuel valve 108

109 Handling, maintenance and periodic inspections manual Pic Clamp W Pic Clamp W Remove the fuel pipes from the fuel valve 109

110 Handling, maintenance and periodic inspections manual Using a screwdriver and an open-end wrench remove the two screws M4x30 DIN 7985 that fix the assembly J to the bracker J Pic Screw M4x30 J J Remove the assembly J from the fuselage Remove the screw M4x20 DIN 965 and take out the fuel valve (ULM 70223) Part no Screw M4x20 DIN 965 Pic

111 Handling, maintenance and periodic inspections manual 9. Removal of the electric fuel pump Remove the fuel pipe clamps (the below picture shows the pump dismounted from the airplane) and remove the pipes Pic J Fuel pump FACET SS501 (40105) Clamp W Clamp W J J Disconnect the electrical connector Using an open-box key 13 mm and Allen key 5 mm remove the fuel pipe mounting bolts Bolt M6x30 DIN 912 Washer Ø6 DIN 9021 Pic

112 Handling, maintenance and periodic inspections manual J Pic Nut M6 DIN 982 Remove the pump from the fuselage 10. Removal of the fuel pressure sensor Disconnect the connector Pic Hermetic connector 112

113 Handling, maintenance and periodic inspections manual Loosen the fuel pipe clamp on the fuel pressure sensor barb fitting Pic Clamp W J Remove the rubber lined clamp that fixes the sensor to the former of the fuselage Pic Clamp RUBBER P- CLIP D35 113

114 Handling, maintenance and periodic inspections manual Remove the fuel pressure sensor 11. Replacement of the rubber fuel pipes 12. Installation of the additional left fuel tank (compare to the pictures in point 3) Put the additional fuel tank with the drain pipe into the bay in the fuselage Connect the overflow pipe and secure with the steel clamp W Connect the drain pipe to the barb fitting of the sediment bowl and secure with the clamp W Mount the fuel tank with the mounting bolts Connect the fuel pipe and secure with a clamp W Installation of the additional left fuel tank (compare to the pictures in point 4) Put the additional fuel tank with the drain pipe into the bay in the fuselage Connect the electric cable to the no fuel sensor. Secure the connection with a heat shrinking sleeve. Install the connection pipe and secure with the clamp W Connect the drain pipe to the barb fitting of the sediment bowl and secure with the clamp W Mount the fuel tank with the mounting bolts Connect the fuel pipe and secure with a clamp W Installation of the sediment bowl (compare to the picture in point 5) Insert the sediment bowl J into the fuselage hole located behind the crosswise beam of the main undercarriage Using an open-end wrench 20 mm tighten the nut J putting the washer J under it Connect and secure with clamps W the drain pipes of the left and the right additional tank Connect the fuel pipe J and secure with the clamp W Installation of the fuel valve install the valve in the assembly J and secure with the screws M4x20 DIN 963; Pay special attention to the position of the valve in relation to the base. The arrow in the below picture shows the direction the valve is opened 114

115 Handling, maintenance and periodic inspections manual Part no Pic Screw M4x20 DIN 963 J The fuel valve, together with the element J is to be put on the bracket J , cover with the disc J and connect using screws M4x30 DIN 7985 washers Ø4 DIN 1440 and nuts M4 DIN 982 J Pic Nut M4 DIN 1440 Screw M4x30 DIN 7685 Fuel valve J

116 Handling, maintenance and periodic inspections manual Pic Screw M4x30 DIN 7985 J Connect the fuel pipes J & J to the fuel valve and secure with the clamps W (compare to the pictures of point 8) 16. Installation of the electric fuel pump Screw in the barb fittings J W into the holes of the electric fuel pump Facet SS501 (40105). Use thread sealant to secure the connection Pompa paliwa FACET SS501 (40105) Pic J Put the pump behind the diagonal former and fix to the structure using bolts M6x30 DIN 912, nuts M6 DIN 982, and washers Ø6 DIN Between the pump and the former the rubber parts J are to be placed. Pay 116

117 Handling, maintenance and periodic inspections manual special attention to correct position of the pump - flow direction must be according to the arrow stamped on the pump body (see the below picture) Pic Connect the fuel pipes J i J to the barb fittings J and secure with clamps W Connect the electric cable connector 17. Installation of the fuel pressure sensor Connect the sensor to the diagonal former with the clamp Rubber P-CLIP D35, bushing J , bolt M4x30 DIN 7985, washer Ø4 DIN 9021 and nut M4 DIN 934, securing the conection with thread sealant. All parts of the assemble are shown in the below picture. 117

118 Handling, maintenance and periodic inspections manual Nut M4 DIN 934 J Washer Ø4 DIN 9021 Bolt M4x30 DIN 7985 J Clamp RUBBER P-CLIP D35 Fuel pressure sensor Pic Put the fuel pipe on the barb fitting J iand secure with the clamp W Connect the connector to the fuselage wiring ENGINE LUBRICATION SYSTEM 1. Removal of the engine oil tank Disconnect the oil hoses (see point 10 in procedure 9.4.6) and drain oil from the engine (see point 11 in procedure 9.4.6) Remove the breather pipe (see point 10 in procedure 9.4.6) Drain the oil tank Unscrew the nuts M5 DIN 982 retain the bracket J the nuts are located inside the fuselage, on the firewall. This activity should be performed by 2 persons to avoid the tank to be dropped. 118

119 Handling, maintenance and periodic inspections manual Pic J J

120 Handling, maintenance and periodic inspections manual Pic M4 DIN pcs. Remove the bracket J and remove the oil tank Drain the oil tank through the inlet 2. Removal of the engine oil cooler Drain oil from the engine (see point 10 in procedure 9.4.6) Disconnect the oil hoses J & J from the barb fittings on the oil cooler Pic J

121 Handling, maintenance and periodic inspections manual Pic J Unscrew the bottom bracket J from the engine block Pic J J

122 Handling, maintenance and periodic inspections manual Unscrew the bracket J from the reducer body and remove the cooler Pic J Installation of then oil tank Fix the tank using clamping rings J and brackets J and secure with nuts M4 DIN 982 inside the cockpit (see the picture in point 1) Connect the oil hose J to the tank barb fitting (see point 10 in the procedure 9.4.6) Connect the breather pipe to the barb fitting on the oil tank (see point 10 in the procedure 9.4.6) Connect the oil hose J to the barb fitting on the oil tank (see the point 10 in the procedure 9.4.6) Check oil level and fill up if necessary, according to recommendations placed in the Operation of Rotax Engines 4. Installation of the oil cooler Brackets J & J should be mounted with rivets to the oil coolers, according to the assembly drawing J

123 Handling, maintenance and periodic inspections manual The bracket J should be fixed with bolts M8x20 DIN 931 to the reducer body The bracket J should be fixed with bolts J and washers J to the oil pump body Pic J J J Connect the oil hose J to the right barb fitting of the cooler (see point 2) Connect the oil hose J to the left barb fitting of the cooler (see point 2) 5. Replacement of rubber elements of the engine oil circuit Oil hose J Pic J Clamp W Barb fitting Rotax 123

124 Handling, maintenance and periodic inspections manual a. Remove the oil hose from the oil tank barb fitting (see point 10 in the procedure 9.4.6) b. Remove the oil hose from the oil cooler barb fitting (see point 2) c. Remove the steel clamps and remove the rubber hose d. Install new rubber hose on the barb fittings and secure with steel clamps W e. Install the oil hose on the oil cooler barb fitting (see point 2) f. Install the oil hose to the oil tank barb fitting (see point 8 in the procedure 9.4.7) Oil hose J Pic J Hose W Barb fitting Rotax a. Remove the breather pipe from the oil tank (see point 10 in the procedure 9.4.6) b. Remove the oil hosej from the oil tank (see point 10 in the procedure 9.4.6) c. Drain oil from the engine (see point 11 in the procedure 9.4.6) d. Disconnect the oil hose from the oil sump at the bottom of the engine block 124

125 Handling, maintenance and periodic inspections manual Pic Clamp W J e. Loosen the clamps on the hose and remove the rubber hose f. Put a new rubber hose and secure with the clamp W ; put the other clamp on the other tip of the hose g. Connect the oil hose J to the oil tank (see point 8 in the procedure 9.4.7) h. Connect the oil hose J to the oil sump barbed fitting at the bottom of the engine i. Connect the breather pipe to the oil tank and secure with the clamp W (see point 8 of the procedure 9.4.7) j. Fill the system with engine oil according to Operation of the Rotax Engine Oil hose J

126 Handling, maintenance and periodic inspections manual Oil hose CONTI-TCH- OLNS1-12x3.5 AEM/AEM Pic Barb fitting Rotax Clamps W J a. Remove the oil hose J from the cooler Pic J b. Remove the oil hose J from the oil pump 126

127 Handling, maintenance and periodic inspections manual Pic J Clamp W c. Remove the clamps from the rubber hose d. Remove the rubber hose e. Put a new hose on the pipe J and secure with clamps W f. Put the barb fitting on the upper rubber hose and secure with the clamp W g. Connect the oil hose J to the oil cooler (see the point a ) Connect the oil pipe J to the oil pump barbed fitting and secure with the clamp W (see the picture in point b ) ENGINE COOLING SYSTEM 1. Engine cooling system diagram 127

128 Handling, maintenance and periodic inspections manual Dwg E engine P coolant pump R radiator D expansion tank L surge tank C carburetors 1 the-way manifold of the pump J thermostat J three-way manifold J heating J right hose J left hose J hose J hosej heating hose J heating hose J heating hose J hose J heating control J Coolant pump cover with barbed outlets/inlets and installation of the three-way manifold Body of the pump with mounting bolts as delivered by Rotax Rys Gasket 2. Cover 3. Bolt M6x90 DIN Bolt M6x35 DIN Bolt M6x35 DIN Sealing ring 7. O-ring 8. Inlet elbow 9. Bolt M6x20 DIN

129 Handling, maintenance and periodic inspections manual Unscrew the bolts (9) and remove the inlet elbow (8) Remove the pump cover by unscrewing the cover mounting bolts (3, 4 & 5). The below drawing shows factory set of the fitting in the pump Rys Unscrew the inlet fittings, clean the threads and change position of the inlet fittings according to the below drawing Pic The inlet fittings should be secured with LOCTITE 243 Install the cover with the bolts (3, 4 & 5). Secure the bolts thread with a thread sealant. 129

130 Handling, maintenance and periodic inspections manual Pic Put the coolant hoses on the inlet fittings and secure with selfacting clamps Pic Self acting clamp 130

131 Handling, maintenance and periodic inspections manual Fix the three-way manifold J to the pump cover with bolts (9) Pic J Pic Bolt M6x20 DIN 912 Install the coolant hoses J & J and secure with clamps W

132 Handling, maintenance and periodic inspections manual Pic J J J Thermostst Complete thermostat assembly diagram Dwg Thermostst body J Cover J Thermostat WAHLER º 4. O-ring Ø48x3 5. Socket cap bolt M6x18 DIN Washer Ø6 DIN 1440 Removal of the thermostat from the cooling system o Loosen the coolant hose clamps 6, 7 & 8 shown in the diagram in point

133 Handling, maintenance and periodic inspections manual J Pic Clamp W J Pic J J o Remove the hoses from the thermostat and take out the thermostat Replacement of the thermostat o Remove the thermostat assembly (see the previous point) o Unscrew the bolts M6x18 and remove the cover o Remove the faulty thermostat 133

134 Handling, maintenance and periodic inspections manual o Insert the new thermostat into the body J thermost O-ring Ø48x3 Pic J o Close the body placing the o-ring Ø48x3 into the groove o Tighten the bolts M6x18 using the thread sealant o Install the coolant hoses 6, 7 & 8 on appropriate inlets of the thermostat and secure with clamps W (compare to the picture from the previous point) 4. Carburetors heating system Removal of the carburetors heating system o Drain the coolant from the engine cooling system (see point 8 in the procedure ) o Disconnect the control system of the carburetors heating system (see the point 5c in the procedure ) o Remove the clamps from the heating hoses no 9, 10, & 11 and remove the hoses 134

135 J Handling, maintenance and periodic inspections manual Pic Clamp W J Pic J J Clamp W

136 Handling, maintenance and periodic inspections manual Pic J Clamp W o Remove the springs Pic Springs o Remove the clamps that mounts the heating system to the suction manifold and remove the system together with carburetors 136

137 Handling, maintenance and periodic inspections manual Pic Clamp o Remove the bolt M5x8 and remove the heating elements from the carburetors o Put the carburetors back on the suction manifolds and secure with the clamps o Install the springs o Blind the inlets in the manifolds J and J o Remove the carburetors heating control system Installation of the carburetors heating system o Drain the coolant from the engine cooling system o Remove the spring o Loosen the clamps on the suction manifolds and remove the carburetors from the manifolds (see the below picture) 137

138 Handling, maintenance and periodic inspections manual Pic Carburetor Clamp o Install the carburetor heating system assembly. secure with the bolt M5x8. be aware of differences between the left and right assembly. Pic o Insert the carburetors with the heaters onto the suction manifolds and secure with the steel clamps. 138

139 Handling, maintenance and periodic inspections manual Pic Clamp o Install the safety springs Spring Pic o Fix the heating control mechanism J and the valve to the elbow on the left heating assembly Pic J

140 Handling, maintenance and periodic inspections manual o Connect the heating hose no 9 to the fitting on the threeway manifold J and to the external fitting on the left heating assembly and secure with the clamp W J Pic J o Connect the heating hose no 10 to the fitting on the three-way manifold J and to the internal fitting on the right heating assembly and secure with the clamp W Pic J Clamp W

141 Handling, maintenance and periodic inspections manual J Opaska W Pic o Connect the heating hose no 11 to the external fitting on the right heating assembly and the control system valve and secure with the clamp W J Clamp W Pic

142 Handling, maintenance and periodic inspections manual Pic J Clamp W Valve 5. Coolant surge tank and connecting hose Removal of the surge tank o Put a clean pan under the surge tank, loosen the clamp of the hose J , remove the hose and drain the coolant from the system and the tank Pic

143 Handling, maintenance and periodic inspections manual o Remove the surge tank assembly bolts Pic Pic the nuts inside the cockpit 143

144 Handling, maintenance and periodic inspections manual o Remove the surge tank with the clamping ring J Installation of the surge tank o Put the clamping ring on the tank J o Fix the clamp and the tank with bolts M5x15 DIN 912, washers Ø5 DIN 9021 and nuts M5 DIN982 o Connect the hose J to the tank stub pipe and secure with the clamp W o Fill the coolant to the required level, according to the operation of Rorax Engine 6. Hoses of the engine cooling system Positions of hoses of the cooling system mounted on the engine are defined by relevant drawings, as it is shown on the cooling system diagram Drain the system every time replacement on any cooling system element is required Replacement of the rubber hoses is to be performed in the following way: loosen the steel clamps, remove the old hose, install the new hose and tighten the clamps. 144

145 Handling, maintenance and periodic inspections manual 9.5 AIRFRAME STRUCTURE DOORS (left door is shown in the picture, right door is symmetrically identical) Rear lock of the door T Pic T T Pic Washer Ø5 DIN 1440 Cotter pin Ø1.6 DIN 94 T T Bolt M5x5 DIN 913 T use LOCTITE 262 T use LOCTITE

146 Handling, maintenance and periodic inspections manual Washer Ø5 DIN 1440 Cotter pin Ø1.6 DIN 94 T Pic T Bolt M5x5 DIN 913 T T Upper rear interlock Pic T T

147 Handling, maintenance and periodic inspections manual use LOCTITE 262 Pic T T T Front upper lock Pic Bolt M5x5 DIN 913 T T

148 Handling, maintenance and periodic inspections manual Pic T T Bolt M5x5 DIN 913 T Pic use LOCTITE 262 Bolt M5x5 DIN 913 T T T

149 Handling, maintenance and periodic inspections manual Zawiasy Cover of the upper hinge Pic Cover of the lower hinge Pic Bolt M6x25 DIN 966 Nut M6 DIN 982 T T Bolt M6x20 DIN pcs. 149

150 Handling, maintenance and periodic inspections manual Pic T T T Pic T T T

151 Handling, maintenance and periodic inspections manual Door travel limiter Pic T Nut M5 DIN 1587 Washer Ø5 DIN 1440 Pic T Nut M5 DIN 1587 Washer Ø5 DIN

152 Handling, maintenance and periodic inspections manual Removal of the doors 1. Remove the hinge covers (Pic , ) 2. Disconnect the door travel limiter T (Pic ) 3. Remove the bolts M6x20 (Pic ) 4. Remove the bolt M6x25 (Pic ) 5. Remove the hinges from the fuselage seats Pic Screw M6x25 DIN Installation of the door 1. Insert the hinges into the fuselage seats 2. Insert the screw M6x 25 into the upper hinge holet Tighten the nut M6 inside (Pic ) 4. Screw in M6x20 using epoxy glue for metal. 5. Check if the door operates properly. 6. Use silicon glue to attach the hinges covers. 7. Mount the travel limiter T secure the nut with LOCTITE

153 Handling, maintenance and periodic inspections manual REPLACEMENT OF GLAZING Removal of cracked glazing 1. Using a heat gun heat the edges of the broken glazing in order to make them flexible. Secure the structures bordering the glazing not to destroy painting and composite structure. 2. Tear of the heated edges of the structure. the glazing should come off with the paint layer. 3. Clean the frame after removal of the glazing carefully, paying attention not to destroy the composite structure. Installation of ne glazing 1. Adjust the glazing, so it fit the frame correctly. Small maladjustment that can be corrected by light pressing is acceptable. 2. Perform the mounting according to the instruction delivered with the new glazing. 153