Evector SportStar RTC Maintenance Manual Download

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MAINTENANCE MANUAL

ERTC022-10-AS

Effectivity: All

71-00

Page 71-5

2017-12-22

Edition 2 | Rev. 0

CAUTION

ALL THE DATA NECESSARY FOR ROTAX ENGINE

OPERATION AND HANDLING INSTALLED IN THE

SPORTSTAR RTC AIRCRAFT IS INCLUDED IN THE

ACCOMPANYING DOCUMENTATION PROVIDED BY THE

ENGINE MANUFACTURER, AS AMENDED. IF THERE IS

ANY DISCREPANCY BETWEEN THIS MANUAL AND THE

DATA PROVIDED BY THE ENGINE MANUFACTURER, THE

ENGINE MANUFACTURER´S DATA AND VALUES ARE

VALID. THE EXCEPTION IS THE MAXIMUM TEMPERATURE

OF CYLINDER HEADS THAT HAS BEEN REDUCED (128 °C /

262 °F), COMPARED TO THE DATA PROVIDED BY THE

ENGINE MANUFACTURER.

TROUBLESHOOTING

Defects, their possible causes and their elimination are discussed in Chapter 4.7 of the Operators

Manual for Rotax Engine Type 912 Series, doc. No. OM-912, 899649.

Summary of Contents for SportStar RTC

Page 1: ...Issue 02 of this manual is approved by the manufacturer under the DOA privilege EASA 21J 057 on 26 1 2018 Copyright 2017 EVEKTOR spol s r o Airplane manufacturer EVEKTOR AEROTECHNIK a s 686 04 Kunovi...

Page 2: ......

Page 3: ...TC Illustrated Parts Catalogue Doc No SPORTSTAR 0396G 02172 00 Operators Manual for Rotax Engine Type 912 Series Ref No OM 912 Part No 899649 Maintenance Manual Line Maintenance for Rotax Engine Type...

Page 4: ...ERTC022 10 AS MAINTENANCE MANUAL 01 00 Page 01 4 2017 12 22 Effectivity All Edition 2 Rev 0 Intentionally Left Blank...

Page 5: ...al primary construction with some composite parts The power plant standardly consists of four cylinder four stroke Rotax 912 ULS2 or S2 engine and on ground adjustable three bladed composite propeller...

Page 6: ...ERTC022 10 AS MAINTENANCE MANUAL 01 10 Page 01 6 2017 12 22 Effectivity All Edition 2 Rev 0 Intentionally Left Blank...

Page 7: ...ktor cz http www evektorairplane cz 2 ENGINE MANUFACTURER BRP Powertrain GmbH Co KG Welser Strasse 32 A 4623 Gunskirchen Austria http www flyrotax com 3 PROPELLER MANUFACTURER Woodcomp s r o Vodolsk 4...

Page 8: ...ERTC022 10 AS MAINTENANCE MANUAL 01 20 Page 01 8 2017 12 22 Effectivity All Edition 2 Rev 0 Intentionally Left Blank...

Page 9: ...onsidered to be important 4 EQUIPMENT LIST Refer to the Supplement No 1 Equipment List Doc No ERTC 020 10 AS 001 of the Pilot s Operating Handbook for SportStar RTC for actual equipment 5 SOURCE TO PU...

Page 10: ...installed Switch off the ignition switch and master switch prior performing maintenance or repair Do not eat drink smoke and do not use open flame while working on an airplane When starting the engin...

Page 11: ...ication Specification for Light Sport Aeroplanes CT Coolant Temperature EASA European Aviation Safety Agency EIS Engine Information System EGT Exhaust Gas Temperature ELT Emergency Locator Transmitter...

Page 12: ...e OHV Overhead Valve R Right PC Polycarbonate PE Polyethylene foil PFD Primary Flight Display POH Pilot Operating Handbook P N Part Number PMMA Polymethylmethacrylate PP Polypropylen P S Pitot static...

Page 13: ...01 40 2019 03 22 01 7 2019 03 22 01 41 2017 12 22 01 8 2017 12 22 01 42 2017 12 22 01 9 2017 12 22 01 10 2017 12 22 01 11 2019 03 22 01 12 2017 12 22 01 13 2017 12 22 01 14 2019 03 22 01 15 2017 12 22...

Page 14: ...2019 03 22 05 12 2019 03 22 05 48 2017 12 22 05 13 2019 03 22 05 14 2019 03 22 05 15 2017 12 22 05 16 2019 03 22 05 17 2017 12 22 05 18 2017 12 22 06 06 1 2019 03 22 05 19 2017 12 22 06 2 2017 12 22...

Page 15: ...11 2017 12 22 08 5 2017 12 22 10 12 2017 12 22 08 6 2017 12 22 08 7 2017 12 22 08 8 2017 12 22 08 9 2017 12 22 08 10 2017 12 22 08 11 2017 12 22 11 11 1 2017 12 22 08 12 2017 12 22 11 2 2017 12 22 11...

Page 16: ...17 12 22 20 14 2017 12 22 12 10 2017 12 22 20 15 2017 12 22 12 11 2017 12 22 20 16 2017 12 22 12 12 2017 12 22 12 13 2017 12 22 12 14 2017 12 22 12 15 2017 12 22 12 16 2017 12 22 12 17 2017 12 22 21 2...

Page 17: ...4 8 2019 03 22 23 16 2017 12 22 24 9 2019 03 22 23 17 2017 12 22 24 10 2019 03 22 23 18 2017 12 22 24 11 2019 03 22 23 19 2017 12 22 24 12 2019 03 22 23 20 2017 12 22 24 13 2019 03 22 23 21 2017 12 22...

Page 18: ...17 12 22 24 41 2019 03 22 25 28 2017 12 22 24 42 2019 03 22 25 29 2017 12 22 24 43 2019 03 22 25 30 2017 12 22 24 44 2019 03 22 25 31 2017 12 22 24 45 2019 03 22 25 32 2017 12 22 24 46 2019 03 22 25 3...

Page 19: ...2 22 27 19 2017 12 22 27 55 2017 12 22 27 20 2017 12 22 27 56 2017 12 22 27 21 2017 12 22 27 57 2017 12 22 27 22 2017 12 22 27 58 2017 12 22 27 23 2017 12 22 27 24 2017 12 22 27 25 2017 12 22 27 26 20...

Page 20: ...017 12 22 31 11 2017 12 22 28 27 2017 12 22 31 12 2017 12 22 28 28 2017 12 22 31 13 2017 12 22 28 29 2017 12 22 31 14 2017 12 22 28 30 2017 12 22 31 15 2017 12 22 28 31 2017 12 22 31 16 2017 12 22 28...

Page 21: ...22 32 18 2017 12 22 32 54 2019 03 22 32 19 2017 12 22 32 55 2019 03 22 32 20 2017 12 22 32 56 2019 03 22 32 21 2017 12 22 32 57 2019 03 22 32 22 2017 12 22 32 58 2019 03 22 32 23 2017 12 22 32 59 201...

Page 22: ...12 22 33 26 2019 03 22 34 33 2017 12 22 33 27 2019 03 22 34 34 2017 12 22 33 28 2019 03 22 34 35 2017 12 22 34 36 2017 12 22 34 34 1 2017 12 22 34 37 2017 12 22 34 2 2017 12 22 34 38 2017 12 22 34 3 2...

Page 23: ...2017 12 22 56 5 2017 12 22 56 6 2017 12 22 56 7 2017 12 22 61 61 1 2017 12 22 56 8 2017 12 22 61 2 2017 12 22 56 9 2017 12 22 61 3 2017 12 22 56 10 2017 12 22 61 4 2019 03 22 56 11 2017 12 22 61 5 201...

Page 24: ...2017 12 22 74 10 2017 12 22 71 11 2019 03 22 71 12 2019 03 22 71 13 2019 03 22 71 14 2019 03 22 71 15 2017 12 22 71 16 2017 12 22 75 75 1 2017 12 22 71 17 2017 12 22 75 2 2017 12 22 71 18 2017 12 22 7...

Page 25: ...17 12 22 77 4 2017 12 22 78 7 2017 12 22 77 5 2017 12 22 78 8 2017 12 22 77 6 2017 12 22 78 9 2017 12 22 77 7 2017 12 22 78 10 2017 12 22 77 8 2017 12 22 77 9 2017 12 22 77 10 2017 12 22 77 11 2017 12...

Page 26: ...12 22 79 26 2017 12 22 91 31 2017 12 22 91 32 2019 03 22 91 33 2017 12 22 91 34 2017 12 22 91 35 2017 12 22 91 36 2017 12 22 91 91 1 2017 12 22 91 37 2017 12 22 91 2 2017 12 22 91 38 2017 12 22 91 3 2...

Page 27: ...3 22 91 101 2017 12 22 91 66 2019 03 22 91 102 2019 03 22 91 67 2017 12 22 91 103 2019 03 22 91 68 2017 12 22 91 104 2017 12 22 91 69 2017 12 22 91 105 2019 03 22 91 70 2017 12 22 91 106 2019 03 22 91...

Page 28: ...ERTC022 10 AS MAINTENANCE MANUAL 01 50 Page 01 34 2017 12 22 Effectivity All Edition 2 Rev 0 Chapter Page Date Chapter Page Date...

Page 29: ...nual Added R 912 S engine TBO of propellers increased to 72 months added EPS rocket check every 6 years Changed title of Bulletin corrected Flight hours tole rance per 50 hours added capacity test of...

Page 30: ...control pull rod Changed color of signaling lamp added information con cernings P S tube heating signalization with G3X system Added new GoldFren parking brake valve corrected length of S5 20 01 01 pu...

Page 31: ...tervals and or maintenance requirements for parts of the airplane systems and structures determined to be life limited and or parts which require monitoring of the schedule maintenance NOTE All time l...

Page 32: ...ngine Rotax 912 S 1200 hours or 10 years whichever comes first X Up to and including S N 4 922 776 1500 hours or 12 years whichever comes first From S N 4 922 777 up to and including S N 4 923 889 200...

Page 33: ...the unit of ELT Kannad Integra AF 7 years X Additional information about the service life is provided in Operation Manual AF INTEGRA AF H INTEGRA ELT With built in GPS Integral Antenna Doc No DOC0907...

Page 34: ...2 Effectivity All Edition 2 Rev 0 C Structure restrictions 1 The service life of the airframe is 7 000 flight hours 2 The initial service life of the airframe 2 100 flight hours applies to airplane S...

Page 35: ...s 05 6 Scheduled maintenance 05 20 05 7 1 Responsibility of owner or operator 05 7 2 Inspection minimum requirements 05 7 3 Inspection tolerances 05 7 4 Inspection intervals 05 9 5 Engine inspections...

Page 36: ...2 2017 12 22 Effectivity All Issue 2 Rev 0 6 Exceeding of engine propeller limitations 05 47 A Exceeding of engine limitations 05 47 B Exceeding of propeller limitations 05 47 7 Airplane immersing 05...

Page 37: ...ent 2 INSPECTION PROGRAM The manufacturer inspection program has been developed to enable an owner or operator to accomplish requested inspections and maintenance with Civil Aviation Authorities regul...

Page 38: ...Emergency Procedures changes in the time limits and content maintenance tasks that have an impact on safety The issue of this bulletin is always followed by the issuance of an Airworthiness Directive...

Page 39: ...e that all service bulletins which are pertinent to his particular operation are complied with 2 INSPECTION MINIMUM REQUIREMENTS The described requirements on inspections accomplishment must be unders...

Page 40: ...ERTC022 10 AS MAINTENANCE MANUAL 05 20 Page 05 8 2017 12 22 Effectivity All Issue 2 Rev 0 Fig 05 1 Description and application of inspection tolerances...

Page 41: ...eriod can be exceeded by 5 hours at maximum on condition that the above exceeding will be used only to finish the flight which started before the 100 hours were reached or for a flight intended to rea...

Page 42: ...sion and any other apparent damage STRUCTURAL FASTENERS lnspect for correct torque in accordance with applicable torque values when visual inspection indicates the need for a torque check FILTERS SCRE...

Page 43: ...that the replacement of these parts is made within the pre scribed time limits 05 30 Check the time limits of all scheduled special inspections Check the implementation of all Airworthiness Directive...

Page 44: ...ocks for condition replace those cracked and excessively deformed Engine air intake 71 60 MML 912 Check air filter for condition attachment and security impure filter clean acc to the engine manual re...

Page 45: ...eck and tighten hose clamps as required 12 10 Check coolant quantity in the expansion tank add or change coolant as required 75 00 Check overflow bottle for condition and attachment Oil system 79 10 C...

Page 46: ...acc to the engine maintenance manual Propeller UM 05 07 EN Do the maintenance acc to the propeller manual 3 NOSE LANDING GEAR Nose landing gear leg 32 20 Check nose landing gear leg for condition and...

Page 47: ...airplane Main landing gear legs 32 10 Check fiberglass legs for condition cracks repaint damaged areas Contact airplane manufacturer if cracks were found 32 10 Check leg attachment into the fuselage...

Page 48: ...02 brakes or 2 54 mm Matco brakes 32 42 Check brake disc for condition wear and overheating Min admissible thickness of brake disc is 3 2 mm S5 10 03 01 S5 10 03 02 brakes or 3 3 mm Matco brakes 12 1...

Page 49: ...ake system for leaks add brake fluid as required Wing flap control 27 50 Check control lever for free movement 27 50 Check operation of flap control lever lock push button 10 OPERATIONAL TEST 33 40 33...

Page 50: ...tools and instruments used during the inspection 12 20 Lubricate all items according to the lubrication chart 25 10 Install upholstery and seats 06 40 Install and close all covers and hatches Do the...

Page 51: ...tank add or change coolant as required Oil system 79 20 Check oil cooler for condition attachment and leaks 79 20 Check hoses for condition leaks attachment and security 12 10 Check oil quantity add...

Page 52: ...landing gear legs 32 10 Check fiberglass legs for condition cracks repaint damaged areas Contact airplane manufacturer if cracks were found 32 10 Check joints for tightening and security Tires 12 10 C...

Page 53: ...ontrol lever lock push button 9 FINISHING WORKS Check the completeness of tools and instruments used during the inspection 12 20 Lubricate all items according to the lubrication chart 06 40 Install an...

Page 54: ...e with valid regulations max 24 months 25 60 ELT AK 451 check function 1 month 25 60 ELT Kannad AF Integra check function 6 months 25 60 ELT Artex ME406 check function 12 months 12 10 Replace the brak...

Page 55: ...27 Check control brackets and bellcranks for condition 27 50 Check wing flaps control for condition 27 50 Check wing flaps for play 4 POWER PLANT AND ENGINE COPMARTMENT 71 10 Check quick closing lock...

Page 56: ...ondition and attachment Ch 27 Check control pulleys and levers for condition 27 20 Check rudder cables for condition Ch 28 Check fuel system hoses tubes and other fuel system plants for condition 7 TA...

Page 57: ...3 Ref Prescribed works Made by Checked by 1 GENERAL PREPARATORY WORKS 06 40 Remove an open all required covers and hatches 07 10 Jack the airplane 08 30 Do the airplane leveling contact airplane manuf...

Page 58: ...tion and free movement Ch 23 Ch 34 Check individual instruments and COMM NAV equipment for condition and attachment 4 FUSELAGE 53 10 53 30 Check fuselage structure skin for condition especially in the...

Page 59: ...rd 57 51 57 52 Check ailerons and wing flaps structure skin for condition 57 51 57 52 Check ailerons and wing flaps hinges for condition and free movement Ch 27 Check control brackets and bellcranks f...

Page 60: ...an open all required covers and hatches 2 COCKPIT Ch 27 Check all control systems for function and free movement Ch 27 Check control stops for condition and security 27 20 Check stops at rudder contro...

Page 61: ...eck ailerons and wing flaps structure skin for condition 57 51 57 52 Check ailerons and wing flaps hinges for condition and free movement Ch 27 Check control brackets and bellcranks for condition 27 5...

Page 62: ...e detected during inspection In most cases the damage is obvious In some cases however hidden damage may result Expected mechanical damage of a lightning strike On metallic skin eroded metal and local...

Page 63: ...ture along this path should be carefully inspected 06 40 Remove an open all required covers and hatches 2 POWER PLANT AND ENGINE COPMARTMENT Engine cowlings 71 10 Check cowlings for condition and evid...

Page 64: ...evidence of damage Exhaust system 78 10 Check exhaust pipes for condition and evidence of damage 78 20 21 40 Check muffler and heat exchanger for condition and evidence of damage Engine MML 912 Do th...

Page 65: ...40 Check rudder attachment for condition 9 COCKPIT 76 10 Check throttle and choke levers for free movement 25 60 Check emergency parachute and rocket for contidion Instrument panel Ch 23 Ch 34 Check...

Page 66: ...ck function Check all instruments for function 61 20 Propeller governor CS 3 5 and propeller KW 31 check function Radiocommunication and radionavigation equipment check function 10 FINISHING WORKS Che...

Page 67: ...MMERSING Do the following procedure when the airplane has been immersed Dry and clean the interior exterior of the airplane Clean engine compartment Remove the engine Section 71 00 and follow instruct...

Page 68: ...ERTC022 10 AS MAINTENANCE MANUAL 05 50 Page 05 48 2017 12 22 Effectivity All Issue 2 Rev 0 Intentionally Left Blank...

Page 69: ...le Section Page Airplane 3 View Drawing 06 10 06 3 Dimensions and Areas 06 20 06 5 1 External dimensions 06 5 2 Wing 06 5 3 Ailerons 06 5 4 Flaps 06 5 5 Horizontal Tail Units 06 5 6 Vertical Tail Unit...

Page 70: ...ERTC022 10 AS MAINTENANCE MANUAL 06 TOC Page 06 2 2017 12 22 Effectivity All Edition 2 Rev 0 Intentionally Left Blank...

Page 71: ...MAINTENANCE MANUAL ERTC022 10 AS Effectivity All 06 10 Page 06 3 2019 03 22 Edition 2 Rev 1 AIRPLANE 3 VIEW DRAWING Figure 06 1 3 view drawing of the airplane SportStar RTC page 1 of 2...

Page 72: ...ERTC022 10 AS MAINTENANCE MANUAL 06 20 Page 06 4 2019 03 22 Platnost V echny letouny Edition 2 Rev 1 Figure 06 1 3 view drawing of the airplane SportStar RTC page 2 of 2...

Page 73: ...hown in Figure 06 2 Legends of these figures include description of attachment of the lids covers and the areas which can be accessed after they are open removed If the legend of the figure does not i...

Page 74: ...ERTC022 10 AS MAINTENANCE MANUAL 06 40 Page 06 8 2019 03 22 Effectivity All Edition 2 Rev 1 2 LIST OF COVERS AND LIDS ON THE AIRPLANE Figure 06 2 Lids and covers on the airplane...

Page 75: ...R Cover on the wing lower surface for access to the aileron control rods W4L W4R Cover on the wingtip lower surface for access to the venting hose of the fuel tank W5L W5R Cover on the wing lower surf...

Page 76: ...ERTC022 10 AS MAINTENANCE MANUAL 06 40 Page 06 10 2019 03 22 Effectivity All Edition 2 Rev 1 Intentionally Left Blank...

Page 77: ...Black R inner side of the cockpit in front of the ventilation window airplane equipped with the KW 31 033 propeller 11 2 1 Black R inner side of the cockpit in front of the ventilation window airplane...

Page 78: ...of the instrument panel above COM NAV block 11 2 9 Black white Bulkhead of the area behind the baggage compartment 11 2 10 Black white Central panel below the controls of ventilation heating and prehe...

Page 79: ...a behind the baggage compartment 11 2 16 Black white Central panel at the emergency hammer 11 2 17 Black Baggage compartment on the fire extinguisher 11 2 18 Black Engine compartment on the brake flui...

Page 80: ...ignalling light 11 2 27 Black white L part of the instrument panel at the generator signalling light 11 2 28 Black white Central part of the instrument panel above the throttle handle 11 2 29 Black wh...

Page 81: ...he above specified layout of the placards applies to the standard design of the airplane it may vary depending on the installed equipment 37 Black white R part of the instrument panel at circuit break...

Page 82: ...ding on the installed equipment 40 Black Relay behind the instrument panel 41 Black Fuse holder behind the instrument panel 42 Black Fuse holder behind the instrument panel 43 Black L part of the inst...

Page 83: ...nel at circuit breakers and circuit breakers 11 2 NOTE The above specified layout of the placards applies to the standard design of the airplane it may vary depending on the installed equipment 51 Bla...

Page 84: ...e instrument panel above the switch 11 2 57 Black white L part of the instrument panel at circuit breakers and circuit breakers 11 2 NOTE The above specified layout of the placards applies to the stan...

Page 85: ...MAINTENANCE MANUAL ERTC022 10 AS Effectivity All 11 30 Page 11 17 2017 12 22 Edition 2 Rev 0 Fig 11 2 Interior placards and markings page 1 of 2...

Page 86: ...ERTC022 10 AS MAINTENANCE MANUAL 11 30 Page 11 18 2019 03 22 Effectivity All Edition 2 Rev 1 Fig 11 2 Interior placards and markings page 2 of 2...

Page 87: ...ubbles do not form tighten the valve plug or replace it f Attach the dustcap g Remove the wheel blocks C Filling of the brake system 1 Brake fluid check refilling Refilling of the brake fluid is neces...

Page 88: ...en both marks 2 S5 00 61 01 Matco brake system the brake fluid level must be approximately 6 mm from the top of the brake fluid expansion tank c Release the parking brake d Put the hose from transpare...

Page 89: ...e a Align the airplane in a horizontal position Section 08 10 b Remove the upper engine cowling Section 71 10 c Remove cap from the brake fluid tank 9 Fig 12 1 d Unscrew the brake hoses on brake cylin...

Page 90: ...onmental influences and variable load You must monitor these points during periodical inspections and preflight inspections and lubricate them as often as circumstances require but at least in specifi...

Page 91: ...X MOGUL MOLYKA G foreign lubricants Two armed aileron control levers inside the wing X MOGUL MOLYKA G foreign lubricants Hinge joint of rods under the wing fillet X MOGUL MOLYKA G foreign lubricants F...

Page 92: ...splay cleaner Sponge Brush A Cleaning of the airplane surface The exterior surface of the airplane especially leading edges of wings and the propeller must be kept clean in order to maintain the fligh...

Page 93: ...cleaner It is dangerous for electrical installation and crankshaft seals Oxidation of various elements may cause a malfunction of the engine After each cleaning use air flow to clean all electrical i...

Page 94: ...replace it d Check the fuel tank bleeding e Check attachment of wings ailerons flaps and tail units lubricate in accordance with the Lubricating Chart 2 Engine Do procedures mentioned in the Operators...

Page 95: ...Battery IBBS 12v 3ah 24 9 I Socket for 12 V appliances 24 10 2 Maintenance practices 24 11 A Generator 24 11 B Generator rectifier 24 11 C Auxiliary generator 24 13 D Auxiliary generator regulator 24...

Page 96: ...ERTC022 10 AS MAINTENANCE MANUAL 24 TOC Page 24 2 2019 03 22 Effectivity All Edition 2 Rev 1 2 Maintenance practices 24 44 A Switches 24 44 B Circuit breakers 24 45...

Page 97: ...the aircraft is of a single wire DC type It works with a voltage of 14 V and the negative pole on the airframe Optionally the electrical system can be equipped with the auxiliary generator or the ext...

Page 98: ...ERTC022 10 AS MAINTENANCE MANUAL 24 00 Page 24 4 2019 03 22 Effectivity All Edition 2 Rev 1 Fig 24 1 Source system without auxiliary generator...

Page 99: ...MAINTENANCE MANUAL ERTC022 10 AS Effectivity All 24 00 Page 24 5 2019 03 22 Edition 2 Rev 1 Fig 24 2 Source system with auxiliary generator...

Page 100: ...ERTC022 10 AS MAINTENANCE MANUAL 24 00 Page 24 6 2019 03 22 Effectivity All Edition 2 Rev 1 Fig 24 3 Source system with eaternal alternator...

Page 101: ...m The values of voltage and current of the electrical system are indicated on the EMS screen of the Dynon SkyView system or on the EIS screen of the G3X system The sensor of electrical current a shunt...

Page 102: ...of the rectifier Type electronical Output voltage 14 0 4 V Weight 0 59 kg E External alternator The F3A external alternator can be optionally installed on the airplane The alternator is mounted on the...

Page 103: ...0 3 9 6 10 3 FG12200 20 1 0 10 5 20 10 1 85 10 5 18 5 5 3 45 10 5 17 25 1 13 4 9 6 13 4 Table 24 1 Battery discharging G Battery SV BAT 320 The standby battery SV BAT 320 serves for feeding the Dynon...

Page 104: ...THE BATTERY BY USING AN EXTERNAL BATTERY CHARGER DIRECTLY CONNECTED TO THE INPUT OF THE BATTERY I Socket for 12 V appliances The socket for 12 V appliances is located in the right lower corner of the...

Page 105: ...move the engine cowlings Section 71 10 c Disconnect the connector 2 from the rectifier 1 Fig 24 4 d Unscrew and remove the nuts 8 and the washers 7 from the rear part of the firewall 10 e Unscrew the...

Page 106: ...All Edition 2 Rev 1 Legend to Fig 24 4 1 Generator rectiofier 7 Washer 5 3 2 Connector 8 Nut M5 3 Capacitor 9 Cable tie 4 Holder of capacitor 10 Spacing insert 5 Wire with cable eye For information 6...

Page 107: ...ck After pressing down the safety lock it is possible to take it out from the socket e Unscrew and remove the nuts 4 and the washers 5 of the generator attachment 1 on the propeller gearbox 8 f Remove...

Page 108: ...4 14 2019 03 22 Effectivity All Edition 2 Rev 1 Legend to Fig 24 5 1 Auxiliary generator 5 Washer 2 Cable 6 Rubber cover of contact 3 Regulator connector 7 Hose fastener 4 Nut 8 Propeller gearbox Fig...

Page 109: ...Note down the position of individual wires on the terminal strip d Unscrew the nuts 6 of the regulator attachment 1 on the firewall 8 remove the washers 5 remove the eye of the ground wire 3 and remo...

Page 110: ...22 Effectivity All Edition 2 Rev 1 Legend to Fig 24 6 1 Auxiliary generator regulator 6 Nut M5 2 Wires 7 Terminal strip of regulator 3 Ground wire For information 4 Screw M5 8 Firewall 5 Washer 5 3 Fi...

Page 111: ...fter pressing down the safety lock it is possible to take it out from the socket d Loosen the bolts 6 8 15 and release the belt 11 e Unscrew and remove the bolt 6 and the washers 9 10 f Hold the alter...

Page 112: ...ev 1 Legend to Fig 24 7 1 External alternator 9 Lock washer 2 Cable 10 Washer 8 4 3 Nut M5 11 V belt 4 Washer 6 For information 5 Connector 12 Bracket 6 Bolt M10x45 13 Tension bar 7 Washer 10 1 14 V b...

Page 113: ...elt with a force of 50 N the deflection can be max 6 mm see Fig 24 8 If the deflection is larger tension the belt 1 Loose the bolts 2 3 4 2 Press the alternator 1 upwards and tighten the bolt 4 3 Tigh...

Page 114: ...move the V belt 2 f As necessary remove the V belt pulley 1 Unscrew and remove the screws 4 with the washers 5 2 Remove the V belt pulley 1 and two pulley carrier plates 3 2 Installation external alte...

Page 115: ...71 10 j Connect the battery switch the electrical network on k Start the engine do the engine test and check engine parameters Legend to Fig 24 9 1 V belt pulley 4 Screw M5x16 8 pcs 2 V belt 5 Lock wa...

Page 116: ...uld cause a damage of the equipment or could cause a damage to the health e Connect the screws to the end terminals correctly otherwise a sparking could occur or the terminals could be damaged f It is...

Page 117: ...capacity is higher Too high temperature may cause a reduction of the battery service life The ideal operating temperature of the battery is between 20 to 25 C If the airplane isn t in the operation m...

Page 118: ...the screw 2 2 Remove the washers 4 and 5 3 In a suitable way insulate the cable end 4 In the same way disconnect the cable 3 of the positive pole d Cut the lockwire of the lock of buckle 6 or turnbuck...

Page 119: ...nect he battery contacts to the cables 3 At first connect the positive cable to the positive pole of the battery 1 1 Position the cable eye of the cable 3 marked as plus to the positive pole of the ba...

Page 120: ...the batteries Fig 24 11 Charging characteristics of battery at constant voltage 6 Inspection check battery FG Forte a Visually check the battery 1 Appearance of the battery terminals connectors event...

Page 121: ...ectrical network off and disconnect the battery b Remove the cover of the upper part of fuselage F4 Section 53 30 c Disconnect the connector 2 Fig 24 12 from the harness d Unscrew and remove the nuts...

Page 122: ...indicates other status than CHARGED charge the battery After switching on the display the battery is charged automatically if the voltage of the network is higher than 12 5 V A partly discharged batt...

Page 123: ...emoval battery IBBS 12v 3ah a Switch the electrical network off and disconnect the battery b Remove the cover of the upper part of fuselage F4 Section 53 30 c Disconnect the connector 2 Fig 24 13 from...

Page 124: ...2019 03 22 Effectivity All Edition 2 Rev 1 Legend to Fig 24 13 1 Battery IBBS 12v 3ah 5 Washer 4 3 4 pcs 2 Wires with connector For information 3 Screw M4x10 4 pcs 6 Bracket 4 Nut M4 4 pcs 7 Bracket F...

Page 125: ...from the airplane s electrical network before the next flight To charge the battery it is necessary to provide 13 9 14 V onboard voltage J Socket for 12 V appliances Maintenance type Line Personnel qu...

Page 126: ...4 30 Page 24 32 2019 03 22 Effectivity All Edition 2 Rev 1 Legend to Fig 24 14 1 Socket body 5 Cap 2 Nut For information 3 Wire with connector 6 Instrument panel 4 Wire with Faston connector Fig 24 14...

Page 127: ...e procedure of installation and removal is typical for all relays 1 Removal relay 12 V 30 A a Switch the electrical network off and disconnect the battery b Remove the cover of the upper part of fusel...

Page 128: ...on 2 Rev 1 Legend to Fig 24 15 1 Relay 12 V 30 A 8 Wire with cable eye 2 Wire with connector 9 Screw M5 3 Screw M4 10 Nut M5 4 Washer 4 3 11 Washer 5 3 5 Nut M4 12 Screw 6 Relay 12 V 75 A For informat...

Page 129: ...ect the connectors 7 e Unscrew and remove the nuts 10 with the washers 11 f Slide out the screws 9 and remove the relay 6 4 Installation relay 12 V 75 A a Position the relay 6 Fig 24 15 on the bracket...

Page 130: ...ehind the firewall After opening the socket cap it is possible to connect the 12 V ground source of electrical energy provided with the corresponding plug Piper The external power source connection is...

Page 131: ...ANUAL ERTC022 10 AS Effectivity All 24 40 Page 24 37 2019 03 22 Edition 2 Rev 1 Fig 24 16 Source system with socket for ground source of electrical energy NOTE Fig 24 16 supplements Fig 24 1 Fig 24 2...

Page 132: ...e upper part of fuselage F4 Section 53 30 c Unsolder the positive pole of the cable 3 Fig 24 17 d Unscrew the nuts 5 remove the washers 6 and the eye of ground cable 2 e Slide out the screws 4 and rem...

Page 133: ...40 Page 24 39 2019 03 22 Edition 2 Rev 1 Legend to Fig 24 17 1 Socket 5 Nut M8 2 Cable of electrical bonding 6 Washer 8 4 3 Cable For information 4 Screw M8 9 Right side skin of fuselage Fig 24 17 So...

Page 134: ...TCH Switches on off the avionics power supply TURN IND Switches on off the turn indicator HORIZON Switches on off the attitude horizon DIR GYRO Switches on off the directional gyro BEACONS Switches on...

Page 135: ...ircuit breakers are permanently switched on The sequence of the circuit breakers in the tables shows the typical installation of the circuit breakers for the airplanes equipped with analog instruments...

Page 136: ...erator AUX GEN FIELD 5 Circuit breaker of auxiliary generator excitation BEACONS 7 5 Circuit breaker of strobe lights POS LIGHTS 2 Circuit breaker of position lights LDG LIGHT 4 Circuit breaker of lan...

Page 137: ...FD 5 Circuit breaker of MFD display MFD 5 Circuit breaker of PFD display ADAHRS 1 2 Circuit breaker of main ADAHRS unit ADAHRS 2 2 Circuit breaker of backup ADAHRS unit EMS 2 Circuit breaker of EIS un...

Page 138: ...witches is identical for the type 1 PST 2 PST and as well as for the illuminated rocker switches type R13 66 and S7 68 72 01 1 Removal switches a Switch the electrical network off and disconnect the b...

Page 139: ...screwdriver 1 pc Wrench No 14 1 pc NOTE Removal installation procedure of circuit breakers 2TC2 and ETA is similar 1 Removal circuit breakers a Switch the electrical network off and disconnect the bat...

Page 140: ...vity All Edition 2 Rev 1 Legend to Fig 24 19 1 Circuit breaker 2TC2 7 Screw 2 Circuit breaker ETA 8 Spring washer 3 Holder of circuit breakers 9 Spring washer 4 Nut 10 Spring washer 5 Nut 11 Spring wa...

Page 141: ...RAL 1 INTRODUCTION The equipment and furnishings of the airplane includes the seats for the crew safety harnesses baggage compartment interior panels carpets on the airplane cabin floor and emergency...

Page 142: ...e switches which afford three levels of heating The thermostat maintains an optimal temperature that automatically turns on and off the heating according to the preset heating level Both switches are...

Page 143: ...safety harness protect it against moisture dirt or other unwanted material Keep it protected untiul the visual inspection and return of the safety harness to the operation b Mechanical parts WARNING...

Page 144: ...seat 1 Fig 25 3 the upholstery is attached with Velcro fasteners b As necessary remove the handgrip of the parking brake valve Section 32 42 c Valid for the original version of the control rod covers...

Page 145: ...e board network and disconnect the battery b Before you remove the ledges of the instrument panel remove the ignition switch Section 74 30 throttle and choke control Section 76 10 and the emergency pa...

Page 146: ...by bolts 5 c Align the ledge 3 with the instrument panel and attach if by the nuts 7 with washers 9 d Between the instrument panel angle and the ledge 3 insert the circuit breakers panel and attach th...

Page 147: ...e carpet 1 in the baggage compartment is attached with Velcro fasteners to the floor You can access the baggage compartment after you tilt the cockpit canopy Maximum baggage weight is mentioned on the...

Page 148: ...ition of the switch on the control panel is ARM when the transmitter is ready for an automatic activation The ELT operation starts automatically switch on the unit in the ARM position when the ELT is...

Page 149: ...h is used to extinguish fire Fire protection is provided by a hand fire extinguisher mounted in the cockpit Passive fire protection is provided as follows On the inner surface of the engine cowlings i...

Page 150: ...fire extinguisher 1 Fig 26 1 mounted within a quick release holder 5 attached on the bulkhead 4 separating the cockpit and baggage compartment In a new version the extinguisher 1 is located on the lef...

Page 151: ...cover 6 2 Installation hand fire extinguisher a Position the fire extinguisher 1 Fig 26 1 in the holder 2 cover 6 b Secure with quick release clamps 3 Velcro fasteners 5 on the straps 3 Inspection che...

Page 152: ...2019 03 22 Effectivity All Edition 2 Rev 1 Legend to Fig 26 1 1 Hand fire extinguisher 4 Bulkhead 2 Holder 5 Strap with Velcro fasteners 3 Strap with quick release clamp 6 Left control rod cover Fig...

Page 153: ...g of elevator 1 pc Check of the play in the control system Blocking of ailerons 1 pc Check of the play in the control system WARNING NON OBSERVANCE OF PRESCRIBED DEFLECTIONS OF CONTROL SURFACES WING F...

Page 154: ...the pull rod The checking needle or mandrel with a diameter capable of passing through the check hole must always hit the threaded part of end piece Fig 27 2 Item Drawing No Length of Pull Rod mm Adju...

Page 155: ...rator failure Applies only to the airplanes with an auxiliary generator CANOPY red Unsecured cockpit canopy Applies only to the airplanes with analog instrumentation EMS red Exceeding of the engine li...

Page 156: ...d in the left section of the instrument panel For the wiring diagram of the optical signalization refer to Chapter 91 Legend to Fig 31 7 1 Signaling light CHARGING 6 Signaling light PITOT HEAT 2 Signa...

Page 157: ...the screwed fasteners The parking brake valve 9 is incorporated in the brake system The airplane can be equipped with the Matco or GoldFren parking brake valve The parking brake serves for braking th...

Page 158: ...e sliding movement that is necessary for the brake function By depressing the brake pedal the pressure in the brake fluid is generated that is led from the brake pump through the plastic hoses to the...

Page 159: ...and remove the spring 5 c Unscrew the cap 2 d Slide out the piston 3 with the U collar 6 e As needed remove the inlet screw fitting from the body 1 f Remove the sealing rings 8 and 9 5 Assembling brak...

Page 160: ...mps 1 2 3 Obr 32 16 into the forks 10 on the intermediate shaft of the foot control b Insert the pins 4 into the corresponding holes Put the washers 6 on the pins 10 and secure them by the new cotter...

Page 161: ...22 Edition 2 Rev 0 Legend to Fig 32 15 1 Brake pump E5 10 40 01 7 Fork pin 2 Brake pump E5 10 40 02 8 Swivel nut 3 Brake pump S5 20 40 01 9 Hose 4 Pin 5x20 10 Intermediate shaft fork 5 Washer 5 3 11...

Page 162: ...2 46 2019 03 22 Effectivity All Edition 2 Rev 1 Legend to Fig 32 16 1 Pump body 6 Ring U 2 Cap 7 Fork with pin 3 Piston 8 Sealing ring 6x12 4 Securing nut 9 Sealing ring 7 3x2 4 5 Spring Fig 32 16 Bra...

Page 163: ...17 1 Brake pump body 9 Spring 2 Piston 10 Fork with pin 3 Cylinder closure 11 Locking ring 4 Securing nut 12 Sealing ring 4x2 5 Piston 13 Sealing ring 7 3x2 4 6 Brake cylinder packing 14 Sealing ring...

Page 164: ...4 6 6 pcs Cotter pin 1 6x12 8 pcs 2 pcs per pupm 1 Removal brake a Lift the airplane Section 07 10 b Remove the main wheels Section 32 41 remove the brake disk c Disconnect the hose from the brake 1 F...

Page 165: ...Page 32 53 2017 12 22 Edition 2 Rev 0 Legend to Fig 32 20 1 Brake pump 6 Washer 6 4 2 Pin 5x20 7 Angular connection 3 Washer 5 3 8 Hose 4 Cotter pin 1 6x12 9 Intermediate shaft fork 5 Pin 6x20 10 Peda...

Page 166: ...the washers 11 and the nut 10 i Unscrew and remove the nuts 10 washers 13 22 and remove the valve 5 j Remove the screws 7 21 and at the Matco valve also the washers 13 16 2 Installation parking brake...

Page 167: ...MAINTENANCE MANUAL ERTC022 10 AS Effectivity All 32 42 Page 32 55 2019 03 22 Edition 2 Rev 1 Fig 32 21 Parking brake valve removal installation page 1 of 2...

Page 168: ...Personnel qualification Independent verification personnel qualified in accordance with Part 66 or higher Recommended tools and material Item Designation Size Quantity Note Wrench No 4 1 pc Flat scre...

Page 169: ...91 c Cover the joints by the shrinkable hose and carefully warm it up using the gun d Adjust the mutual position of the switch and the lever 1 In the area opened the switch must be mechanically conne...

Page 170: ...58 2019 03 22 Effectivity All Edition 2 Rev 1 Legend to Fig 32 22 1 Switch For information 2 Screw M2x12 2 pcs 6 Bracket 3 Nut M2 2 pcs 7 Bracket 4 Washer 2 2 4 pcs 8 Lever 5 Wires Fig 32 22 Switch o...

Page 171: ...ockpit lighting 33 5 B Controlled power source 33 7 C PWM dimmer 33 8 Exterior 33 40 33 10 1 Description and operation 33 10 A 90340 series positon strobe lights 33 10 B Orion 600 series positon anti...

Page 172: ...ERTC022 10 AS MAINTENANCE MANUAL 33 00 Strana 33 2 2017 12 22 Platnost V echny letouny Vyd n 2 Rev 0 Intentionally Left Blank...

Page 173: ...stem of interior optionally and exterior lighting is installed on the SportStar RTC airplane The interior lighting includes the cockpit lighting which includes the instrument lighting and the instrume...

Page 174: ...IT LIGHT to control the lamp This switch is located in the row of switches All the switches on the instrument panel have integrated internal illumination The instrument lighting and switches are switc...

Page 175: ...he cockpit canopy equipped with the sunshade c Slightly pull the wires from the bushing 5 and remove the shrinkable tubes d Use the soldering iron to disconnect the wires e Unscrew the screws 4 and re...

Page 176: ...INTENANCE MANUAL 33 10 Page 33 6 2019 03 22 Effectivity All Edition 2 Rev 1 Legend to Fig 33 1 1 Lamp 4 Screw M3x16 2 pcs 2 Wires 5 Bushing 3 Guide rail 6 Middle column Fig 33 1 Cockpit lighting remov...

Page 177: ...iver 1 pc Phillips screwdriver No 2 1 pc Wrench No 7 1 pc 1 Removal controlled power source a Switch the electrical network off and disconnect the battery b Remove the cover of the fuselage upper part...

Page 178: ...Part 66 or higher Recommended tools and material Item Designation Size Quantity Note Flat screwdriver 1 pc Phillips screwdriver No 2 1 pc Wrench No 11 1 pc 1 Removal PWM dimmer a Switch the electrica...

Page 179: ...E MANUAL ERTC022 10 AS Effectivity All 33 10 Page 33 9 2019 03 22 Edition 2 Rev 1 Legend to Fig 33 3 1 PWM dimmer 4 Wire 2 Knob For information 3 Nut 5 Instrument panel Fig 33 3 PWM dimmer removal ins...

Page 180: ...h POS LIGHTS to switch the position lights on Use the switch BEACONS to switch the strobe lights on The two switches are located in the row of switches B Orion 600 series positon anti collision lights...

Page 181: ...RTC022 10 AS Effectivity All 33 40 Page 33 11 2019 03 22 Edition 2 Rev 1 Legend to Fig 33 4 1 Left position and strobe light 3 Landing taxi light 2 Right position and strobe light 4 Taxi light Fig 33...

Page 182: ...Shrinkable tube 3x1 mm Cleaning agent Technical benzine Sealant Transparent sanitary silicone Lint free cloth NOTE The removal installation procedures for left and right lights are identical 1 Remova...

Page 183: ...lashtube 3 Fig 33 5 with seal 10 into the light body 1 b Put the flashtube cover 2 including the lens 4 on the light body attach and tighten the screws 9 c Connect the connector with wires 13 to the h...

Page 184: ...OTE Refer to the wiring diagram in Chapter 91 c Cover the joints with a shrinkable tube and carefully heat it with a heat gun d Put the connector with wires 13 into the holes in the wingtip 14 align t...

Page 185: ...eakage through the glass tube of the flashtube or around the seal of the wire on the glass This leakage is caused by rapid heating when the normally operating system of the strobe lights is switched o...

Page 186: ...crew 6 32 5 16 2 pcs 2 Flashtube cover 10 Seal 3 Flashtube 11 Screw M4x16 3 pcs 4 Flashtube lens 12 Wires of the front pos light 5 Lens of the front light 13 Connector with wires 6 Seal 14 Wires of th...

Page 187: ...partment floor c Remove the baggage compartment floor IN3 Fig 06 2 d Disconnect the connectors with wires 2 Fig 33 6 from the power source 1 NOTE The power source removal must be performed by two pers...

Page 188: ...the electrical network on and check function of the strobe lights Legend to Fig 33 6 1 Power source of the lights 5 Washer 4 3 4 pcs 2 Connector with wires 6 Grounding wire 3 Screw M4x16 4 pcs For inf...

Page 189: ...nect the battery b Remove the cover W4L or W4R Fig 06 2 c Disconnect the connector with wires 8 Fig 33 7 from the harness d Carefully unscrew the screws 7 and remove the retainer 2 CAUTION DO NOT TOUC...

Page 190: ...TICAL PERFORMANCE OF THE LEDS e Put the lens 4 on the body 1 f Align the retainer 2 with the body 1 and lens 3 and attach it with screws 7 g Connect the connector with wires 8 to the harness h Use the...

Page 191: ...2017 12 22 Edition 2 Rev 0 Legend to Fig 33 7 1 Light body 6 Screw M3x16 3 pcs 2 Retainer 7 Screw 2 56 3 16 2 pcs 3 Baseplate 8 Connector with wires 4 Lens For information 5 Screw 4 40 5 16 3 pcs 9 Wi...

Page 192: ...witch the electrical network off and disconnect the battery b Remove the light cover W8L Fig 06 2 c Unscrew the bolts 17 Fig 33 8 and remove the cover 16 d Remove the nut 9 washer 10 bolt 8 and slight...

Page 193: ...MAINTENANCE MANUAL ERTC022 10 AS Effectivity All 33 40 Page 33 23 2017 12 22 Edition 2 Rev 0 Fig 33 8 Landing taxi light removal installation page 1 of 2...

Page 194: ...leveling point NiB 2 is approx 980 mm from the floor b Remove the light cover W8L Fig 06 2 remove the bolts 17 Fig 33 8 and remove the cover 16 c Put the test jig 7810E2550001 in front of the airplan...

Page 195: ...cation personnel qualified in accordance with Part 66 or higher Recommended tools and material Item Designation Size Quantity Note Test jig 7810E2550001 1 pc Light adjustment Jig with magnifier 7910S7...

Page 196: ...attach it with bolts 4 nuts 5 and washers 6 d Connect wires with the connector 2 to the harness e Put the light including the bracket 3 on the bracket 7 and attach it with the bolt 8 nut 9 and washer...

Page 197: ...switch TAXI LIGHT on 2 Use the adjusting screws 8 12 to set vertical and horizontal position of the light so that the cone of light falls on the centre of the crosshair on the test jig 3 Repeat steps...

Page 198: ...r 2 pcs 2 Wires with connector 12 Bolt M6x45 2 pcs 3 Bracket 13 Nut M6 2 pcs 4 Bolt M4x12 4 pcs 14 Washer 6 4 2 pcs 5 Nut M4 4 pcs 15 Washer 6 1 2 pcs 6 Washer 4 3 8 pcs 16 Cover 7 Bracket 17 Bolt M4x...

Page 199: ...ANUAL ERTC022 10 AS Effectivity All 61 00 Page 61 3 2017 12 22 Edition 2 Rev 0 GENERAL 1 INTRODUCTION SportStar RTC airplane may be equipped with Woodcomp Klassic 170 3 R propeller or Woodcomp KW 31 0...

Page 200: ...issue B Woodcomp KW 31 033 propeller Woodcomp Klassic KW 31 033 is a three blade right hand electrically adjustable propeller with rated diameter 1726 mm The propeller may operate either in manual co...

Page 201: ...i Install the engine cowlings Section 71 10 j Connect the battery switch the electrical network on k Start the engine do the engine test and check engine parameters Legend to Fig 61 1 1 Propeller 6 W...

Page 202: ...he inspections of the propeller refer to the document User Manual Klassic 170 3 Aircraft propeller Doc No UM 07 EN date of issue 01 09 2015 or later valid issue 4 Approved repairs Klassic 170 3 R prop...

Page 203: ...ers on the propeller blades and put it in a horizontal position on a pad which supports the spacer 2 Installation KW 31 033 propeller CAUTION WHEN INSTALL THE PROPELLER MAKE SURE THAT THE CARBON BRUSH...

Page 204: ...d function of the propeller Section 61 20 Legend to Fig 61 3 1 Propeller 4 Engine flange 2 Nut M8 6 pcs 5 Carbon brush 3 Bushing 6 pcs Fig 61 3 KW 31 033 propeller removal installation 3 Check inspect...

Page 205: ...ctual engine speed compares the value with pre set value and keeps the actual engine speed within pre set tolerance The propeller is operated in constant speed mode manual pilot controls the propeller...

Page 206: ...SPEED MANUAL Use the mode selector to switch between automatic mode and manual mode Value setting control knob Turn the control knob to scroll through the menu and adjust the values RPM INC DEC In man...

Page 207: ...ling 71 10 71 11 1 Description and operation 71 11 2 Maintenance practices 71 12 A Engine cowlings 71 12 Mounts 71 20 71 15 1 Description and operation 71 15 2 Maintenance practices 71 18 A Engine mou...

Page 208: ...ERTC022 10 AS MAINTENANCE MANUAL 71 TOC Page 71 2 2017 12 22 Effectivity All Edition 2 Rev 0 Intentionally Left Blank...

Page 209: ...a mechanical fuel pump Mixture charging atmospheric pressure The recommended kinds of fuel are shown in Section 12 00 The engine is started electrically using a starter 12 V 0 7 kW The engine is equip...

Page 210: ...r 29 73 PSI Oil temperature Max 130 C 266 F Min 50 C 120 F Operational 90 110 C 190 230 F Exhaust gas temperature 880 C 1616 F Cylinder head temperature max 128 C 262 F Output temperature of coolant c...

Page 211: ...S AMENDED IF THERE IS ANY DISCREPANCY BETWEEN THIS MANUAL AND THE DATA PROVIDED BY THE ENGINE MANUFACTURER THE ENGINE MANUFACTURER S DATA AND VALUES ARE VALID THE EXCEPTION IS THE MAXIMUM TEMPERATURE...

Page 212: ...Workshop crane 1 pc Load capacity min 250 kg Suspension straps 3 pcs Load capacity min 250 kg WARNING BEFORE STARTING THE WORK COOL DOWN THE ENGINE UP TO THE AMBIENT TEMPERATURE NON COMPLIANCE WITH T...

Page 213: ...exhaust system Section 78 20 o Disconnect and close the fuel inlet hoses Section 28 20 p Disconnect and close the oil system hoses Section 79 20 q Disconnect the hoses of the engine cooling system in...

Page 214: ...1 Install the bolts 1 for suspending the engine mount 11 to the attachments on the firewall Section 71 20 2 Tighten the bolts using a torque of 23 Nm 3 Secure the bolts by means of lockwire Section 20...

Page 215: ...MAINTENANCE MANUAL ERTC022 10 AS Effectivity All 71 00 Page 71 9 2017 12 22 Edition 2 Rev 0 Fig 71 1 Engine removal installation page 1 of 2...

Page 216: ...22 Effectivity All Edition 2 Rev 0 Legend to Fig 71 1 1 Bolt 4 pcs 7 Washer 2 pcs 2 Washer 2 2 pcs 8 Crane 3 Cup 2 2 pcs 9 Straps 4 Silent block 8 pcs 10 Engine 5 Insert 4 pcs 11 Engine mount 6 Washe...

Page 217: ...y a semielliptical cut out located in the rear part of the cowling The exhaust pipe and the engine drains also lead to this hole The upper part of the engine cowling is provided on the left side with...

Page 218: ...er engine cowling 1 remove the released engine cowling 1 from the airplane c Remove the screws 3 with the washers 5 that attach the liquid cooler to the lower cowling of the engine 2 d Remove the scre...

Page 219: ...MAINTENANCE MANUAL ERTC022 10 AS Effectivity All 71 10 Page 71 13 2019 03 22 Edition 2 Rev 1 Fig 71 2 Engine cowlings removal installation page 1 of 2...

Page 220: ...4 2019 03 22 Effectivity All Edition 2 Rev 1 Legend to Fig 71 2 1 Upper engine cowling 4 Screw M4x12 4 pcs 2 Lower engine cowling 5 Polyamide washer 3 7 12 pcs 3 Screw M4x16 4 pcs 6 Camlock Fig 71 2 E...

Page 221: ...e eyes of attachments are modified for the installation of silent blocks The engine mount is attached by means of screws through the silent blocks to the attachments on the firewall The tube frames ru...

Page 222: ...ERTC022 10 AS MAINTENANCE MANUAL 71 20 Page 71 16 2017 12 22 Effectivity All Edition 2 Rev 0 Fig 71 3 Engine mount page1 of 2...

Page 223: ...all 11 Cup 4 Screw 12 Washer 5 Screw 13 Locking washer 6 Safety plug 14 Cotter pin 7 Silent block 15 Bracket for attachment of exhaust pipe muffler 8 Washer Fig 71 3 Engine mount page 2 of 2 NOTE The...

Page 224: ...the engine from the aircraft Section 71 00 put the engine in a suitable place in order to prevent from its damaging b Remove the cotter pins 5 Fig 71 4 c Remove the safety plugs 2 d Remove the screws...

Page 225: ...ty All 71 20 Page 71 19 2017 12 22 Edition 2 Rev 0 Legend to Fig 71 4 1 Engine mount 4 Locking washer 2 Safety plug 5 Cotter pin 3 Screw of suspension 6 Bracket for attachment of exhaust pipe muffler...

Page 226: ...ape and is equipped with the flanges for connection to the carburettors inlet necks for cold and hot air and with the regulation flaps located in the inlet necks The inlet of cold air is designed as t...

Page 227: ...MAINTENANCE MANUAL ERTC022 10 AS Effectivity All 71 60 Page 71 21 2019 03 22 Edition 2 Rev 1 Legend to Fig 71 5 1 Upper engine cowling 2 Lower engine cowling Fig 71 5 Air inlets...

Page 228: ...illips screwdriver No 2 1 pc Air filter ROTAX P N 825 750 1 pc Wrench No 7 1 pc Wrench No 8 1 pc Wrench No 10 1 pc Hex key No 5 1 pc Flat screwdriver 1 pc 1 Servicing air filter replacement a Switch t...

Page 229: ...aching the hoses 19 and 20 to the airbox 1 pull down the hoses from the outlets on the airbox 1 e Remove the nut 35 and remove the washer 34 connecting the silent block 5 with the strut of the airbox...

Page 230: ...t drain sump isn t shown for better clarity it is a mirror image of the left one d Connect the drain hoses 17 and 18 to the airbox outlets 1 by means of the clamps 22 e Connect the air hoses 8 and 9 t...

Page 231: ...RTC022 10 AS Effectivity All 71 60 Page 71 25 2017 12 22 Edition 2 Rev 0 o Install the engine cowlings Section 71 10 p Connect the battery switch the electrical network on Fig 71 7 Airbox removal inst...

Page 232: ...lation flap of airbox 19 Venting hose of carburettor 39 Bracket of bowden cable 20 Venting hose of carburettor Fig 71 7 Airbox removal installation page 2 of 2 4 Removal carburettor preheating control...

Page 233: ...of the string 3 and secure it by means of the screw 7 f Check the function of the carburettor preheating control Legend to Fig 71 8 1 Handle 6 Washer 8 4 2 Terminal 7 Screw M3x4 3 Bowden string with t...

Page 234: ...burettors with the outlets on the front upper part of the airbox The condensate sumps are installed under the carburettors These sumps serve also as a heat shield of carburettors The condensate sumps...

Page 235: ...d Remove the clamps 11 for attachment of the hoses 12 and 13 of the airbox drains 1 e Using the nippers cut the cable ties 16 f Pull down the hoses 12 and 13 from the outlets on the airbox 1 g In the...

Page 236: ...mount 10 Condensate sump of R carburettor 3 Strut 11 Cobra clamp 4 Venting hose of L carburettor 12 Left drain hose of airbox 5 Venting hose of R carburettor 13 Right drain hose of airbox 6 Lockwire 1...

Page 237: ...ity All 79 10 Page 79 7 2017 12 22 Edition 2 Rev 0 Legend to Fig 79 2 1 Oil tank 5 Venting hose 2 Clamp 140 160 6 Clamp Rotax 853725 3 Hose to oil pump 7 Clamp 14 7 4 Return hose from engine 8 Firewal...

Page 238: ...e cowlings are installed on the airplane Section 71 10 the airplane is equipped with a smaller oil cooler which is only attached by means of the brackets to the firewall The thermostat is installed in...

Page 239: ...ttery b Remove the engine cowlings Section 71 10 c Drain the oil Section 12 10 d Valid for the original version of the cooler installation 1 Unscrew and remove the nut 9 Fig 79 3 washer 10 bolt 8 and...

Page 240: ...uspension on the cooler and attach it by means of the bolt 10 nut 9 and the washer 10 2 Screw the screw fittings 3 on the reductions and tighten them 3 Fill the system with oil Section 12 10 4 Do the...

Page 241: ...MAINTENANCE MANUAL ERTC022 10 AS Effectivity All 79 20 Page 79 11 2019 03 22 Edition 2 Rev 1 Fig 79 3 Oil cooler removal installation page 1 of 2...

Page 242: ...m Designation Size Quantity Note Wrench No 10 1 pc Wrench No 8 1 pc NOTE If the oil cooler P N 886027 is installed the cooler strut is not mounted 1 Removal cooler strut a Switch the electrical networ...

Page 243: ...age 91 1 2017 12 22 Edition 2 Rev 0 CHAPTER 91 CHARTS WIRING DIAGRAMS TABLE OF CONTENTS Title Section Page General 91 00 91 3 1 Introduction 91 3 Wiring diagrams 91 10 91 4 1 List of wiring diagrams 9...

Page 244: ...ERTC022 10 AS MAINTENANCE MANUAL 91 TOC Page 91 2 2017 12 22 Effectivity All Edition 2 Rev 0 Intentionally Left Blank...

Page 245: ...agrams covers interconnection of the components instruments and electronic systems on the SportStar RTC airplane The wiring diagram contain the name of part of the electricity system identification nu...

Page 246: ...ctifier capacitor E7 68 20 01 1 Avionics switch E7 68 99 01 1 Garmin GPS Aera 500 Airgizmos E7 86 10 01 1 SL40 PM3000 GTX328 A30 E7 88 30 01 2 Strobe lights Whelen LED 90340 E7 91 10 01 1 Landing ligh...

Page 247: ...Chronometer Mitchell S7 40 01 01 1 Clock SC 5 S7 40 02 01 1 Canopy closing signalization ver G3X S7 47 10 01 1 Flaps closing signalization ver G3X S7 47 11 01 1 Signalization parking brake S7 47 60 0...

Page 248: ...g No Sheets Strobe lights Whelen LED Orion 600 NVFR S7 91 01 99 1 Taxi light Whelen LED 71141 NVFR S7 91 10 99 1 Landing light Whelen LED 71141 NVFR S7 91 11 99 1 Cockpit light S7 99 51 01 1 Cockpit l...

Page 249: ...MAINTENANCE MANUAL ERTC022 10 AS Effectivity All 91 10 Page 91 7 2017 12 22 Edition 2 Rev 0 A Standard equipment...

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