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DOVA AIRCRAFT DV-1 SKYLARK, Maintenance Manual

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DOVA AIRCRAFT DV-1 SKYLARK Maintenance Manual Download Page 1

 MAINTENANCE MANUAL

FOR

DV-1 SKYLARK  

 Type certificate is registered by LAA ČR under Nb.: ULL 05/2005 amendment ,,A”

Manufacturer: 

DOVA AIRCRAFT, s.r.o.

 

Kirilovova 115 
739 21 Paskov 
Tel./fax: +420 558 671 081, +420 558 671 139 

Number of sheets: 78
Number of attachment: 2 (32 sheets)
Version: 2
Date of release: 31.10. 2011

Serial Nb.:             Nb. of manufacture:             Registration mark: 

Summary of Contents for DV-1 SKYLARK

Page 1: ... ČR under Nb ULL 05 2005 amendment A Manufacturer DOVA AIRCRAFT s r o Kirilovova 115 739 21 Paskov Tel fax 420 558 671 081 420 558 671 139 Number of sheets 78 Number of attachment 2 32 sheets Version 2 Date of release 31 10 2011 Serial Nb Nb of manufacture Registration mark ...

Page 2: ...Aircraft Owner Name Address Matriculation sign Owner change Owner Date of change Name Address Owner change Owner Date of change Name Address Owner change Owner Date of change Name Address 2 ...

Page 3: ...pection after first 25 flight hours 3 5 Periodical inspection after 50 flight hours 3 6 Periodical inspection after 100 flight hours 3 7 Lubrication plan 3 8 Ground handling 3 9 Pre flight inspection maintenance 3 10 After flight inspection maintenance 3 11 Maintenance s entries 3 12 Instruction for installation of brakes with closed hydraulic circuit Filling of brake circuit Brake and brake system cont...

Page 4: ...ge construction In the middle part of the fuselage there is a two pilot s space covered with canopy from one single piece of organic glass Engine compartment is separated with steel firewall from pilots Firewall creates important construction point for the front undercarriage leg engine bed even for the ballistic rescue system Empennages Tail surfaces are designed as T tail Horizontal tail surfaces...

Page 5: ...h metal pull out system The canopy latch is placed in the top of the canopy and it is lock able Ventilate system Ventilation is provided through rounded valve in front of the canopy As an option there are side sliding windows Electrical installation Electrical system is single phase 12V system with negative pole grounded As a source there is a duty free battery and engine alternator Each electrica...

Page 6: ...Previews DV 1 SKYLARK 6 ...

Page 7: ...1 2 BASIC DIMENSIONS AND AIRCRAFT PREVIEW 2288 90 08 2863 112 72 5 1092 42 99 1486 58 49 776 30 56 8136 320 32 1756 69 12 6624 3 260 80 ø1 090 42 92 ø1 620 63 78 1367 53 81 4315 161 89 ...

Page 8: ...m h Stall speed with flaps 64 km h Never exceeded speed 280 km h Maximum horizontal speed 240 km h Cruise speed 210 km h Climb speed 8 m s Ceiling 3 650 m Range 45 min reserve 1 200 km Term of engine overhaul is given as 2000 flight hours or 10 years for ROTAX 912 UL S first reached is valuable See Rotax Bulletins operational condition of engine manufacturer Had to be changed every 5 years air supply...

Page 9: ...mated inspections In case that you will find any sign of rising wear of parts higher friction or backlashes during your pre after flight check call authorized service center flight navigate and engine instruments DV 1 SKYLARK is equipped with 1 6 LIST OF PARTS WITH RESTRICTED LIFETIME Item Basic equipment Air Speed indicator Altimeter Vertical speed indicator Side slip ball Compass Fuel gauges Tachom...

Page 10: ...Item Options Fuel pressure indicator Manifold pressure indicator Artificial horizon Transponder Garmin Ballistic Rescue System Nb Overhaul flight Hours years Date of installation Fl hours years 10 ...

Page 11: ...trols 1 24 10 00 steering rod 1 24 20 00 elevator control 1 24 30 00 rudder front wheel control 1 24 40 00 flap control Empennage 1 30 00 00 empennage 1 31 00 00 horizontal tail surfaces 1 31 10 00 stabilizer 1 31 20 00 elevator 1 32 00 00 vertical tail surfaces 1 32 00 00 fin 1 32 20 00 rudder Undercarriage 1 41 00 00 main undercarriage 1 42 00 00 front undercarriage Fuel tanks 1 51 00 00 fuel tank...

Page 12: ...im position indicator 9 Fuel pressure indicator 10 Oil pressure indicator 11 Head temperature indicator 12 Oil temperature indicator 13 Tachometer 14 Engine operation hours indicator 15 Fuel gauges 2x 16 Diode for indicating failure of battery loading 18 Radio 19 Transponder 20 Fuel valve 21 Master switch 22 Switches 23 Fuses 24 Starter button 25 Magnetos 26 Choke 27 Throttle control 28 Heating co...

Page 13: ...ges on main and rear beam 6 6 peaces on main 2 2 peaces on rear one remove bolts from rear hinges remove bolts from main hinges except 1 1 in upper hinges and except 1 1 in lower hinges one man holds the end of the wing and second one remove upper and lower bolts little up and down movement of wings end is required to release the bolts one man holds the end and second one holds the wing root attac...

Page 14: ...information can be found in Original ROTAX 912 engines manual Oil pressure max 7 bar min 0 8 bar optimum 2 5bar Oil temperature min 50 C max 130 C optimum 90 110 C Cylinders head temperature max 135 C Exhaust gas temperature max 880 C start max 850 C in flight optimum 800 C Fuel pressure max 0 4 bar optimum 0 15 0 4 bar Operational filling for ROTAX 912S Fuel Natural 95 Pb free Engine Oil Castrol GT...

Page 15: ...locks fasteners and removing two screws in front of the cowlings close to the propeller nose Removing of this cowling for the pre after flight check of the engines compartment is required Removing creates easy access to check level of engines liquids like oil and cooling liquid Disassembling of lower part of the cowlings requires disconnecting vent hoses from Naca s inlets and removing of bolts con...

Page 16: ...ual b Propeller inspection after first 5 20 and 50 flight hours see Technical description of the propeller Note To be performed with a newly installed propeller or with the propeller that was dismantled and reinstalled on the airplane c Inspection after the first 25 flight hours engine inspection Inspection after the first 25 flight hours to be performed with the new engine or Caution with the engine af...

Page 17: ...ge check the bolts on lower and upper guide bolt of shock absorber bolt of front wheel and bolts attaching fork to leg Main undercarriage check bolts attaching legs to U C beam check the M12 bolt with plastic washer on the leg check the main wheels nuts Elevator control system check the bolts connections of the control rods with steering angle lever and elevator At same places check the secure nut...

Page 18: ...f necessary of engine s ring and frame bolts Inspection of welded frames for any signs of cracks inspection of rubber shock absorbers between engine s ring and frame Inspection of air filters their attachment to carburetors Inspection of intake pipes Visual inspection of seal installation Inspection of carburetors attachment control cleanness Inspection of wires and cables for undamaged condition t...

Page 19: ... of cooling liquid in system Inspection tightening securing if necessary of engine s ring and frame bolts Damaged hoses need to be replaced Check the oil level in oil tank according to engine s manual Provide inspection of cooler for cleanness seal and undamaged condition Check the cooler attachment for cracks Inspect and tight if necessary all unmovable joints with bolts all moveable joints secur...

Page 20: ...al tail surfaces Inspect condition of composite leg for cracks cranny or holes even for paint damage In case of finding mentioned fault contact the manufacturer Inspect tightening of bolts Check hydraulic brake system for leak Wing Visual inspection for loose rivets skin deformation cracks or other damages Visual inspection of fuel tank for leak Visual inspection Check free noiseless movement Inspe...

Page 21: ...spect proper function of choke control Inspect proper function of throttle control Inspect proper function of propeller control Steering joystick Inspect free noiseless movement Inspect backlashes in the system Inspect securing of bolts Inspect strength of system Inspect securing of bolts Inspection for hydraulic brake system leak Inspection of rudder ropes condition and attachment Made by Checked...

Page 22: ...ncluding fiberglass parts Inspection of fiberglass fairing between fin and fuselage for faultless condition Inspection of fiberglass fairing between wing and fuselage for faultless condition Inspection of ventilation system for proper function and condition Inspection of side windows of fuselage for faultless condition Inspection of proper function and condition of canopy latch Inspection of condition...

Page 23: ...ns Inspection of free noiseless movement Inspection of hinge Flaps Visual inspection for loose rivets deformations cracks and other damages of construction including fiberglass parts Inspection of wing hinges backlashes in fuselage attachment Visual inspection for loose rivets deformations cracks and other damages of construction Visual inspection for loose rivets deformations cracks and other dama...

Page 24: ...Steering joystick Inspection of attaching and securing of horizontal tail surfaces Visual inspection for loose rivets deformations cracks and other damages of construction Inspection of fiberglass ends of stabilizer and its attachment Visual inspection for loose rivets deformations cracks and other damages of construction including fiberglass parts Visual inspection of trim surface s and elevator s ...

Page 25: ...k the system limits conditions Serve control inspection Inspect trim surface position indicator Inspect system backlashes Inspect free noiseless movement Elevator s trim surface control Flap control Equipment Inspect instruments connections and functionality Inspect securing of trim surface hinge pin Verify its completeness and its validity of documentation Verify neutral position of trim surface ...

Page 26: ...ke liquid can be done Main legs condition and attachment inspection Inspect wheel s condition and its attachment Main undercarriage Inspection of undercarriage bolts tightening Inspect the wheel s free and noiseless rotation Inspect wheel s covers conditions and its attachment Verify brake system function Check tires wear conditions and pressure Inspect wheel s disc for any signs of cracks or dama...

Page 27: ...t fuel system for leak of fuel Fuel hoses connections inspection Propeller and engine Fuel filter exchange Inspect condition of fuel pump seek for any signs of cracks and of fuel hoses in engine s compartment Inspect the shock absorbers condition and level of wear Inspect the front wheel disc for any sign of cracks or damages Inspect the front wheel control system and its free movement Inspect the ...

Page 28: ... Inspect the seal status of the system Inspect inlets of pitot static tube for its cleanness and waterless condition Inspect pitot static system for presence of condensate water if so remove it Inspection of pitot static system connections with instruments and their securing Disassembling of engine s cowlings and inspec t their condition for sign of thermal damage cracks or other defects Inspectio...

Page 29: ...ts Inspection of status Inspection of functionality Re calibrate compensation of compass declination NOTES Inspection of thermal exchanger condition and its attachment to exhaust system Check the faultless condition of distribution s hoses Made by Checked by Date Sign Annual periodical inspection after 50 flight hours ...

Page 30: ...including fiberglass parts Inspection of fiberglass fairing between fin and fuselage for faultless condition Inspection of fiberglass fairing between wing and fuselage for faultless condition Inspection of ventilation system for proper function and condition Inspection of side windows of fuselage for faultless condition Inspection of proper function and condition of canopy latch Inspection of conditio...

Page 31: ...ns Inspection of free noiseless movement Inspection of hinge Flaps Visual inspection for loose rivets deformations cracks and other damages of construction including fiberglass parts Inspection of wing hinges backlashes in fuselage attachment Visual inspection for loose rivets deformations cracks and other damages of construction Visual inspection for loose rivets deformations cracks and other dama...

Page 32: ...Steering joystick Inspection of attaching and securing of horizontal tail surfaces Visual inspection for loose rivets deformations cracks and other damages of construction Inspection of fiberglass ends of stabilizer and its attachment Visual inspection for loose rivets deformations cracks and other damages of construction including fiberglass parts Visual inspection of trim surface s and elevator s ...

Page 33: ... the system limits conditions Serve control inspection Inspect trim surface position indicator Inspect system backlashes Inspect free noiseless movement Elevator s trim surface control Flap control Equipment Inspect instruments connections and functionality Inspect securing of trim surface hinge pin Verify its completeness and its validity of documentation Verify neutral position of trim surface I...

Page 34: ...e liquid can be done Main legs condition and attachment inspection Inspect wheel s condition and its attachment Main undercarriage Inspection of undercarriage bolts tightening Inspect the wheel s free and noiseless rotation Inspect wheel s covers conditions and its attachment Verify brake system function Check tires wear conditions and pressure Inspect wheel s disc for any signs of cracks or damag...

Page 35: ...t fuel system for leak of fuel Fuel hoses connections inspection Propeller and engine Fuel filter exchange Inspect condition of fuel pump seek for any signs of cracks and of fuel hoses in engine s compartment Inspect the shock absorbers condition and level of wear Inspect the front wheel disc for any sign of cracks or damages Inspect the front wheel control system and its free movement Inspect the ...

Page 36: ...Inspect the seal status of the system Inspect inlets of pitot static tube for its cleanness and waterless condition Inspect pitot static system for presence of condensate water if so remove it Inspection of pitot static system connections with instruments and their securing Disassembling of engine s cowlings and inspec t their condition for sign of thermal damage cracks or other defects Inspection...

Page 37: ...ts Inspection of status Inspection of functionality Re calibrate compensation of compass declination NOTES Inspection of thermal exchanger condition and its attachment to exhaust system Check the faultless condition of distribution s hoses Made by Checked by Date Sign Annual periodical inspection after 100 flight hours ...

Page 38: ...the area of mounting Landing gear leg in the area of mounting All movable links in the cockpit All movable links in the cockpit Propeller Engine oil Engine oil Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease Pro Long Grease ...

Page 39: ...fix aircraft movement For easy movement on the ground the aircraft is equipped by hangers on sides of fork of front undercarriage leg So you can pull push aircraft through towing rod Remove all covers disconnect anchors in case of parking aircraft outside of hangar and block the wheels On figure above there are checkpoints marked and each point is described in text bellow For providing proper inspec...

Page 40: ...uction checking of free movement locking of each flaps position check hinge line of flaps 7 Main landing gear check pressure of tires check fixation 8 Fuselage Visual check for any damage of construction check antenna status fixation 9 Horizontal Tail surfaces Visual check of construction check the connection to vertical tail surfaces check hinge of elevator and trim surfaces check free movement easy ...

Page 41: ...sed brake circuit for 6 eco power brake wheels Type of brakes Single disc with disc placed in the wheel with single piston brake valve closed hydraulic circuit one main brake cylinder with a 16 mm diameter on the control lever or two 14 mm cylinders on pedals Brake wheel installation Installation the assembly of brake wheels is usually simple and trouble free providing the output diameter and leng...

Page 42: ...lled using a physician s syringe though this filling method is not easy and quality venting of the brake system is not ensured and could lead to impaired brake functionality Filling Place the pressure container hose on the filling screw of the brake valve pos 1 and verify all other filling and venting screws are closed Place the overflow hose on the venting screw of the main brake cylinder The entire ...

Page 43: ...n and increases in the counter clockwise direction Check the purity of the brakes if you experience improper functionality though the adjustment and venting processes were executed properly The brakes shall not come into contact with substances such as lubricants or other greasy substances Remove all other impurities CAUTION The closed brake system is subject to small thermal expansivity during ex...

Page 44: ...authorized service center Only small cracks and cranny of non structural parts can be repaired by you According to type of the defect the damaged area is cut out or just re brushed Paint in close area of repair had to be removed In case of using fiberglass patch use 40 50mm oversized one During overlying the patches apply bonding material at the same time Two layers should be enough For faster dryi...

Page 45: ...levator rudder In case of repair or exchange of undercarriage engine propeller After such changes the flight performances of the aircraft can be different That s why flight test had to be done again It will be rechecked handling and control during start climb cruise stall descend and lading After finishing flight tests the Test Flight Report had to be made Contact local authorized service center or man...

Page 46: ...additions are executed by Bulletins It is owner s duty to write down provided changes to the table Bulletins can be found on manufacturer websites Change Nb Bulletin Nb Bulletin Nb Note Write down by 2008 001 2008 001 1 Wing system L1 11 00 0 Flap backlash check 46 ...

Page 47: ... s part repaired 1 7 Technical description Repaired by Authorized service technician Recorded by Signature 1 Repairs records All kinds of repairs which were done on the aircraft had to be written down archive documentation from repair ...

Page 48: ... controls 1 24 10 00 steering rod 1 24 20 00 elevator control 1 24 30 00 rudder front wheel control 1 24 40 00 flap control Empennage 1 30 00 00 empennage 1 31 00 00 horizontal tail surfaces 1 31 10 00 stabilizer 1 31 20 00 elevator 1 32 00 00 vertical tail surfaces 1 32 00 00 fin 1 32 20 00 rudder Undercarriage 1 41 00 00 main undercarriage 1 42 00 00 front undercarriage Fuel tanks 1 51 00 00 fuel ...

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Page 78: ...Attachement Nb 2 to point 3 13 Instalation with main brake cylinder on steering rod joystick Instalation with main brake cylinder on pedals 78 ...

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