Ekolot KR-030 TOPAZ Handling, Maintenance And Periodic Inspections Manual Download

Page: 1 / 189

Manufacturer: PPHU
EKOLOT
Type: KR-030 TOPAZ

Handling, maintenance and periodic inspections

manual

Issue: 1
Rev. N

Date: July 2010
Date:

Page
1

HANDLING, MAINTENANCE AND PERIODIC

INSPECTIONS MANUAL

AIRCRAFT

KR-030 TOPAZ

SERIAL NUMBER:

30 - ..…. - …...

Summary of Contents for KR-030 TOPAZ

Page 1: ...HU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 1 HANDLING MAINTENANCE AND PERIODIC INSPECTIONS MANUAL AIRCRAFT KR 030 TOPAZ SE...

Page 2: ...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 SYSTE...

Page 3: ...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...

Page 4: ...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 Attachmen...

Page 5: ...eans 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 part...

Page 6: ...ed 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...

Page 7: ...ter 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...

Page 8: ...U EKOLOT Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 8 Pic 8 1 Placing the wing on the fuselage Pic 8 2 Installation of mounting pins...

Page 9: ...rer PPHU EKOLOT Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 9 Pic 8 3 Flaps drive connection Pic 8 4 Ailerons drive connection to the...

Page 10: ...Inspections Manual Issue 1 Rev No Date July 2010 Date Page 10 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...

Page 11: ...Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 11 Pic 8 7 Bolts for fixing elevator unit to the fuselage Pic 8 8 Connecting of elevator...

Page 12: ...udder 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 mou...

Page 13: ...ement 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 poss...

Page 14: ...er 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...

Page 15: ...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 0...

Page 16: ...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...

Page 17: ...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...

Page 18: ...2010 Date Page 18 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 8 Nut M8 DIN...

Page 19: ...ctions Manual Issue 1 Rev No Date July 2010 Date Page 19 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 Bo...

Page 20: ...T Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 20 2 Move the fairing upward along the pole 3 Unscrew the shock absorbers mounting bolt...

Page 21: ...HU EKOLOT Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 21 4 Unscrew the rocker mounting bolts 5 Remove the wheel and the rocker Pic 9...

Page 22: ...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 Ins...

Page 23: ...aintaining 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 4 through the hole 5 in the po...

Page 24: ...Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 24 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 0 0 U...

Page 25: ...KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 25 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 t...

Page 26: ...Nut M8 DIN 982 J 13 610 08 00 J 13 610 07 00 J 13 611 00 00 J 13 620 00 0 1 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...

Page 27: ...Date Page 27 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 ulmtechnolog...

Page 28: ...ce and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 28 9 2 4 Removal of wheel from the axle 1 Remove the fairing unscrew the retaining bolts remove the fairing 2 Remove the 4 bo...

Page 29: ...l 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 u...

Page 30: ...p 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...

Page 31: ...andling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 31 9 2 8 Removal of the spring 1 Perform point 3 of the procedure 9 2 7 2 Detach the brake hose from the spr...

Page 32: ...l Issue 1 Rev No Date July 2010 Date Page 32 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 th...

Page 33: ...Date July 2010 Date Page 33 9 3 CONTROL SYSTEM 9 3 1 Rudder control system 1 2 3 4 5 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 Interme...

Page 34: ...Date July 2010 Date Page 34 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 6H7 22 Nut M6 DIN 93...

Page 35: ...5 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 6 DIN 1440 Washer 6 DIN 1440 Use LOCTITE 262 Use LOCTITE 603 Use LOCTITE 603 Use L...

Page 36: ...d Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 36 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 sli...

Page 37: ...PAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 37 The left side view J 12 630 00 01 Nut M6 DIN 937 Washer 6 DIN 9021 Cotter pin 1 6 DIN 94 J 12 621 00...

Page 38: ...Date July 2010 Date Page 38 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 6 DIN 9021 Nut M6 DIN 937 Cotter pin...

Page 39: ...No Date July 2010 Date Page 39 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...

Page 40: ...Manufacturer PPHU EKOLOT Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 40 1 2 3 T 12 630 00 01 Pic 9 3 13 Pic 9 3 14...

Page 41: ...m 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...

Page 42: ...31 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...

Page 43: ...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...

Page 44: ...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 botto...

Page 45: ...Manufacturer PPHU EKOLOT Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 45 Pic 9 3 18 Pic 9 3 19...

Page 46: ...Manufacturer PPHU EKOLOT Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 46 Pic 9 3 20 Pic 9 3 21 J 12 642 02 02...

Page 47: ...AILERONS CONTROL SYSTEM A D C 1 2 3 4 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...

Page 48: ...enance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 48 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 P...

Page 49: ...ntenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 49 T 12 120 00 03 T 12 122 00 00 J 12 122 00 00 J 12 210 08 02 Nut M6 DIN 937 Cotter pin 1 6 DIN 94 Nut M6 DIN 937 Cott...

Page 50: ...50 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 6 DIN 1440 T 12 121 00 01 T 12 120 00 03 Cotter pin 2...

Page 51: ...riodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 51 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 ho...

Page 52: ...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 6 DIN 1440...

Page 53: ...riodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 53 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...

Page 54: ...ndling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 54 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 M4x1...

Page 55: ...e Page 55 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...

Page 56: ...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...

Page 57: ...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...

Page 58: ...Manufacturer PPHU EKOLOT Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 58 Pic 9 3 39...

Page 59: ...TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 59 Pic 9 3 41 Pic 9 3 40 T 12 125 00 00 T 12 125 00 00 Blind rivet 4 with steel stem 3 pcs use LOCTI...

Page 60: ...LOT Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 60 Pic 9 3 43 Pic 9 3 42 T 12 125 00 00 Bolt M6x15 DIN 912 Washer 6 DIN 1440 T 12 125...

Page 61: ...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 ac...

Page 62: ...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...

Page 63: ...te Page 63 1 Propeller assembly 2 Remove the engine cowling Using a flat head screwdriver turn all cam locks of the upper cowling by 90 angle Upper cowling Bottom cowling J 15 000 01 00 M8x100 8 8 DIN...

Page 64: ...EKOLOT Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 64 Remove the upper cowling Disconnect the landing lamp connector Connector Pic 9...

Page 65: ...TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 65 Using a flat head screwdriver turn all cam locks of the bottom cowling by 90 angle Remove the bot...

Page 66: ...ling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 66 3 Remove the spinner J 15 000 01 00 Remove the spinner mounting bolts M4x16 6 pcs Remove the spinner J 15 00...

Page 67: ...intenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 67 4 Remove the propeller Using a box end wrench 13 mm and Allen wrench 6mm unscrew the hub mounting bolts M8x100 6 pc...

Page 68: ...Date July 2010 Date Page 68 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 c...

Page 69: ...ate July 2010 Date Page 69 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 th...

Page 70: ...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...

Page 71: ...ce and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 71 6 Disconnect the electrical connector Remove the safety wire from the connector Undo the nut in the bottom part of the con...

Page 72: ...72 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 th...

Page 73: ...Issue 1 Rev No Date July 2010 Date Page 73 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 f...

Page 74: ...osen 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...

Page 75: ...s Manual Issue 1 Rev No Date July 2010 Date Page 75 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...

Page 76: ...Rev No Date July 2010 Date Page 76 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...

Page 77: ...tions Manual Issue 1 Rev No Date July 2010 Date Page 77 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 dra...

Page 78: ...ntenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 78 13 Remove the plastic clamps of pipes and control cables 14 Sling the engine on a crane of safe working load 200 kg...

Page 79: ...79 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 st...

Page 80: ...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 remov...

Page 81: ...EKOLOT Type KR 030 TOPAZ Handling Maintenance and Periodic Inspections Manual Issue 1 Rev No Date July 2010 Date Page 81 Do the same on the firewall Rubber ring J 14 000 06 00 Magneto cables Pic 9 4...

Page 82: ...nual Issue 1 Rev No Date July 2010 Date Page 82 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 lef...

Page 83: ...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 th...

Page 84: ...5 255 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...

Page 85: ...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...

Page 86: ...t C B A K K Z Z Z Z Diagram of the cables travel J 12 430 00 03 J 12 440 00 03 between the levers J 12 410 00 03L J 12 410 00 03P and the intermediate bracket J 12 420 00 03 A left lever J 12 410 00 0...

Page 87: ...ol 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 41...

Page 88: ...88 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...

Page 89: ...9 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...

Page 90: ...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 d...

Page 91: ...talled 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 c...

Page 92: ...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...

Page 93: ...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...

Page 94: ...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 F...

Page 95: ...anual Issue 1 Rev No Date July 2010 Date Page 95 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 re...

Page 96: ...PAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 96 3 Removal of the left additional fuel tank Loosen the hose clamp on the fuel pipe and remove the pip...

Page 97: ...c inspections manual Issue 1 Rev No Date July 2010 Date Page 97 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...

Page 98: ...PPHU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 98 Lift the additional tank and remove the hose clamp from the overflow hose...

Page 99: ...KOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 99 Remove the additional fuel tank Hose clamp W1 Overflow hose Overflow hose Pic 9...

Page 100: ...c inspections manual Issue 1 Rev No Date July 2010 Date Page 100 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...

Page 101: ...c inspections manual Issue 1 Rev No Date July 2010 Date Page 101 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 moun...

Page 102: ...periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 102 Lift the additional tank loosen the hose clamp of the overflow pipe and cut the no fuel sensor electric cable Remove the additi...

Page 103: ...dic inspections manual Issue 1 Rev No Date July 2010 Date Page 103 5 Removal of the sediment bowl Remove the hose clamps from the drain pipes of the additional tanks and remove the pipes from the tank...

Page 104: ...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 fusel...

Page 105: ...spections manual Issue 1 Rev No Date July 2010 Date Page 105 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 0...

Page 106: ...wl 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 th...

Page 107: ...n 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...

Page 108: ...KOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 108 Remove the fuel pipes from the fuel valve Clamp W1 13 15 Clamp W1 13 15 Pic 9 4...

Page 109: ...d 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...

Page 110: ...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...

Page 111: ...tenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 111 Remove the pump from the fuselage 10 Removal of the fuel pressure sensor Disconnect the connector J 15 400 16 00 Nut...

Page 112: ...ons manual Issue 1 Rev No Date July 2010 Date Page 112 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 fuse...

Page 113: ...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 cl...

Page 114: ...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 4 DIN 1440 and nuts M4 DIN 982 J 15 440 01...

Page 115: ...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 dia...

Page 116: ...cture 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 pressu...

Page 117: ...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 co...

Page 118: ...030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 118 Using a paper band tape the fairing and then draw a line on it at 35 mm distance from wing s...

Page 119: ...HU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 119 Using a small electric saw cut the fairing along the marked line Pic 9 4 3...

Page 120: ...Manufacturer PPHU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 120 Pic 9 4 3 47 Pic 9 4 3 48...

Page 121: ...tions manual Issue 1 Rev No Date July 2010 Date Page 121 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...

Page 122: ...rer PPHU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 122 Unsolder the electrical wires Heat shrinkable tubing Pic 9 4 3 51 Pic...

Page 123: ...U EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 123 Remove the hose clamps AML 12 from a rubber pipe Hose clamp AML12 Pic 9 4 3...

Page 124: ...ic inspections manual Issue 1 Rev No Date July 2010 Date Page 124 Pull out the ventilation pipe from a rubber pipe Remove rubber pipe from a sensor ferrule and pull out from the electrical wires Lever...

Page 125: ...Manufacturer PPHU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 125 Pic 9 4 3 57 Pic 9 4 3 58...

Page 126: ...126 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 wh...

Page 127: ...ate July 2010 Date Page 127 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 pip...

Page 128: ...spections manual Issue 1 Rev No Date July 2010 Date Page 128 Slide over the rubber sector on the aluminium tube Make sure that the electrical wires are not damaged in the process Secure the rubber sec...

Page 129: ...spections manual Issue 1 Rev No Date July 2010 Date Page 129 Protect the end of the rubber sector along with the electrical wires by using preparation LOCTITE 5922 Put on the heat shrinkable tubing on...

Page 130: ...OPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 130 Solder the electrical wires and secure it with heat shrinkable tubing by heating it up Heat shrink...

Page 131: ...KOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 131 Wrap already soldered electrical wires with spiral casing Spiral casing Pic 9 4...

Page 132: ...manual Issue 1 Rev No Date July 2010 Date Page 132 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...

Page 133: ...30 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 133 Glue the straps and plates to the internal fairing surface in the way shown below Fairing Plat...

Page 134: ...ntenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 134 Apply the already cut off upper part of a faring on the lower one and holding them both together drill four opening...

Page 135: ...acturer PPHU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 135 Use screw tap M4 to tap the drilled openings Pic 9 4 3 77 Pic 9 4...

Page 136: ...maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 136 Put on the upper part of the fairing right on to the lower part and protect the place of contact by using adhesi...

Page 137: ...EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 137 Secure the fairing by using four M4x10 DIN 7985 screws Adhesive foil Pic 9 4...

Page 138: ...Manufacturer PPHU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 138 Pic 9 4 3 83 Pic 9 4 3 84...

Page 139: ...ats 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 pu...

Page 140: ...Manufacturer PPHU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 140 Pic 9 4 3 85 Pic 9 4 3 86 Band clip W1...

Page 141: ...e 141 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...

Page 142: ...EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 142 Unscrew upper bolts fastening fuel tank with luggage rack Pic 9 4 3 89 Pic 9...

Page 143: ...T Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 143 Unscrew a lower bolt fastening bracket with a fuel tank 15 410 13 01L Pic 9 4 3 91...

Page 144: ...iodic inspections manual Issue 1 Rev No Date July 2010 Date Page 144 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 an...

Page 145: ...TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 145 Undo a hose clamp on the overflow pipe and slide down the pipe from a ferrule Foto 9 4 3 94 Pic...

Page 146: ...odic inspections manual Issue 1 Rev No Date July 2010 Date Page 146 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 a...

Page 147: ...Manufacturer PPHU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 147 Pic 9 4 3 97 Pic 9 4 3 98 Hose clamp W1...

Page 148: ...e KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 148 Undo a hose clamp from a refueling pump pipe and slide down the pipe Pic 9 4 3 99 Pic 9...

Page 149: ...Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 149 Undo a lower hose clamp on a filling elbow and remove it from the fuel runner and filling pipe on a tan...

Page 150: ...ions manual Issue 1 Rev No Date July 2010 Date Page 150 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 fr...

Page 151: ...EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 151 Unscrew upper bolts fastening the tank with luggage rack Pic 9 4 3 105 Pic 9 4...

Page 152: ...ce and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 152 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...

Page 153: ...Manufacturer PPHU EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 153 Pic 9 4 3 110 Pic 9 4 3 109 Pic 9 4 3 111...

Page 154: ...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 accordi...

Page 155: ...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...

Page 156: ...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 t...

Page 157: ...TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 157 Unscrew the bottom bracket J 15 250 02 00 from the engine block J 15 256 00 00 J 15 250 02 00 J...

Page 158: ...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 o...

Page 159: ...d 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 2...

Page 160: ...0 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...

Page 161: ...ntenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 161 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...

Page 162: ...Page 162 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...

Page 163: ...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 mani...

Page 164: ...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 b...

Page 165: ...nual Issue 1 Rev No Date July 2010 Date Page 165 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 cool...

Page 166: ...0 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 166 Fix the three way manifold J 15 505 00 00 to the pump cover with bolts 9 Self acting clamp J 15...

Page 167: ...tions manual Issue 1 Rev No Date July 2010 Date Page 167 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...

Page 168: ...1 Thermostst body J 15 501 01 00 2 Cover J 15 501 02 00 3 Thermostat WAHLER 11 04 82 4 O ring 48x3 5 Socket cap bolt M6x18 DIN 912 6 Washer 6 DIN 1440 Removal of the thermostat from the cooling system...

Page 169: ...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...

Page 170: ...ets 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...

Page 171: ...R 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 171 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 1...

Page 172: ...uction 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 secu...

Page 173: ...ating 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 I...

Page 174: ...No Date July 2010 Date Page 174 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...

Page 175: ...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 m...

Page 176: ...manual Issue 1 Rev No Date July 2010 Date Page 176 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 1...

Page 177: ...U EKOLOT Type KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 177 J 15 502 04 00 Clamp W1 13 15 J 15 502 04 00 Clamp W1 13 15 Valve Pic 9 4 5...

Page 178: ...ons manual Issue 1 Rev No Date July 2010 Date Page 178 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 0...

Page 179: ...ntenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 179 o Remove the surge tank assembly bolts o Remove the surge tank with the clamping ring J 15 250 10 00 the nuts insid...

Page 180: ...k 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...

Page 181: ...RFRAME 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...

Page 182: ...periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 182 9 5 1 2 Upper rear interlock Bolt M5x5 DIN 913 T 14 200 01 00 Washer 5 DIN 1440 Cotter pin 1 6 DIN 94 T 14 205 04 00 T 14 206 00...

Page 183: ...ling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 183 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 2...

Page 184: ...maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 184 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...

Page 185: ...enance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 185 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 pc...

Page 186: ...ype KR 030 TOPAZ Handling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 186 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...

Page 187: ...andling maintenance and periodic inspections manual Issue 1 Rev No Date July 2010 Date Page 187 9 5 1 5 Door travel limiter T 14 210 00 00 Nut M5 DIN 1587 Washer 5 DIN 1440 Pic 9 5 14 Pic 9 5 13 T 14...

Page 188: ...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 u...

Page 189: ...dering 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 g...

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