aircraft kr-030 topaz - ekolottype: kr-030 topaz handling, maintenance and periodic inspections...

Manufacturer: PPHU EKOLOT Type: KR-030 TOPAZ

Handling, maintenance and periodic inspections manual

Issue: 1 Rev. No:

Date: July 2010 Date:

HANDLING, MAINTENANCE AND PERIODIC INSPECTIONS MANUAL

AIRCRAFT KR-030 TOPAZ

SERIAL NUMBER: 30 - ..…. - …...


Handling, Maintenance and Periodic Inspections Manual

Issue: 1 Rev. No:


CONTENTS

PAGE

1 SMALL REPAIRS 2 2 PREPARATION OF THE AIRCRAFT FOR LONG-TERM

SUSPENSION OF OPERATION 4

3 WORKS TO BE DONE AFTER THE LONG-TERM SUSPENSION OF OPERATION

5

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 12

9.1 FRONT UNDERCARRIAGE 15 9.2 MAIN UNDERCARRIAGE 24 9.3 CONTROL SYSTEMS 33

9.3.1 RUDDER CONTROL SYSTEM 33 9.3.2 ELEVATOR AND AILERONS CONTROL SYSTEM 47 9.3.3 FLAPS DRIVE SYSTEM 57

9.4 POWER PLANT 62 9.4.1 ENGINE MOUNTING SYSTEM 62 9.4.2 ENGINE CONTROL SYSTEM 87 9.4.3 FUEL SYSTEM 95 9.4.4 ENGINE LUBRICATION SYSTEM 118 9.4.5 ENGINE COOLING SYSTEM 127

9.5 AIRFRAME STRUCTURE 145 9.5.1 DOORS 145 9.5.2 REPLACEMENT OF GLAZING 153



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1. SMALL REPAIRS NOTICE: In case of any damage to the propeller, please read the

instructions placed in the Operation Manual 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.

Pzawieszenie

Aileron balance measurement diagram

SUSPENSION POINT



Issue: 1 Rev. No:


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

Manual. - 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



Issue: 1 Rev. No:


- 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 8.6. - 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 8.6. - Assemble the aircraft (see: point 8.9). - Carry out activities 10, 11, 12 , in the procedure 8.6.

4. 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 8.5.3

Lamination scheme of the KR-030 wing

Flaps and ailerons suspension position



Issue: 1 Rev. No:


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 Manual 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

structure - control system components

Depending on technical condition

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 and electric)

Depending on technical condition

5 Radio and other electronic equipment

According to the updated manuals and instructions of respective manufacturers.

6 Rubber pipes for fuel and oil Depending on technical condition but no longer than 6 years counted from the year of production

7 Rubber shock absorbers of the front wheel

8 Tires and inner tubes

9 Rubber dampers in the engine frame



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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.



Issue: 1 Rev. No:


Pic. 8-1 Placing the wing on the fuselage

Pic. 8-2 Installation of mounting pins to the fuselage



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Pic. 8-3 Flaps drive connection

Pic. 8-4 Ailerons drive connection to the fuselage



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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

1

2

3



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Pic. 8-7 Bolts for fixing elevator unit to the fuselage

Pic. 8-8 Connecting of elevator rod to the elevator lever



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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 262.

8.2 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.

9 Pic. 8-10. 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.

Adjustable tip of the rudder push-pull rod

Middle lever

View of the central tunnel from then right side of the cockpit



Issue: 1 Rev. No:


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.

Pic. 8-11. 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.

Push-pull rod movement limiters

Rudder push-pull rod

Bumper plate



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8.4 Elevator trimmer adjustment

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.12.310.03.00 (blue arrow in the above photograph)

3. Move the clamp along the rod T.12.121.00.01 to the point elevator is in neutral position.

4. Tighten the bolt on the clamp J.12.310.03.00 (blue arrow in the above photograph) in order to fix the clamp J.12.310.03.00 on the rod T.12.121.00.01.

a

a

T.12.121.00.01

J.12.310.03.00



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PARTS AND SUBASSEMBLIES TO BE REPLACED OUTSIDE THE MANUFACTURER’S FACTORY

9.1 FRONT UNDERCARRIAGE

9.1.1 Shock absorber assembly J.13.201.00.00

9.1.2 Axle, rocker and hub assembly

J.13.201.01.00

J.13.201.01.00

3 pcs. J.13.201.02.00

J.13.201.03.00

4 pcs. AP.PF 126P

J.13.201.01.00

1

2

1. Washer Ø5 – 16 – 1,5 2. Nut M5 DIN 982

Use LOCTITE 262

Pic. 9.1.1

Pic. 9.1.2



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9.1.3 Fork assembly J.13.200.00.04 with shock absorbers J.13.200.00.00

J.13.130.01.02

J.13.100.01.02

J.13.200.01.00P

J.13.200.01.00L

J.13.200.02.00

J.13.200.03.00

J.13.100.02.00

Bearing 6004 ZZ zzZ

J.13.200.02.00

J.13.200.03.00

Bearing 6004 ZZ

1

2

3

1

2

3

J.13.200.00.04

J.13.201.00.00

J.13.201.00.00

1. Bolt M6x50 gat. 8,8 DIN 912 2. Washer Ø6 DIN 1440 3. Nut M6 DIN 982

Pic. 9.1.3

Pic. 9.1.4



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9.1.4 Complete assembly: hub, rims, tire, inner tube

9.1.5 Complete wheel assembly with axle and rockers

Tyre 4.00x6 6 ply

1

Inner tube 4.00x6

J.13.130.01.02

6 pcs. Bolt M6x50, 8,8 DIN 912

2

J.13.130.02.01

6 pcs. Washer Ø6 6 pcs. Nut M6 DIN 982

1. Part no. 42206-0 www.ulmtechnologie.com 2. Part no. 42206-1 www.ulmtechnologie.com

Pic. 9.1.5

Pic. 9.1.6

http://www.ulmtechnologie.com




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9.1.6 Wheel mounted on the fork

The other side of the wheel is identical. 9.1.7 Front undercarriage control lever with the pole (removed from the airplane)

Bolt M8 Washer Ø8 Nut M8 DIN 982

Bolt M5 Washer Ø5 DIN 1440 Nut M5 DIN 982

J.13.200.00.04

J.13.122.00.01 T.12.622.00.00

Clamp bolt

Pic. 9.1.7

Pic. 9.1.8



Issue: 1 Rev. No:


(installed in the airplane)

9.1.8 Removal of wheel from fork

1. Remove the fairing retaining bolts.

J.13.200.00.04

J.13.122.00.01 T.12.622.00.00

Bolt M5x10, 8,8 DIN 912

Bolt M5x10, 8,8 DIN 912 Washer Ø5 DIN 1440

Pic. 9.1.10

Pic. 9.1.9



Issue: 1 Rev. No:


2. Move the fairing upward, along the pole.

3. Unscrew the shock absorbers mounting bolts.

Pic. 9.1.11

Pic. 9.1.12



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4. Unscrew the rocker mounting bolts.

5. Remove the wheel and the rocker.

Pic. 9.1.14

Pic. 9.1.13



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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

9.1.10 Removal of the front undercarriage pole

1. Unscrew the bolt Mx10, 8,8 DIN 912 (Pic. 9.1.7 at the page 18) 2. Start the clamp bolt (Pic. 9.1.7 at the page 17) 3. Move the lever J.13.122.00.01 from the pole J.13.200.00.04 upward. 4. Remove the pole from the fuselage bushing.

9.1.11 Installation of the front undercarriage

1. After reassembly the front undercarriage (Pic. 9.1.6 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.13.122.00.01 (Pic. 9.1.7, page 17) with the bar

assembled J.12.622.00.00 (Pic. 9.1.7, page18)

Pic. 9.1.15



Issue: 1 Rev. No:


4. The lever must be fixed in a position allowing to screw in the locking bolt (Pic. 9.1.7, page 18 – Bolt M5x10, 8,8 DIN 912). The bolt must be secured with LOCTITE 262.

5. Tighten the clamp bolt (Pic. 9.1.7, 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.

9.1.11, 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.13.122.00.01 (Pic. 9.1.7, 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. 9.1.7, page 18 – Bolt M5x10, 8,8 DIN

912). Secure the bolt with LOCTITE 262. 9.1.12 Replacement of tyre

1. Perform the procedure 9.1.8 2. Take the assembly shown in 9.1.5, perform the procedure 9.1.9, but do

not dismantle the assembly shown in the point 9.1.2. 3. 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 42206-0 (Pic. 9.1.4, page 16). Put

the wheel valve into the hole located in the rim. 6. Put the rim and tyre on the hub J.13.130.01.02 in assembly 9.1.2 (see

point 5), and the rim 42206-1 and the clamp ring J.13.130.02.01. 7. Screw the bolts as shown in the point 9.1.4. 8. 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).



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9.2 MAIN UNDERCARRIAGE

9.2.1 Suspension spring with the wheel axle

J.13.611.00.00

J.13.610.05.00

J.13.610.06.00

J.13.610.04.00

Use epoxy glue for metal surfaces

Use LOCTITE 262 Pic. 9.2.1

Pic. 9.2.2



Issue: 1 Rev. No:


J.13.620.00.01

J.13.610.07.00

J.13.611.00.00

Axis of the joint is parallel to the wall of the spring

Pic. 9.2.4

Pic. 9.2.3



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9.2.2 Disk brake assembly

Heat shrink sleeve

Nut M8 DIN 982

J.13.610.08.00

J.13.610.07.00

J.13.611.00.00

J.13.620.00.01

J.13.610.09.00

AP.PF 126P

1. Part no. 42354-6 www.ulmtechnologie.com 2. Part no. 42139 DOT www.ulmtechnologie.com 3. J.13.650.01.02 (left - right)

2

1

3

Bushing J.13.680.01.01 Bolt M5x30 DIN 912 Nut M5 DIN 1587 Washer Ø5 DIN 9021

Bolt M6x50 DIN 912 Washer Ø6 DIN 9021 Nut M6 DIN 982

Pic. 9.2.5

Pic. 9.2.6

Use LOCTITE 262





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9.2.3 Wheel - rim and hub assembly

Part no. 42354-6 www.ulmtechnologie.com

1. Part no. 42025-0 www.ulmtechnologie.com 2. Part no. 42025-1 www.ulmtechnologie.com 3. Part no. 4206 6’’ www.ulmtechnologie.com

1

2

3

J.13.613.01.02

6 pcs. Bolt M6x25 DIN 931 gat.8,8

6 pcs. Nut M6 DIN 982 6 pcs. Washer Ø 6 DIN 1440

Pic. 9.2.8

Pic. 9.2.7







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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

2

2

2

2 3

Pic. 9.2.9



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3. Remove the cotter pin (1) and the circlip (2)

4. Remove the wheel from the axle.

9.2.5 Removal of the wheel As in the procedure 9.1.9

9.2.6 Tire replacement

1. Perform procedure 9.2.4 2. Perform procedure 9.2.5 3. 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 42025-0 (see point 9.2.3). Put the

wheel valve into the hole located in the rim.

1 2

Pic. 9.2.10



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6. Put the rim 42025-1 and the rim 42025-0 with tire (see point 5) on the hub J.13.613.01.02 in the assembly 9.2.3 and the clamp ring 4206 6’’

7. Screw all the elements with bolts. 8. Pump the wheel to the required pressure.

9.2.7 Removal of the disc brake from the spring

1. Perform procedure 9.2.4 2. Remove the disc from the caliper. 3. Disconnect the brake hose from the caliper:

press the fitting ring (A) and pull the hose (B)

4. Undo the nut and replace the bolt that attach the brake plate to the spring (3) shown in the picture 9.2.4.

5. Remove the caliper assembly from the spring axle.

A

B

Pic. 9.2.11



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9.2.8 Removal of the spring

1. Perform point 3 of the procedure 9.2.7 2. Detach the brake hose from the spring – remove the mounting

clamps00 .

Pic. 9.2.12



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3. Remove the spring retaining nut (inside the cockpit), remove the

washers and the rubber damper AP.PF126P.

4. Pull out the spring from the fuselage seat (see the Pic. 9.2.12).

J.13.620.00.0

Nut M8 DIN 982

AP.PF 126P

J.13.610.09.00

J.13.610.08.00

Pic. 9.2.13



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9.3 CONTROL SYSTEM

9.3.1 Rudder control system

12

3

45

6

5

A

B

C

D

E

F

Diagram of the rudder control system

1. Main rod T.12.630.00.01 2. Front rod J.12.621.00.01 3. Intermediate lever J.12.620.00.02 4. Drive arm J.12.640.00.02 5. Pedals J.12.610.00.01 6. Rudder J.33.000.00.01

Dwg. 9.3.1



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9.3.1.1 Pedals, front rods and the intermediate lever (items „A”, „B” and „C” in the Dwg. 9.3.1)

J.12.612.02.00

J.12.612.01.00

J.12.612.00.01

J.12.612.00.01

Shaft Ø6H7-22 Nut M6 DIN 937 Washer Ø6 DIN 1440 Cotter pin Ø1.6 DIN 94

Bolt M6x15 DIN 912

J.12.621.00.01

J.12.620.01.03

Pic. 9.3.1

Pic. 9.3.2



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J.12.620.01.03

J.12.620.01.03

J.12.620.01.03

Bearing 6001 2RS

Bearing 6001 2RS

Nut M6 DIN 934

Nut M6 DIN 934

Washer Ø6 DIN 1440

Washer Ø6 DIN 1440

Use LOCTITE 262 Use LOCTITE

603

Use LOCTITE 603

Use LOCTITE 262

Pic. 9.3.3

Pic. 9.3.4

4 pcs. Bolt M6x25 DIN 912

J.10.500.06.04

J.12.620.04.01

J.12.620.03.00

Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94



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J.12.612.00.01

J.12.612.02.00

J.12.612.01.00

J.12.612.00.01

Pic. 9.3.6

„X” (do not remove this bolt from any of the three pedal slide bearings.)

Pic. 9.3.5

J.10.500.06.04

J.12.620.04.01

J.12.620.03.00



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The left side view

J.12.630.00.01

Nut M6 DIN 937 Washer Ø6 DIN 9021 Cotter pin Ø1.6 DIN 94

J.12.621.00.01

Pic. 9.3.7

Pic. 9.3.8

T.12.622.00.00



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The right side view

9.3.1.2 Rudder travel limiters. Item „D” (Dwg. 9.3.1)

J.12.612.02.00

J.12.612.01.00

J.12.621.00.01

T.12.630.00.01

Washer Ø6 DIN 9021 Nut M6 DIN 937 Cotter pin Ø1.6 DIN 94

T.12.630.00.01

J.10.500.12.02

J.12.630.04.01

Bolt M6x20 DIN 912

Pic. 9.3.9

Pic. 9.3.10

J.12.620.01.03



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9.3.1.3 Rudder drive arm. Item “E” (Dwg. 9.3.1)

J.10.506.00.01

J.12.641.00.02

J.12.642.02.02

J.12.642.02.02

J.12.642.01.02

J.12.640.01.00

Nut M6 DIN 934

use LOCTITE 262

J.12.642.01.02

J.12.642.02.02

J.12.642.02.02

J.10.506.00.01 Steel pin Ø5x20 use LOCTITE 262

Pic. 9.3.11

Pic. 9.3.12



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1

2

3

T.12.630.00.01

Pic. 9.3.13

Pic. 9.3.14



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9.3.1.4 Top hinge of the rudder. Item „F” (Dwg. 9.3.1)

9.3.1.5 Removal of pedals 1. Disconnect the rods J.12.621.00.01 from the pedals lever

J.12.612.00.01 (Pic. 9.3.1, 9.3.2 & 9.3.8) 2. Remove the top parts of the slide bearings J.12.612.02.00 – Pic. 9.3.1.

(remove the bolts M6x15 DIN 912 – Pic. 9.3.2) Attention! Do not remove the bolt „X” shown in the picture Pic. 9.3.6.

3. Remove the pedals.

J.33.110.00.00

J.33.000.00.01

Pic. 9.3.15



Issue: 1 Rev. No:


9.3.1.6 Removal of the main rod T.12.630.00.01 (can be performed

only after removal of the elevator unit)

1. Disconnect the rod T.12.630.00.01 from the intermediate lever

12.621.01.03 – Pic. 9.3.9 (remove the cotter pin, undo the nut and remove the eye J.12.131.00.01 from the pin).

2. Replace the plastic that covers the inspection hole in the rear part of the fuselage, under the elevator unit.

3. Loosen the limiter bolts J.12.630.04.01 – (Pic. 3.9.10) 4. Through the inspection hole disconnect the rod T.12.630.00.01 joint eye

J.12.630.05.01 from the ball J.12.640.01.00 (Pic. 9.3.11, 9.3.13 & 9.3.14) As shown in the Pic. 9.3.14: - put the locking wedge under the spring (1) - lift the spring (2) - move the head J.12.630.05.01 of the rod from the ball (3)

T.12.630.01K.0J.12.131.00.01 J.12.630.05.01

Nut M6 DIN 934

rod T.12.630.00.01

front

tył

Pic. 9.3.2

Pic. 9.3.16 Pic. 9.3.17



Issue: 1 Rev. No:


5. Unscrew the eye nut J.12.131.00.01 from the front part of the rod T.12.630.00.01

6. Remove the rod in the backward direction, holding the limiters cubes J.12.630.04.01 down not to lose them (Pic. 3.9.10).

9.3.1.7 Installation of the main rod T.12.630.00.01 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.12.630.00.01 without the eye nut J.12.131.00.01 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.10.500.12.02 (Pic. 9.3.10) the limiter cube must be put on it J.12.630.04.01 and drive the rod through the limiter J.10.500.12.02.

4. Put the second cube on the tip of the rod J.12.630.04.01 and push the rod in a way the joint head J.12.630.05.01 (Dwg. 9.3.2) is located close to the ball J.12.640.01.00 (Dwg. 9.3.3).

5. The head J.12.630.05.01 should be pressed on the ball J.12.640.01.00 until a clicking sound is made.

6. Check if the rod is free to move in the eyes and rotation of the lever J.12.641.00.02 in the bushing J.10.506.00.01.

7. Screw the eye nut on the front tip of the rod J.12.131.00.01.

9.3.1.8 Adjustment of the rudder control system, according to the section 8, (after installing all elements of the control system, according to the Dwg. 9.3.1, except the connection of the main rod (1) with the intermediate lever (3)).



Issue: 1 Rev. No:


9.3.1.9 Removal of the rudder 1. Displace the rudder in one direction as much as possible (Pic. 9.3.18). 2. Remove the retaining bolts of the top hinge from the stabilizer (Pic.

9.3.19). 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. 9.3.20). 5. Remove the rudder by lifting it up along the axis of rotation (Pic. 9.3.21).

9.3.1.10 Installation of the rudder (Pic. 9.3.18 to 9.3.21 – reverse order) 1. Put the rudder on the pins J.12.642.02.02 of the bottom seat (Pic.

9.3.21). 2. Insert the top hinge into the seat in the stabilizer (Pic. 9.3.20). 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. 9.3.19). The bolts must be secured by covering thread with epoxy glue for metal-to-metal connections.

T.12.630.00.01 J.12.641.00.02

Rudder

J.10.506.00.01

J.12.642.01.02

J.12.642.02.02

J.12.630.05.01

J.12.640.01.00

Rys. 9.3.3



Issue: 1 Rev. No:


Pic. 9.3.18

Pic. 9.3.19



Issue: 1 Rev. No:


Pic. 9.3.20

Pic. 9.3.21

J.12.642.02.02



Issue: 1 Rev. No:


9.3.2 ELEVATOR AND AILERONS CONTROL SYSTEM

A

DC1

2

34

B

Elevator and ailerons control system diagram

1. Manual controls T.12.110.00.01 2. Main rod T.12.121.00.01 3. Vertical rod of the ailerons T.12.122.00.00 4. Elevator J.32.000.00.01 9.3.2.1 Manual controls T.12.110.00.01, Item „A”

Dwg. 9.3.4

Pic. 9.3.22

T.12.120.00.03

J.12.111.00.01

J.12.110.03.00

J.12.110.02.00

J.12.110.01.00



Issue: 1 Rev. No:


9.3.2.2 Manual controls J.12.110.00.01, Item „B”

Pic. 9.3.23

T.12.120.00.03

T.12.122.00.00

T.12.121.00.01 T.12.122.00.00

Pic. 9.3.24

brake hoses

Nut M6 DIN 982 Washer Ø 6 DIN 1440 4X



Issue: 1 Rev. No:


T.12.120.00.03

T.12.122.00.00

J.12.122.00.00

J.12.210.08.02



J.12.210.08.02

Pic. 9.3.25

Pic. 9.3.26



Issue: 1 Rev. No:


J.12.110.03.00

J.12.120.05.00

J.12.120.06.00

T.12.120.03.02

J.12.211.02.00

J.12.211.02.00

J.12.120.02.01 use LOCTITE 262

Nut M6 DIN 982 Washer Ø 6 DIN 1440

T.12.121.00.01

T.12.120.00.03

Cotter pin Ø2 DIN 94

J.12.120.04.02

Fill up with grease

Bolt M6x22 DIN 912

Pic. 9.3.27

Pic. 9.3.28

Blind rivet Ø4 with steel stem 2 pcs.

J.12.120.06.00



Issue: 1 Rev. No:


Pic. 9.3.29

T.12.122.01.00 Pic. 9.3.30

Pic. 9.3.31

use LOCTITE 262

T.12.122.02.00

Both tips of the rod T.12.122.00.00 are identical

hole Ø4

J.12.120.06.00

T.12.121.00.01

Cotter pin Ø2 DIN 94

T.12.120.00.03



Issue: 1 Rev. No:


Top connection of vertical rods with the ailerons control system in the wing.

9.3.2.3 Elevator drive system (Item „C”, Dwg. 9.3.4)

Elevator

rod T.12.121.00.01

J.12.610.01.01

Nut M6 DIN 937 Washer Ø 6 DIN 1440 Cotter pin Ø1.6 DIN 94

Dwg. 9.3.5

T.12.122.00.00 T.12.122.00.00

J.12.210.08.02 J.12.210.08.02


Pic. 9.3.32



Issue: 1 Rev. No:


9.3.2.4 Elevator trimmer (Item „D”, Dwg. 9.3.4)

T.12.121.01K.0 J.12.131.00.01

Nut M6 DIN 934

Rod T.12.121.00.01

Front

Aft

T.12.121.00.01

J.12.300.00.00

J.12.310.00.00

Dwg. 9.3.6

Pic. 9.3.33

J.12.310.04.00

A

B



Issue: 1 Rev. No:


J.12.300.00.00

J.12.310.00.00

J.12.310.00.00

T.12.121.00.01

J.12.310.03.00

Pic. 9.3.35

Pic. 9.3.34

Bolt M4x18 DIN 965 Nut M4 DIN 982 Washer Ø 4 DIN 9021 2x



Issue: 1 Rev. No:


J.12.300.00.00

J.12.310.00.00

T.12.121.00.01

J.12.310.03.00

J.12.310.04.00

J.12.310.04.00

T.12.121.00.01

J.12.310.04.00 J.12.310.04.00

J.12.310.00.00 Bolt M5x22 DIN 912

Bolt M5x22 DIN 912 4 pcs.

Pic. 9.3.36

Pic. 9.3.37

J.12.310.03.00

Nut M5 DIN 982 Washer Ø5 DIN 1440 5x

Bolt M6x30 DIN 912 Nut M6 DIN 982 Washer Ø 6 DIN 1440



Issue: 1 Rev. No:


9.3.2.5 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.12.122.00.00 from the controls

T.12.120.00.03 (Pic. 9.3.24 – remove the cotter pins, remove the nuts, remove joints heads from the pins J.12.211.02.00 (Pic. 9.3.27)

5. Disconnect the main rod T.12.121.00.01 from the controls (Pic. 9.3.28 – remove the cotter pin. Put a pin into the hole Ø4 in the ball J.12.120.06.00 (Pic. 9.3.29) and unscrew the rod T.12.121.00.01 from the thread in the ball J.12.122.06.00)

6. Detach the hose from the brake master cylinder (Pic. 9.3.23) as in procedure 9.2.7 (page 29)

7. Undo 4 nuts M6 (Pic. 9.3.23). 8. Pull the controls upward to remove.

9.3.2.6 Installation of the manual controls Activities of the procedure 9.3.2.5 but in reverse order. 9.3.2.7 Removal of the main rod T.12.121.00.01

1. Carry out activities 1, 2 and 4 of procedure 9.3.2.5. 2. Disconnect the joint head of the rod T.12.121.00.01 from the elevator

lever (Pic. 9.3.32 - remove the cotter pin, remove the nut and take out the pin J.12.610.01.01.

3. Remove the elevator trimmer spring J.12.310.00.00 (procedure 9.3.2.9)

4. Loosen the clamp J.12.310.03.00 by unscrewing the bolt. 5. Remove the clamp J.12.310.03.00 from the rod T.12.121.00.01

pulling forward. 6. Remove the rod T.12.121.00.01 in backward direction through the

rear inspection hole in the fuselage.

9.3.2.8 Installation of the main rod T.12.121.00.01 Access from the cockpit to the internal left rear area of the fuselage.

1. The rod T.12.121.00.01 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.12.310.03.00 on the rod. 3. Front tip of the rod T.12.121.00.01 should be screwed onto the thread

in the ball J.12.120.06.00 (Pic. 9.3.29) and secured with the cotter pin.



Issue: 1 Rev. No:


9.3.2.9 Removal of the elevator trimmer spring J.12.310.00.00 1. Disconnect the trimmer spring J.12.310.00.00 from the trimmer actuator

slider J.12.300.00.00 (Pic. 9.3.33, arrow „A”) 2. Unscrew the 4 bolts that fix the clamps J.12.310.04.00 to the structure.

(Pic. 9.3.33, 9.3.36 and 9.3.37) 3. Pull upward and remove the spring with the cubes. 9.3.2.10 Installation of the elevator trimmer spring J.12.310.00.00 1. Put the clamps J.12.310.04.00 on the spring J.310.00.00 2. Put the complete assembly into the hole in the rear plate of the central

tunnel, (arrow „B” in the Pic. 9.3.33) and put into the clamp J.12.310.03.00 (Pic. 9.3.33, 9.3.35 and 9.3.36).

3. Fix the clamps with mounting bolts M5 (Pic. 9.3.37) to the plate (Pic. 9.3.33)

4. Connect the trimmer spring J.12.310.00.00 with the trimmer actuator slider J.12.300.00.00 (Pic. 9.3.33, arrow „A”) with a bolt M5x22, a nut and a washer (Pic. 9.3.37).

9.3.3 FLAPS DRIVE SYSTEM 9.3.3.1 Electric actuator of the flap drive system and the torsion

pipes

Pic. 9.3.38

T.12.124.00.00

T.12.124.00.00

Bolt M6x15 DIN 912 Washer Ø 6 DIN 1440 4 x use LOCTITE

262

T.12.210.00.00



Issue: 1 Rev. No:


Pic. 9.3.39



Issue: 1 Rev. No:


Pic. 9.3.41

Pic. 9.3.40

T.12.125.00.00

T.12.125.00.00

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

T.12.124.00.00

T.12.124.00.00



Issue: 1 Rev. No:


Pic. 9.3.43

Pic. 9.3.42

T.12.125.00.00

Bolt M6x15 DIN 912 Washer Ø 6 DIN 1440

T.12.125.00.00

T.12.124.00.00



Issue: 1 Rev. No:


9.3.3.2 Removal of the torsion pipe T.12.124.00.00 (can be performed after removal of the wing)

Through the inspection holes in the fuselage (Pic. 9.3.43) remove bolts M6x15 that fix the torsion pipe to the actuator lever T.12.210.00.00. Take the pipe out of the fuselage through the side hole.

1Pic. 9.3.44

Pic. 9.3.45

Blind rivet Ø4 with steel stem 3 pcs.



Issue: 1 Rev. No:


9.3.3.3 Installation and adjustment of the torsion pipe T.12.124.00.00 i T.12.125.00.00 (it refers to a new pipe). Fuselage without the wing.

1. The pipe T.12.124.00.00 is to be fixed with bolts M6x15 to the actuator lever T.12.210.00.00 without LOCTITE 262 (Pic. 9.3.43).

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. 9.3.43) 5. Cover the unpainted tip of the part T.12.125.00.00 (Pic. 9.3.41) with

a thin layer of LOCTITE 603 and insert it into the hole in the part T.12.124.00.00 (Pic. 9.3.41, 9.3.40 and 9.3.43) 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 9.3.3.2. 10. The connection between T.12.124.00.00 and T.12.125.00.00

should be reinforced with three rivets located evenly along the perimeter. (Pic. 9.3.41, 9.3.44 and 9.3.45)

11. Attach the pipe to the flap actuator lever T.12.210.00.00 by means of bolts M6x15 and LOCTITE 262 (Pic. 9.3.38 and 9.3.43).

9.4 POWER PLANT 9.4.1 ENGINE MOUNTING SYSTEM

9.4.1.1 Removal of the power plant



Issue: 1 Rev. No:


1. Propeller assembly

2. Remove the engine cowling. − Using a flat head screwdriver turn all cam locks of the upper cowling

by 90º angle.

Upper cowling

Bottom cowling

J.15.000.01.00

M8x100, 8.8 DIN 912 6 pcs.

Propeller AS 1650/1900

J.15.201.01.00

J.15.200.01.01

Nut M8 DIN 982

6pcs.

M4x16 ISO 7318

6pcs.

Pic. 9.4.1.1

Pic. 9.4.1.2



Issue: 1 Rev. No:


− Remove the upper cowling.

− Disconnect the landing lamp connector.

Connector

Pic. 9.4.1.3

Pic. 9.4.1.4



Issue: 1 Rev. No:


− Using a flat head screwdriver turn all cam locks of the bottom

cowling by 90º angle.

− Remove the bottom cowling

Pic. 9.4.1.5

Pic. 9.4.1.6



Issue: 1 Rev. No:


3. Remove the spinner J.15.000.01.00.

− Remove the spinner mounting bolts M4x16 (6 pcs.).

− Remove the spinner J.15.000.01.00

J.15.000.01.00

Pic. 9.4.1.7

Pic. 9.4.1.8



Issue: 1 Rev. No:


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. 9.4.1.9

Pic. 9.4.1.10



Issue: 1 Rev. No:


− Remove the propeller and the bolts, remove the disc J.15.201.01.00 and the ring J.15.200.01.01 off of the engine reduction gear.

5. Disconnect the engine controls a. Throttle control cable

− Remove the securing cap from the tip of the cable

Propeller

Securing cap

Pic. 9.4.1.11

Pic. 9.4.1.12



Issue: 1 Rev. No:


- Using a wrench 8 mm and Allen wrench 4 mm unscrew the clamping bolt and pull out the rope from the clamp

b. Choke control cable − Straighten the choke control cable fixed in the assembly

J.12.421.00.02, which is located on the engine body

J.12.421.00.02

Choke tie

Pic. 9.4.1.13

Pic. 9.4.1.14



Issue: 1 Rev. No:


− Using a wrench 10 mm and Allen wrench 4 mm unscrew the clamping bolt and pull out the rope from the clamp

c. Carburetors heating control − Using an Allen wrench 2.5 mm remove the bolt M5 from the

bushing J.12.460.02.01, then slide the control rod a J.12.461.03.00 to the cockpit direction

J.12.460.02.01

Bolt M5

J.12.461.03.00

Pic. 9.4.1.15

Pic. 9.4.1.16



Issue: 1 Rev. No:


6. Disconnect the electrical connector − Remove the safety wire from the connector

− Undo the nut in the bottom part of the connector and disconnect the connector.

Pic. 9.4.1.17

Pic. 9.4.1.18



Issue: 1 Rev. No:


7. 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

8. Disconnect the right hose of the engine coolant and empty the engine coolant circuit.

Hot air hose GATES

Nr. 7743-01060

clamp MIKALOR W1 50-70

Pic. 9.4.1.19

Pic. 9.4.1.20



Issue: 1 Rev. No:


− Using a socket wrench 7 mm loosen the clamps on the coolant hose

− Place a clean pan under the hose and drain the coolant

9. Disconnect the fuel pipe from the fuel pump and the overflow pipe from the four-way manifold.

Hose clamps

Pic. 9.4.1.21

Pic. 9.4.1.22



Issue: 1 Rev. No:


− Using a socket wrench 7 mm loosen the clamp and disconnect the fuel pipe J.15.407.00.00 from the pump

− Using a socket wrench 7 mm loosen the clamp and disconnect the fuel pipe 15.406.00.00 from the four-way manifold J.15.400.12.00

10. Disconnect oil hoses from the oil tank. − Remove the plastic clamp that supports the choke cable

J.15.407.00.00

J.15.406.00.00

J.15.400.12.00

Pic. 9.4.1.23

Pic. 9.4.1.24



Issue: 1 Rev. No:


− Using a wrench 22 mm unscrew the barb fitting fitting from oil tank (oil hose J.15.255.00.00)

− Using a wrench 7 mm loosen the clamp and disconnect the breather pipe from the oil tank

J.15.255.00.00

Breather pipe

Pic. 9.4.1.25

Pic. 9.4.1.26



Issue: 1 Rev. No:


− Using fork wrench 19 mm and 22 mm replace the hose barb fitting fitting from the oil tank (oil pipe J.15.254.00.00)

11. Drain oil from the engine − Put a clean pan under the oil hose J.15.254.00.00 and drain the oil

from the engine

J.15.254.00.00

Pic. 9.4.1.27

Pic. 9.4.1.28



Issue: 1 Rev. No:


12. 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.

Surge tank

Pic. 9.4.1.29

Pic. 9.4.1.30



Issue: 1 Rev. No:


13. Remove the plastic clamps of pipes and control cables.

14. Sling the engine on a crane of safe working load 200 kg, as shown in the below picture.

Pic. 9.4.1.31

Pic. 9.4.1.32



Issue: 1 Rev. No:


15. Using a box-end wrench 13 mm undo the nut and disconnect the electrical bonding cable between the fuselage and the engine frame.

16. Using an open-end wrench 10 mm disconnect the cable from the starter contactor.

17. Disconnect the magneto cables

Bonding cable

J.15.251.11.00

Starter cable

Starter contactor

Pic. 9.4.1.33

Pic. 9.4.1.34



Issue: 1 Rev. No:


− Disconnect the magneto cables connector that is connected to the dashboard wiring. The connector is located to the left hand behind the dashboard

− Pull the connector through the hole in the diagonal former after removal of the rubber ring J.14.000.06.00 (the below picture shows the area after removal of the dashboard)

Rubber ring J.14.000.06.00

Pic. 9.4.1.35

Pic. 9.4.1.36



Issue: 1 Rev. No:


− Do the same on the firewall

Rubber ring J.14.000.06.00 Magneto

cables

Pic. 9.4.1.37

Pic. 9.4.1.38



Issue: 1 Rev. No:


18. 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.

Safety wire

Bolt M8x40

Pic. 9.4.1.39

Pic. 9.4.1.40 0



Issue: 1 Rev. No:


19. 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.

9.4.1.2 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.15.250.12.00 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 9.4.1.39)

3. Install and tighten the lower bolts J.15.250.12.00 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 9.4.1.39).

4. Connect the electrical bonding cable between the fuselage and the engine frame (compare to the picture 9.4.1.33).

5. Connect the starter cable (compare to the picture 9.4.1.33). 6. Connect the magneto cables (compare to the picture 9.4.1.35)

− Pull the magneto cables through the eyes in the diagonal former and the firewall and secure the edges J.14.000.06.00 with the rubber rings

− Connect the magneto connectors with the instrument panel socket

Pic. 9.4.1.41



Issue: 1 Rev. No:


7. Connect the coolant hose to the surge tank (compare to the picture 9.4.1.30).

8. Connect the oil hose to the surge tank (compare to the picture 9.4.1.25). − Tight the barb fitting fitting J.15.254.00.00 to the oil tank − Put the breather pipe on the barb fitting and secure with a hose

clamp − Tighten the barb fitting nut J.15.255.00.00 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 9.4.1.23 and 9.4.1.24).

10. Connect the right hose of the engine coolant to the radiator (compare to the picture 9.4.1.21).

− Put the hose on the radiator barb fitting − Tighten the hose clamps

11. Connect the hot air hose (compare to the picture 9.4.1.20). − Put a hose clamp Mikalor W1 50-70 on the corrugated hose (see

the below picture, elements outside the airplane)

− Put the hose on the air butterfly valve (J.14.010.01.00) located on the firewall

− Tighten the clamp

Corrugated hose GATES

Nr 7743-01060

MIKALOR W1 50-70

Pic. 9.4.1.42



Issue: 1 Rev. No:


12. Connect the electrical connector (compare to the picture 9.4.1.17, 9.4.1.18 and 9.4.1.19).

− Twist the connector’s nut − Secure with safety wire 1.2 mm

13. Connect the engine controls (compare to the picture 9.4.1.12, 9.4.1.13, 9.4.1.14, 9.4.1.15, 9.4.1.16).

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.12.421.03.02 − Bend the tip of the cable by 90º

c. Carburetors heating control − Put the cap J.12.460.01.01 together with the control rod

into the bushing J.12.460.02.01 − Install the bolt M5x5 DIN 916

14. Fill the lubrication system with engine oil according to the Rotax Engine Operation Manual.

15. Fill the cooling system with coolant according to the Rotax Engine Operation Manual.

16. Install the propeller. − Install the distance ring J.15.200.01.01 on the reduction gear shaft − Install the spinner disc J.15.201.01.00 on the distance ring − Install the propeller and tighten using bolts bolts M8x100 DIN 912,

8.8 17. 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 9.4.1.4). 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



Issue: 1 Rev. No:


9.4.2 ENGINE CONTROL SYSTEM Throttle control diagram in the cockpit

7

24

6

6

6

4

43

4

1

Thro

ttle

cont

rol d

iagr

am in

the

cock

pit

C

BA

K

KZ

Z

ZZ

Dia

gram

of t

he c

able

s tr

avel

J.1

2.43

0.00

.03

& J

.12.

440.

00.0

3 be

twee

n th

e le

vers

J.

12.4

10.0

0.03

L &

J.1

2.41

0.00

.03P

and

the

inte

rmed

iate

bra

cket

J.1

2.42

0.00

.03

A –

left

leve

r J.1

2.41

0.00

.03L

, B

– ri

ght l

ever

J.1

2.41

0.00

.03P

, C

– i

nter

med

iate

bra

cket

J.1

2.42

0.00

.03

K –

tip

and

seat

J.1

2.43

0.01

.03,

Z

– ad

just

able

cla

mp

- car

bure

tors

cab

les

4 –

J.12

.430

.00.

03

6 –

J.12

.450

.00.

03

7 –

J.12

.430

.01.

03

1 –

J.12

.410

.00.

03L

2 –

J.12

.410

.00.

03.P

3

– J.

12.4

20.0

0.03

Dwg. 9.4.2.1

Dwg. 9.4.2.2



Issue: 1 Rev. No:


9.4.2.1 Throttle control levers J.12.410.00.03L & J.12.410.00.03P

Pic. 9.4.2.1

The lever on the left side

J.12.432.00.03

J.12.411.00.03L

J.12.412.00.03L (J.12.412.00.03P)

Bolt M5X10 DIN 912

J.12.411.00.03

J.12.410.01.03

J.12.410.02.03

Bolt M6x15 DIN 965 3 pcs.

Pic. 9.4.2.2

use LOCTITE 262

J.12.412.05.03 Bolt M5x5 DIN 913

J.12.412.05.03 Bolt M5x5 DIN 913

Bolt M5X10 DIN 912

J.12.412.00.03L



Issue: 1 Rev. No:


9.4.2.2 Intermediate bracket

Pic. 9.4.2.3

Pic. 9.4.2.4

J.12.420.00.03

J.12.432.00.03 J.12.432.00.03

J.12.450.00.03

J.12.423.00.03

J.12.422.00.03

J.12.423.05.03 Nut M6 DIN 934 - 4 x

J.12.420.02.03

J.12.420.01.03

Nut M6 DIN 982 use LOCTITE

262

J.12.423.05.03 Nut M6 DIN 934

„N”

J.12.412.05.03 Bolt M5x5 DIN 913

J.12.431.00.03

J.12.430.01.03



Issue: 1 Rev. No:


9.4.2.4 Removal of the throttle control system

1. Disconnect the cables J.12.450.00.03 from the carburetors clamps. 2. Remove the cover J.12.400.02.03 of the intermediate bracket.

3. Disconnect the cable J.12.450.00.03 from the intermediate bracket.

J.12.400.02.03

Bolt Ø4.2 x 15 DIN7981C

Pic. 9.4.2.6

Pic. 9.4.2.5

J.12.430.01.03

J.12.431.00.03



Issue: 1 Rev. No:


4. Pull out the cable J.12.450.00.03 from the Bowden conduit. 5. Loosen the bolts M5x5 in the cables clamps J.12.412.05.03 in the

intermediate brackets and in the levers (Pic. 9.4.2.1 & 9.4.2.4). 6. In the intermediate bracket (Pic. 9.4.3) loosen the tension

regulatorJ.12.423.05.03 so the Bowden conduit could be pulled out from the seats.

7. Install the bolt M5x10 (Pic. 9.4.2.1) 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. 9.4.3 white arrow with „N” description) and remove the bracket J.12.422.00.03 from the axle J.12.423.00.03 (Pic. 9.4.2.4).

10. Take out the cable tips from the catches in the bracket J.12.422.00.03.

9.4.2.3 Installation of throttle control in the cockpit

Install the throttle lever brackets J.12.411.00.03 and the intermediate body bracket J.12.423.00.03 on the fuselage structure.

J.12.450.00.03

Bolt M4x12 DIN 7985 Washer Ø4 DIN 1440 Nut M4 DIN 985

Pic. 9.4.2.7

J.12.412.05.03 Bolt M5x5 DIN 913



Issue: 1 Rev. No:


1. The regulatorJ.12.423.05.03 on the bracket J.12.423.00.03 must be screwed in (Pic. 9.4.3)

2. Put the distance element J.12.420.02.03 (Pic. 9.4.2.4) on the axleJ.12.423.00.03

3. Put the cables J.12.431.00.03 to the bracket J.12.421.00.03 with the tip

and the seat J.12.430.01.03 (Pic. 9.4.2) thread through all regulators J.12.423.05.03 in the body.

4. The bracket J.12.422.00.03 is to be installed on the bracket J.12.423.00.03. Then install the disc J.12.42.01.03 and tighten the nut (Pic. 9.4.2.4)

5. Put the conduits J.12.432.00.03 (Pic. 9.4.2.8, arrow „1”), on the cables J.12.431.00.03, thread the cables through the clamps J.12.412.05.03 (Pic. 9.4.2.2) located in the levers J.12.412.00.03 assemble the levers according to the Pic. 9.4.2.1 & 9.4.2.2. Secure the bolts M5x10 with LOCTITE 262.

6. Put conduits J.12.432.00.03 (Pic. 9.4.2.8, arrow „2”), on the cables

J.12.431.00.03 thread the cables through the regulators and clamps J.12.412.05.03 in the bracket (Pic. 9.4.2.3 & 9.4.2.9).

7. Lay the conduits J.12.432.00.03 in the levers seats J.12.411.00.03 and regulators seats J.12.423.05.03 of the intermediate bracket

Pic. 9.4.2.8

1

1

2

2



Issue: 1 Rev. No:


J.12.420.00.03, eliminate play and secure the cables with clamping bolts M5x5 in clamps J.12.412.05.03 (Pic. 9.4.2.7). Secure the bolts with LOCTITE 262.

8. The regulators J.12.412.05.03 on the intermediate bracket J.12.420.00.03 should be screwed in gradually until the cables are properly tightened and then secured with nuts.

9. Turn the bracketJ.12.422.00.03 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. 9.4.2.1). The bolts should be secured with LOCTITE 262.

Pic. 9.4.2.9

J.12.412.05.03

J.12.431.00.03 J.12.431.00.03

J.12.431.00.03

J.12.412.05.03



Issue: 1 Rev. No:


10. 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. 9.4.2.10) 12. Put the conduits J.12.450.00.03 (Pic. 9.4.2.7 white arrow), into the

bracket seats J.12.423.00.03 (Pic. 9.4.2.4), insert the cable J.12.450.00.03 and fix as shown in the Pic. 9.4.2.7.

13. Tips of the cable J.12.450.00.03 should be pulled through the rubber eyes in the former and the firewall to the engine compartment (Pic. 9.4.2.7 red arrow)

14. Install the cover J.12.400.02.03 of the intermediate bracket (Pic. 9.4.2.6).

9.4.2.5 Adjustment of the intermediate bracket clamp J.12.422.00.03

(Pic. 9.4.2.4). After connecting the cables J.12.450.00.03 to the carburetors levers and adjustment of the engine control.

The clamp of the bracket is adjusted with the nut „N” in the Pic. 9.4.2.3. 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 9.4.2.4, point 10.

Pic. 9.4.2.10



Issue: 1 Rev. No:


9.4.3 FUEL SYSTEM 9.4.3.1 Fuel system with tanks installed in the wings

1. Fuel system diagram

1. Tank in left wing 1.a Additional tank - left 2. Tank in right wing 2.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

Dwg. 9.4.3.1

Tanks in wings Tanks in the fuselage



Issue: 1 Rev. No:


2. Replacement of the reserve sensor

− Remove the upper and the lower fuel hose clamps

− Cut out the sensor cable − Uninstall the fuel pipes and remove the reserve sensor assembly

Hose clamp W1 13-15

Hose clampW1

Pic. 9.4.3.1

Pic. 9.4.3.2 Pic. 9.4.3.3



Issue: 1 Rev. No:


3. Removal of the left additional fuel tank − Loosen the hose clamp on the fuel pipe and remove the pipe

Hose clamp W1

Pic. 9.4.3.4

Pic. 9.4.3.5



Issue: 1 Rev. No:


− Loosen the clamp on the outlet hose from the settling tank side J.15.430.00.01, located in the central tunnel

− Remove the bolts that mount the tank to the brackets in fuselage

Hose clamp W1

Pic. 9.4.3.6

Pic. 9.4.3.7



Issue: 1 Rev. No:


− Lift the additional tank and remove the hose clamp from the overflow hose

Pic. 9.4.3.8



Issue: 1 Rev. No:


− Remove the additional fuel tank

Hose clamp W1

Overflow hose

Overflow hose

Pic. 9.4.3.9

Pic. 9.4.3.10



Issue: 1 Rev. No:


4. Removal of the right additional fuel tank − Loosen the hose clamps on the fuel pipe

− Move the rubber part upward and remove it from the fuel tank barb fitting connector

Opaska W1 13-15

Pic. 9.4.3.11

Pic. 9.4.3.12



Issue: 1 Rev. No:


− Remove the hose clamp on the drain pipe from the side of the sediment bowl J.15.430.00.01, located in the central tunnel

− Remove the mounting bolts of the fuel tank bracket

Hose clamp W1

Pic. 9.4.3.13

Pic. 9.4.3.14



Issue: 1 Rev. No:


− Lift the additional tank, loosen the hose clamp of the overflow pipe and cut the “no fuel” sensor electric cable

− Remove the additional tank

Opaska W1 13-15

Electric cable

Pic. 9.4.3.15

Pic. 9.4.3.16



Issue: 1 Rev. No:


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

Clamp W1 25-28

J.15.430.00.01

Clamp W1 25-28

Pic. 9.4.3.17

Pic. 9.4.3.18



Issue: 1 Rev. No:


− Loosen the clamp on the fuel pipe J.15.400.08.00 and remove the pipe from the barb fitting

− Remove the drain valve (see the point 6 below) − Using a wrench 20 mm remove the nut (J.15.430.08.00) that fixes

the sediment bowl to the fuselage structure

− Remove the sediment tank from the fuselage

Fuel pipe J.15.400.08.00

Clamp W1 13-15

J.15.430.00.01

Fuselage belly

J.15.430.08.00

Pic. 9.4.3.19

Pic. 9.4.3.20



Issue: 1 Rev. No:


6. Replacement of the drain valve − Using an open-end wrench 11 mm unscrew the fuel drain valve

(ULM 70569) from the sediment tank J.15.430.00.01

J.15.430.00.01

part no. 70569 www.ulmtechnologie.com

Pic. 9.4.3.21

Pic. 9.4.3.22




Issue: 1 Rev. No:


− 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

7. 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

− Release the filter from the bracket

Clamp W1 13-15

Filter bracket

Pic. 9.4.3.23

Pic. 9.4.3.24



Issue: 1 Rev. No:


− Remove the clamp on the fuel pipe between the filter and the valve and take the filter out

− 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

Filtr paliwa FILTRON PS 878

Pic. 9.4.3.24

Pic. 9.4.3.25



Issue: 1 Rev. No:


− Remove the fuel pipes from the fuel valve

Clamp W1 13-15

Clamp W1 13-15

Pic. 9.4.3.26

Pic. 9.4.3.27



Issue: 1 Rev. No:


− Using a screwdriver and an open-end wrench remove the two screws M4x30 DIN 7985 that fix the assembly J.15.440.00.01 to the bracker J.10.500.22.00

− Remove the assembly J.15.440.00.01 from the fuselage − Remove the screw M4x20 DIN 965 and take out the fuel valve

(ULM 70223)

J.15.440.00.01

J.10.500.22.00

Screw M4x30

Screw M4x20

DIN 965

Part no. 70223 www.ulmtechnologie.com

Pic. 9.4.3.28

Pic. 9.4.3.29

J.15.440.01.01




Issue: 1 Rev. No:


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

− Disconnect the electrical connector − Using an open-box key 13 mm and Allen key 5 mm remove the fuel

pipe mounting bolts

J.15.407.00.00

Fuel pump FACET SS501

(40105)

J.15.400.10.01

J.15.400.14.00

Clamp W1 13-15 Clamp W1

13-15

Bolt M6x30

DIN 912

Washer Ø6 DIN 9021

Pic. 9.4.3.30

Pic. 9.4.3.31



Issue: 1 Rev. No:


− Remove the pump from the fuselage

10. Removal of the fuel pressure sensor − Disconnect the connector

J.15.400.16.00

Nut M6 DIN 982

Hermetic connector

Pic. 9.4.3.32

Pic. 9.4.3.33



Issue: 1 Rev. No:


− Loosen the fuel pipe clamp on the fuel pressure sensor barb fitting

− Remove the rubber lined clamp that fixes the sensor to the former of the fuselage

Clamp W1 13-15

J.15.408.00.00

Clamp RUBBER P-CLIP D35

Pic. 9.4.3.34

Pic. 9.4.3.35



Issue: 1 Rev. No:


− 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 W1 13-

15 − Connect the drain pipe to the barb fitting of the sediment bowl and

secure with the clamp W1 25-28 − Mount the fuel tank with the mounting bolts − Connect the fuel pipe and secure with a clamp W1 13-15

13. 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 W1 13-15 − Connect the drain pipe to the barb fitting of the sediment bowl and

secure with the clamp W1 25-28 − Mount the fuel tank with the mounting bolts − Connect the fuel pipe and secure with a clamp W1 13-15

14. Installation of the sediment bowl (compare to the picture in point 5) − Insert the sediment bowl J.15.430.00.01 into the fuselage hole

located behind the crosswise beam of the main undercarriage − Using an open-end wrench 20 mm tighten the nut J.15.430.08.00

putting the washer J.15.430.07.00 under it − Connect and secure with clamps W1 25-28 the drain pipes of the

left and the right additional tank − Connect the fuel pipe J.15.400.08.00 and secure with the clamp W1

13-15 15. Installation of the fuel valve

− install the valve in the assembly J.15.440.01.01 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



Issue: 1 Rev. No:


− The fuel valve, together with the element J.15.440.01.01 is to be put on the bracket J.10.500.22.00, cover with the disc J.15.440.03.01 and connect using screws M4x30 DIN 7985 washers Ø4 DIN 1440 and nuts M4 DIN 982

J.15.440.01.01 Screw M4x20

DIN 963

Part no. 70223 www.ulmtechnologie.com

J.15.440.03.01

Screw M4x30

DIN 7685

Nut M4 DIN 1440

Fuel valve J.15.440.01.01

Pic. 9.4.3.36

Pic. 9.4.3.37




Issue: 1 Rev. No:


− Connect the fuel pipes J.15.400.09.00 & J.15.400.10.00 to the fuel valve and secure with the clamps W1 13-15 (compare to the pictures of point 8)

16. Installation of the electric fuel pump

− Screw in the barb fittings J.15.400.14.00W into the holes of the electric fuel pump Facet SS501 (40105) . Use thread sealant to secure the connection

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 90201. Between the pump and the former the rubber parts J.15.400.16.00. are to be placed. Pay

J.10.500.22.00

Screw M4x30

DIN 7985

Pompa paliwa FACET SS501

(40105)

J.15.400.14.00

Pic. 9.4.3.38

Pic. 9.4.3.39



Issue: 1 Rev. No:


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)

− Connect the fuel pipes J.15.407.00.00 i J.15.400.10.01 to the barb fittings J.15.400.14.00 and secure with clamps W1 13-15

− 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.15.400.17.00, bolt M4x30 DIN 7985, washer Ø4 DIN 9021 and nut M4 DIN 934, securing the conection with thread sealant. All parts of the assembly are shown in the below picture.

Pic. 9.4.3.40



Issue: 1 Rev. No:


− Put the fuel pipe on the barb fitting J.15.408.00.00 and secure with the clamp W1 13-15

− Connect the connector to the fuselage wiring 18. Oil pressure sensor replacement

− Oil pressure sensor is placed along with the ventilation pipe in the centre section of a wing and covered from the top by a fairing (see the picture below)

Clamp RUBBER

P-CLIP D35

Fuel pressure sensor

Bolt M4x30 DIN 7985

Nut M4 DIN 934

Washer Ø4 DIN 9021

J.15.400.17.00

J.15.408.00.00

Pic. 9.4.3.41

Pic. 9.4.3.42



Issue: 1 Rev. No:


− Using a paper band, tape the fairing and then draw a line on it at 35 mm distance from wing surface

Pic. 9.4.3.43

Pic. 9.4.3.44



Issue: 1 Rev. No:


− Using a small electric saw, cut the fairing along the marked line

Pic. 9.4.3.45

Pic. 9.4.3.46



Issue: 1 Rev. No:


Pic. 9.4.3.47

Pic. 9.4.3.48



Issue: 1 Rev. No:


− Unscrew the bolts M5x15 DIN 912 that are fixing the oil pressure sensor.

− Unroll the spiral casing from the wires and remove the heat shrinkable tubing

Bolts M5x15 DIN 912

Spiral casing

Electrical wires

Pic. 9.4.3.49

Pic. 9.4.3.50



Issue: 1 Rev. No:


− Unsolder the electrical wires

Heat shrinkable

tubing

Pic. 9.4.3.51

Pic. 9.4.3.52



Issue: 1 Rev. No:


− Remove the hose clamps AML 12 from a rubber pipe

Hose clamp AML12

Pic 9.4.3.53

Pic. 9.4.3.54



Issue: 1 Rev. No:


− Pull out the ventilation pipe from a rubber pipe

− Remove rubber pipe from a sensor ferrule and pull out from the electrical wires

− Lever the oil pressure sensor and gently pull it out

Pic. 9.4.3.55

Pic. 9.4.3.56



Issue: 1 Rev. No:


Pic. 9.4.3.57

Pic. 9.4.3.58



Issue: 1 Rev. No:


− Assemble the new oil pressure sensor by gently putting it in the opening inside the pipe. Pay attention to the position of the ring and make sure that you don’t damage the heat shrinkable tubing when putting it in.

− Screw the sensor using bolts M5x15 DIN 912. Lubricate the bolts with a screw joint preparation

Pic. 9.4.3.59

Pic. 9.4.3.60



Issue: 1 Rev. No:


− Put on the rubber sector of the ventilation pipe on the oil pressure sensor ferrule. Push the electrical wires through the rubber pipe.

− Lubricate the aluminum ventilation pipe in a place where it is connected to the rubber sector using LOCTITE 5922 preparation

Pic. 9.4.3.61

Pic. 9.4.3.62



Issue: 1 Rev. No:


− Slide over the rubber sector on the aluminium tube. Make sure that the electrical wires are not damaged in the process.

− Secure the rubber sector of the pipe with hose clamps AML 12

LOCTITE 5922

Pic. 9.4.3.63

Pic. 9.4.3.64



Issue: 1 Rev. No:


− Protect the end of the rubber sector along with the electrical wires by using preparation LOCTITE 5922

− Put on the heat shrinkable tubing on the electrical wires

Hose clamp

AML 12

LOCTITE 5922

Pic. 9.4.3.65

Pic. 9.4.3.66



Issue: 1 Rev. No:


− Solder the electrical wires and secure it with heat shrinkable tubing by heating it up

Heat shrinkable tubing

Pic. 9.4.3.67

Pic. 9.4.3.68



Issue: 1 Rev. No:


− Wrap already soldered electrical wires with spiral casing

Spiral casing

Pic. 9.4.3.70

Pic. 9.4.3.71



Issue: 1 Rev. No:


− Use abrasive paper to clean and degrease the surfaces of the internal fairing sensor.

− Prepare two straps 15x78 mm from a glass panel in thickness 1-1.5 mm and four plates 10x10 mm from a panel in thickness 3 mm

Pic. 9.4.3.72

Pic. 9.4.3.73



Issue: 1 Rev. No:


− Glue the straps and plates to the internal fairing surface in the way shown below:

Fairing

Plate gr. 3 mm

Pic. 9.4.3.74

Dwg. 9.4.3.2



Issue: 1 Rev. No:


− Apply the already cut-off upper part of a faring on the lower one and holding them both together drill four openings Ø3 mm (see the picture above)

Pic. 9.4.3.75

Pic. 9.4.3.76



Issue: 1 Rev. No:


− Use screw-tap M4 to tap the drilled openings

Pic. 9.4.3.77

Pic. 9.4.3.78



Issue: 1 Rev. No:


− Put on the upper part of the fairing right on to the lower part and protect the place of contact by using adhesive foil in width 15-20 mm.

Pic. 9.4.3.79

Pic. 9.4.3.80



Issue: 1 Rev. No:


− Secure the fairing by using four M4x10 DIN 7985 screws

Adhesive foil

Pic. 9.4.3.81

Pic. 9.4.3.82



Issue: 1 Rev. No:


Pic. 9.4.3.83

Pic. 9.4.3.84



Issue: 1 Rev. No:


9.4.3.2 Fuel system installation with the tanks behind pilots’ seats.

1. Fuel system schematic illustration

1. Left tank 2. Right tank 3. Filling elbow 4. Ventilation pipe 5. Tank trap 6. Draining valve 7. Fuel tap 8. Mechanical fuel pump

9. Carburettors 10. Electrical fuel pump 11. Fuel filter 12. Fuel pressure indicatorl 13. Refuelling pump pipe 14. Ventilation pipe 15. Overflow pipe d. Choke

2. Right fuel tank disassembly

− Undo a band clip fastening ventilation line

Dwg. 9.4.3.3

15



Issue: 1 Rev. No:


Pic. 9.4.3.85

Pic. 9.4.3.86

Band clip W1



Issue: 1 Rev. No:


− Remove a ventilation pipe from fuel tank venting ferrule

− Undo a hose clamp on a drain pipe from the tank next to fuel trap J.15.430.00.01 situated in the middle tunnel

opas − Slide down the drain pipe from a decanter tank ferrule

J.15.430.00.01

Pic. 9.4.3.87

Pic. 9.4.3.88

Hose clamp W1

Ventilation pipe

J.15.410.09.03

Hose clamp W1



Issue: 1 Rev. No:


− Unscrew upper bolts fastening fuel tank with luggage rack

Pic. 9.4.3.89

Pic. 9.4.3.90

Bolt M5x20



Issue: 1 Rev. No:


− Unscrew a lower bolt fastening bracket with a fuel tank 15.410.13.01L

Pic. 9.4.3.91

Pic. 9.4.3.92

Bolt M5x25



Issue: 1 Rev. No:


− Carefully pull out the fuel tank from a pit behind the seat

4. Left fuel tank disassembly − Undo a hose clamp on a ventilation pipe and slide down

ventilation pipe no 4 from a venting ferrule

Pic. 9.4.3.93



Issue: 1 Rev. No:


− Undo a hose clamp on the overflow pipe and slide down the pipe from a ferrule

Foto 9.4.3.94

Pic. 9.4.3.95

Hose clamp W1

Band clip W1



Issue: 1 Rev. No:


− Undo a hose clamp from a ventilation pipe no 14 and slide down the pipe from a ferrule

− Undo an upper hose clamp on a filling elbow and slide down the elbow from the fuel runner

Foto 9.4.3.96

Hose clamp W1



Issue: 1 Rev. No:


Pic. 9.4.3.97

Pic. 9.4.3.98

Hose clamp W1



Issue: 1 Rev. No:


− Undo a hose clamp from a refueling pump pipe and slide down the pipe

Pic. 9.4.3.99

Pic. 9.4.3.100

Hose clamp W1 13-15



Issue: 1 Rev. No:


− Undo a lower hose clamp on a filling elbow and remove it from the fuel runner and filling pipe on a tank

Pic. 9.4.3.101

Pic. 9.4.3.102

Hose clamp W1



Issue: 1 Rev. No:


− Undo a hose clamp a drain pipe from the tank next to the fuel decanter J.15.430.00.01 situated in the middle tunnel

− Slide down the drain pipe from a fuel decanter ferrule J.15.430.00.01

Pic. 9.4.3.103

Pic. 9.4.3.104

Trim W1 25-28



Issue: 1 Rev. No:


− Unscrew upper bolts fastening the tank with luggage rack

Pic. 9.4.3.105

Pic. 9.4.3.106

Bolt M5x20



Issue: 1 Rev. No:


Unscrew a lower bolt fastening the bracket with a fuel tank 15.410.13.01P

− Remove the tank from a pit behind pilot’s seat (see the pictures below)

Pic. 9.4.3.107

Pic. 9.4.3.108

Bolt M5x25



Issue: 1 Rev. No:


Pic. 9.4.3.110 Pic. 9.4.3.109

Pic. 9.4.3.111



Issue: 1 Rev. No:


5. Fuel decanter disassembly– perform according to the point 5 from

chapter 9.4.3.1. Sentence: „Undo band clips on the drain pipes from extra tanks and slide down pipes from the tank” changes into: Undo band clips on the drain pipes from fuel tanks and slide down pipes from the tank

6. Draining valve exchange – perform according to the point 6 from chapter 9.4.3.1

7. Fuel filter exchange – perform according to the point 5 from chapter 9.4.3.1

8. Fuel tap disassembly– perform according to the point 8 from chapter 9.4.3.1

9. Electrical fuel pump disassembly– perform according to the point 9 from chapter 9.4.3.1

10. Fuel pressure control disassembly– perform according to the point 10 from chapter 9.4.3.1

11. Left fuel tank assembly– perform in reverse order to the one shown at point 2 in this chapter

12. Right fuel tank assembly– perform in reverse order to the one shown at point 3 in this chapter



Issue: 1 Rev. No:


9.4.4 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.15.250.09.00 -

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.

J.15.250.08.00

J.15.250.09.00

Pic. 9.4.4.1



Issue: 1 Rev. No:


− Remove the bracket J.15.250.09.00 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.15.255.00.00 & J.15.256.00.00 from the

barb fittings on the oil cooler

M4 DIN 982 4 pcs.

J.15.255.00.00

Pic. 9.4.4.2

Pic. 9.4.4.3



Issue: 1 Rev. No:


− Unscrew the bottom bracket J.15.250.02.00 from the engine block

J.15.256.00.00

J.15.250.02.00

J.15.250.13.00

Pic. 9.4.4.4

Pic. 9.4.4.5



Issue: 1 Rev. No:


− Unscrew the bracket J.15.250.03.00 from the reducer body and remove the cooler

3. Installation of then oil tank − Fix the tank using clamping rings J.15.250.09.00 and brackets

J.15.250.08.00 and secure with nuts M4 DIN 982 inside the cockpit (see the picture in point 1)

− Connect the oil hose J.15.254.00.00 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.15.255.00.00 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 Manual of Rotax Engines

4. Installation of the oil cooler

− Brackets J.15.250.02.00 & J.15.250.03.00 should be mounted with rivets to the oil coolers, according to the assembly drawing J.15.257.00.00

J.15.250.03.00

Pic. 9.4.4.6



Issue: 1 Rev. No:


− The bracket J.15.250.03.00 should be fixed with bolts M8x20 DIN 931 to the reducer body

− The bracket J.15.250.02.00 should be fixed with bolts J.15.250.13.00 and washers J.15.250.06.02 to the oil pump body

− Connect the oil hose J.15.256.00.00 to the right barb fitting of the cooler (see point 2)

− Connect the oil hose J.15.255.00.00 to the left barb fitting of the cooler (see point 2)

5. Replacement of rubber elements of the engine oil circuit − Oil hose J.15.255.00.00

J.15.250.13.00

J.15.250.06.02

J.15.250.02.00

J.15.255.00.00

Barb fitting Rotax

Clamp W1 18-20

Pic. 9.4.4.7

Pic. 9.4.4.8



Issue: 1 Rev. No:


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 W1 18-20 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.15.254.00.00

a. Remove the breather pipe from the oil tank (see point 10 in the procedure 9.4.6)

b. Remove the oil hoseJ.15.254.00.00 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 e. Loosen the clamps on the hose and remove the rubber hose f. Put a new rubber hose and secure with the clamp W1 18-20;

put the other clamp on the other tip of the hose g. Connect the oil hose J.15.254.00.00 to the oil tank (see point

8 in the procedure 9.4.7) h. Connect the oil hose J.15.254.00.00 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 W1 13-15 (see point 8 of the procedure 9.4.7) j. Fill the system with engine oil according to Operation Manual

of the Rotax Engine

J.15.254.00.00

Hose W1 18-20 Barb fitting

Rotax

Pic. 9.4.4.9



Issue: 1 Rev. No:


− Oil hose J.15.256.00.00

J.15.254.00.00

Clamp W1 18-20

Clamps W1 18-20

Oil hose CONTI-TCH-OLNS1-12x3.5

AEM/AEM

J.15.256.01.00

Barb fitting Rotax

Pic. 9.4.4.10

Pic. 9.4.4.11



Issue: 1 Rev. No:


a. Remove the oil hose J.15.256.00.00 from the cooler

b. Remove the oil hose J.15.256.00.00 from the oil pump

c. Remove the clamps from the rubber hose d. Remove the rubber hose e. Put a new hose on the pipe J.15.256.00.00 and secure with

clamps W1 18-20

J.15.256.00.00

J.15.256.00.00

Clamp W1 18-20

Pic. 9.4.4.12

Pic. 9.4.4.13



Issue: 1 Rev. No:


f. Put the barb fitting on the upper rubber hose and secure with the clamp W1 18-20

g. Connect the oil hose J.15.256.00.00 to the oil cooler (see the point „a”)

Connect the oil pipe J.15.256.00.00 to the oil pump barbed fitting and secure with the clamp W1 18-20 (see the picture in point „b”) 9.4.5 ENGINE COOLING SYSTEM

1. Engine cooling system diagram

E – engine P – coolant pump R – radiator D – expansion tank L – surge tank C – carburetors 1 – the-way manifold of the pump J.15.505.00.00 2 – thermostat J.15.501.00.00 3 – three-way manifold J.15.500.04.00 4 – heating J.15.502.00.01

5 – right hose J.15.500.01.01 6 – left hose J.15.500.02.01 7 – hose J.15.500.07.00 8 – hoseJ.15.500.08.00 9 – heating hose J.15.502.02.00 10 – heating hose J.15.502.03.00 11 – heating hose J.15.502.04.00 12 – hose J.15.500.09.00 13 – heating control J.12.460.00.00

2. 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

Dwg. 9.4.5.1



Issue: 1 Rev. No:


1. Gasket 2. Cover 3. Bolt M6x90 – DIN 912 4. Bolt M6x35 – DIN 912 5. Bolt M6x35 – DIN 912

6. Sealing ring 7. O-ring 8. Inlet elbow 9. Bolt M6x20 – DIN 912

− 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

− Unscrew the inlet fittings, clean the threads and change position of

the inlet fittings according to the below drawing

Dwg. 9.4.5.2

Dwg. 9.4.5.3



Issue: 1 Rev. No:


− 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.

− Put the coolant hoses on the inlet fittings and secure with self-acting clamps

Dwg. 9.4.5.4

Pic. 9.4.5.1



Issue: 1 Rev. No:


− Fix the three-way manifold J.15.505.00.00 to the pump cover with bolts (9)

Self acting clamp

J.15.505.00.00

Pic. 9.4.5.2

Pic. 9.4.5.3



Issue: 1 Rev. No:


Install the coolant hoses J.15.500.01.01 & J.15.500.07.00 and secure with clamps W1 25-28

3. Thermostst − Complete thermostat assembly – diagram

Bolt M6x20 DIN 912

J.15.505.00.00

J.15.500.07.00 J.15.500.01.01

Pic. 9.4.5.4

Pic. 9.4.5.5



Issue: 1 Rev. No:


1. Thermostst body – J.15.501.01.00 2. Cover – J.15.501.02.00 3. Thermostat – WAHLER 11 04 82º

4. O-ring Ø48x3 5. Socket cap bolt M6x18 – DIN 912 6. 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 1.

J.15.500.08.00

Clamp W1 25-28

J.15.501.00.00

Dwg. 9.4.5.5

Pic. 9.4.5.6



Issue: 1 Rev. No:


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 o Insert the new thermostat into the body

J.15.500.02.01

J.15.500.07.00

J.15.501.01.00

J.15.501.02.00

thermost O-ring Ø48x3

Pic. 9.4.5.7

Pic. 9.4.5.8



Issue: 1 Rev. No:


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 W1 25-28 (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 9.4.1.1) o Disconnect the control system of the carburetors heating

system (see the point 5c in the procedure 9.4.1.1) o Remove the clamps from the heating hoses no 9, 10, &

11 and remove the hoses

J.15.502.02.00

J.15.500.04.00

Clamp W1 13-15

Pic. 9.4.5.9



Issue: 1 Rev. No:


o Remove the springs

J.15.502.04.00

J.15.502.03.00

Clamp W1 13-15

J.15.500.03.00

Clamp W1 13-15

Pic. 9.4.5.10

Pic. 9.4.5.11



Issue: 1 Rev. No:


o Remove the clamps that mounts the heating system to the suction manifold and remove the system together with carburetors

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.15.500.04.00 and

J.15.505.00.00 o Remove the carburetors heating control system

Springs

Clamp

Pic. 9.4.5.12

Pic. 9.4.5.13



Issue: 1 Rev. No:


− 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)

o Install the carburetor heating system assembly. secure

with the bolt M5x8. be aware of differences between the left and right assembly.

Clamp

Carburetor

Pic. 9.4.5.14

Pic. 9.4.5.16



Issue: 1 Rev. No:


o Insert the carburetors with the heaters onto the suction manifolds and secure with the steel clamps.

o Install the safety springs

o Fix the heating control mechanism J.12.460.02.01 and the valve to the elbow on the left heating assembly

Clamp

Spring

Pic. 9.4.5.17

Pic. 9.4.5.18



Issue: 1 Rev. No:


o Connect the heating hose no 9 to the fitting on the three-way manifold J.15.500.04.00 and to the external fitting on the left heating assembly and secure with the clamp W1 13-15

o Connect the heating hose no 10 to the fitting on the three-way manifold J.15.505.00.00 and to the internal fitting on the right heating assembly and secure with the clamp W1 13-15

J.12.460.02.01

J.15.500.04.00

J.15.502.02.00

Pic. 9.4.5.19

Pic. 9.4.5.20



Issue: 1 Rev. No:


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 W1 13-15

J.15.502.03.00

Clamp W1 13-15

J.15.502.03.00

Opaska W1 13-15

Pic. 9.4.5.21

Pic. 9.4.5.22



Issue: 1 Rev. No:


J.15.502.04.00

Clamp W1 13-15

J.15.502.04.00

Clamp W1 13-15

Valve

Pic. 9.4.5.23

Pic. 9.4.5.24



Issue: 1 Rev. No:


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.15.500.09.00, remove the hose and drain the coolant from the system and the tank

Pic. 9.4.5.25



Issue: 1 Rev. No:


o Remove the surge tank assembly bolts

o Remove the surge tank with the clamping ring J.15.250.10.00

the nuts inside the cockpit

Pic. 9.4.5.26

Pic. 9.4.5.27

J.15.250.10.00



Issue: 1 Rev. No:


− Installation of the surge tank o Put the clamping ring on the tank J.15.250.10.00 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.15.500.09.00 to the tank stub pipe

and secure with the clamp W1 13-15 o Fill the coolant to the required level, according to the

operation Manual 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.



Issue: 1 Rev. No:


9.5 AIRFRAME STRUCTURE

9.5.1 DOORS (left door is shown in the picture, right door is symmetrically identical)

9.5.1.1 Rear lock of the door

T.14.206.00.00

T.14.206.00.00

T.14.207.00.00

T.14.207.00.00 T.14.205.04.00

T.14.200.01.00

T.14.200.01.00

Bolt M5x5 DIN 913

Washer Ø5 DIN 1440 Cotter pin Ø1.6 DIN 94

use LOCTITE 262

use LOCTITE 262

Pic. 9.5.1

Pic. 9.5.2



Issue: 1 Rev. No:


9.5.1.2 Upper rear interlock

Bolt M5x5 DIN 913

T.14.200.01.00

Washer Ø5 DIN 1440 Cotter pin Ø1.6 DIN 94

T.14.205.04.00

T.14.206.00.00

T.14.207.00.00

T.14.200.01.00

T.14.208.00.00

Pic. 9.5.3

Pic. 9.5.4



Issue: 1 Rev. No:


9.5.1.3 Front upper lock

T.14.208.00.00

T.14.200.01.00

T.14.208.03.00

use LOCTITE 262

T.14.206.00.00

T.14.205.00.00

Bolt M5x5 DIN 913

Pic. 9.5.6

Pic. 9.5.5



Issue: 1 Rev. No:


T.14.206.00.00

T.14.205.00.00

Bolt M5x5 DIN 913

T.14.205.04.00

Bolt M5x5 DIN 913

T.14.206.00.00

T.14.205.00.00

T.14.205.04.00

use LOCTITE 262

Pic. 9.5.8

Pic. 9.5.7



Issue: 1 Rev. No:


9.5.1.4 Hinge

Cover of the upper hinge

Cover of the lower hinge

T.14.202.01.00

T.14.202.02.00 Bolt M6x20 DIN 912 2 pcs.

Bolt M6x25 DIN 966 Nut M6 DIN 982

Pic. 9.5.10

Pic. 9.5.9



Issue: 1 Rev. No:


T.14.202.02.00

T.14.202.01.00

T.14.202.03.00

Pic. 9.5.11

T.14.202.01.00

T.14.202.02.00

T.14.202.04.00

Pic. 9.5.12



Issue: 1 Rev. No:


9.5.1.5 Door travel limiter

T.14.210.00.00 Nut M5 DIN 1587 Washer Ø5 DIN 1440

Pic. 9.5.14

Pic. 9.5.13

T.14.210.00.00 Nut M5 DIN 1587 Washer Ø5 DIN 1440



Issue: 1 Rev. No:


9.5.1.6 Removal of the doors

1. Remove the hinge covers (Pic. 9.5.9, 9.5.10) 2. Disconnect the door travel limiter T.14.210.00.00 (Pic. 9.5.13) 3. Remove the bolts M6x20 (Pic. 9.5.10) 4. Remove the bolt M6x25 (Pic. 9.5.15) 5. Remove the hinges from the fuselage seats

9.5.1.7 Installation of the door 1. Insert the hinges into the fuselage seats 2. Insert the screw M6x 25 into the upper hinge holeT.14.202.01.00 3. Tighten the nut M6 inside (Pic. 9.5.10) 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.14.210.00.00. secure the nut with

LOCTITE 262.

Pic. 9.5.15

Screw M6x25 DIN 966



Issue: 1 Rev. No:


9.5.2 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.

aircraft kr-030 topaz - ekolottype: kr-030 topaz handling, maintenance and periodic inspections...

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