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EVEKTOR-AEROTECHNIK EV-97 Eurostar SL, Operating, Maintenance And Service Instructions

The EV-97 Eurostar SL is a state-of-the-art aircraft designed by EVEKTOR-AEROTECHNIK. To ensure optimal performance and longevity, it is crucial to have access to comprehensive Operating, Maintenance, and Service Instructions. Download the user manual for free from our website, manualshive.com, to guarantee the proper care and operation of this exceptional product.

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EVEKTOR 

–

 AEROTECHNIK a.s. 

Letecka 1384 

686 04 Kunovice 

CZECH REPUBLIC 

tel.: +420 572 537 111 

fax: +420 572 537 900 

[email protected] 

www.evektor.cz

 

 

 
 
 

AIRPLANE TECHNICAL DESCRIPTION 

OPERATING, MAINTENANCE  

AND REPAIR MANUAL 

 

EV-97 Eurostar SL 

 
 
 

Summary of Contents for EV-97 Eurostar SL

Page 1: ...HNIK a s Letecka 1384 686 04 Kunovice CZECH REPUBLIC tel 420 572 537 111 fax 420 572 537 900 marketing evektor cz www evektor cz AIRPLANE TECHNICAL DESCRIPTION OPERATING MAINTENANCE AND REPAIR MANUAL EV 97 Eurostar SL ...

Page 2: ... EVEKTOR AEROTECHNIK 2008 ...

Page 3: ... Czech Republic tel 420 572 537 111 fax 420 572 537 900 A AI IR RP PL LA AN NE E T TE EC CH HN NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L Model EV 97 Eurostar SL Serial Number Registration Owner ...

Page 4: ...The manufacturer invites suggestions and reminders concerning this manual and appreciates proposals for corrections We invite you to share your experiences with us during operation of your ...

Page 5: ...C CH HN NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 1 1 Document No EV97SLNOEN Date of Issue 02 2008 Revision 1 GENERAL ...

Page 6: ...te of Issue 02 2008 Revision 1 1 Information source Airplane manufacturer issues information and mandatory bulletins to ensure continued airworthiness of the airplane The bulletins are provided to all known owners and dealers of the EV 97 Eurostar SL airplane All bulletins may be downloaded from http www evektor cz at en index htm sportstar You can also contact us via mail telephone fax or e mail ...

Page 7: ...th attached new pages It is in the interests of every user to enter such revision into the table of revisions and to replace the existing page by the new one The revised or corrected text shall be indicated by a vertical line on the page fore edge and the page shall bear a revision number and date of its issue Rev No Affected Section Affected Pages Date of Issue Bulletin No Date of Approval Date I...

Page 8: ...008 2 37 02 2008 3 11 02 2008 4 11 02 2008 5 11 02 2008 2 38 02 2008 3 12 02 2008 4 12 02 2008 5 12 02 2008 2 39 02 2008 3 13 02 2008 4 13 02 2008 5 13 02 2008 2 40 03 2011 3 14 02 2008 4 14 02 2008 5 14 02 2008 2 2 1 02 2008 2 41 02 2008 3 15 02 2008 4 15 02 2008 5 15 02 2008 2 2 02 2008 2 42 02 2008 3 16 02 2008 4 16 02 2008 5 16 02 2008 2 3 02 2008 2 43 02 2008 3 17 02 2008 4 17 09 2011 2 4 02 ...

Page 9: ...Horizontal tail unit 2 8 2 3 5 Vertical tail unit 2 8 2 3 6 Landing gear 2 9 2 3 7 Cockpit 2 16 2 3 8 Equipment 2 19 2 3 9 Avionics 2 21 2 3 10 Additional equipment 2 22 2 3 11 Control system 2 25 2 3 12 Powerplant 2 35 2 3 13 Fuel system 2 43 2 3 14 Engine lubrication system scheme 2 45 2 3 15 Cooling system description 2 46 2 3 16 Heating 2 47 2 3 17 Ventilation 2 48 2 3 18 Wiring 2 49 2 3 19 Pi...

Page 10: ...L engine 4 11 4 5 FLUIDS 4 12 4 5 1 Engine oil 4 13 4 5 2 Coolant 4 15 4 5 3 Brake fluid 4 16 4 5 4 Fuel 4 17 4 6 LUBRICATION 4 19 4 6 1 Lubrication fundamentals 4 19 4 6 2 Recommended lubricants 4 19 4 7 MECHANISM ADJUSTMENTS 4 21 4 7 1 Torque moments 4 21 4 8 NECESSARY MAINTENANCE TOOLS 4 22 4 9 ACCESS HOLES 4 22 4 10 BRAKE SYSTEM EFFICIENCY ADJUSTMENT 4 23 4 10 1 Brake pad replacement 4 23 4 10...

Page 11: ...ts 5 3 5 4 SKIN REPAIR 5 4 5 4 1 Riveting 5 5 5 5 FIBERGLASS PARTS REPAIRS 5 6 5 5 1 Damage classification 5 6 5 5 2 General 5 6 5 5 3 Parts of external appearance 5 6 5 5 4 Structural parts 5 8 5 6 PAINT REPAIRS 5 9 5 6 1 Safety rules 5 9 5 6 2 Recommendation for paint repairs 5 9 5 6 3 Small damage 5 133 5 7 AIRPLANE ASSEMBLY AND LEVELING AFTER A REPAIR 5 154 5 8 FIRST FLIGHT AFTER A REPAIR 5 15...

Page 12: ...NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 1 8 Document No EV97SLNOEN Date of Issue 02 2008 Revision Intentionally left blank ...

Page 13: ... NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 1 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 TECHNICAL DESCRIPTION ...

Page 14: ...tion The EV 97 Eurostar SL is a single engine metal composite low wing monoplane of semimonocoque construction with two side by side seats The aircraft is equipped with fixed tricycle landing gear The standard powerplant consists of the four cylinder 4 stroke ROTAX 912UL 80 hp engine and the two blade wooden V 230 C fixed prop 2 1 1 Designation EV 97 Eurostar SL is an aircraft especially intended ...

Page 15: ...L L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 3 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 2 Basic technical data 2 2 1 Airplane views ...

Page 16: ...NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 4 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 2 2 Three view drawing ...

Page 17: ... 25 m loading MTOW 992 lb 450 kg 9 37 lbf sq ft 45 7 kg m2 MTOW 1058 lb 480 kg 9 99 lbf sq ft 48 8 kg m2 Aileron area 2 26 sq ft 0 21 m 2 Flap area 5 60 sq ft 0 52 m2 Fuselage length 19 62 ft 5 98 m width 3 41 ft 1 04 m height 7 68 ft 2 34 m HTU span 8 20 ft 2 5 m HTU area 20 99 sq ft 1 95 m 2 elevator area 8 61 sq ft 0 8 m 2 VTU height 4 21 ft 1 28 m VTU area 10 93 sq ft 1 02 m2 rudder area 4 67 ...

Page 18: ... Maximum fuel weight 65 l fuel tank standard 104 lbs 47 kg Maximum weight in Baggage Compartment 33 lbs 15 kg NOTE Actual empty weight is stated on the placard LOAD LIMITS located on the cockpit canopy 2 2 5 Center of gravity Empty weight CG standard equipment 18 2 MAC Operating CG 20 34 MAC MAC Mean Aerodynamic Chord 2 2 6 Operating limitations Refer to the PILOT S OPERATING HANDBOOK POH Section ...

Page 19: ...n of the fuselage there is a two man cockpit which is accessible by unfolding the one part perspex overlap canopy The engine section in the nose is separated from the crew by a firewall which the engine mount is attached to 2 3 3 Wing The rectangular wing is of a monospar construction with an auxiliary spar for the ailerons and flap attachments All the elements are riveted together Fiberglass wing...

Page 20: ...cover and ribs The elevator is attached to the stabilizer with a hinge There is also a hinged trim tab at the elevator trailing edge 2 3 4 3 Trim tab Elevator is equipped with the trim tab of rectangular shape The tab is formed with duralumin cover which forms a hollow section The span of the trim tab is 2 3 of the elevator spanwise 2 3 5 Vertical tail unit The trapezoidal VTU consists of the fin ...

Page 21: ...s The legs are formed from fiberglass springs and are fixed by means of screws in the fuselage casing under the seats Wheel axis is screwed at the lower part of the main landing gear legs The main wheels on both legs are equipped with hydraulic disc brakes controlled with toe brake pedals mounted on the rudder pedals The wheels can be covered with the fiberglass fairings wheel pants or mudguards 2...

Page 22: ...E EP PA AI IR R M MA AN NU UA AL L 2 10 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 6 3 2 Main landing gear layout ANGLE REINFORCEMENT MAIN LEG MAIN LEG ATTACHMENT MAIN LEG ATTACHMENT FLIGHT DIRECTION SCREW 4x40 ÈSN 02 1781 04 NUT M16x1 5 ÈSN 02 1412 24 WASHER WHEEL WITH BRAKE SCREW 5x10 ÈSN 02 2150 01 MAIN LEG Fig Main leg attachment into fuselage ...

Page 23: ...R RE EP PA AI IR R M MA AN NU UA AL L 2 11 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 6 3 3 Steerable nosewheel landing gear layout 17 NOSE WHEEL CONTROL ROD FOOT PEDAL SUSPENSION STOP NOSE WHEEL LEG RUBBER ROPE SUSPENSION FUSELAGE FRAME WHEEL AXLE WASHER E 54 04 21 NUT 765 155 WASHER 765 478 NOSE WHEEL ASSEMBLY COTTER PIN 4x40 ÈSN 02 1781 04 1 ...

Page 24: ...A AI IR R M MA AN NU UA AL L 2 12 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 6 4 Auxiliary tail skid 2 3 6 4 1 Description The auxiliary tail skid is attached at the lower rear part of the fuselage and protects the aircraft from inadvertent damage during tail down landing conditions The tail skid is formed from composite material Fig Auxiliary tail skid ...

Page 25: ...andard co pilot as an option hydraulic brake master cylinders plastic hoses brake caliper with the hydraulic brake cylinder brake pads and the brake disc which is bolted onto the inner part of the rim 1 2 3 4 5 Fig The brake on the left wheel 1 brake caliper with the hydraulic cylinder 2 brake disc 3 brake fluid hose 4 brake pad holder 5 air bleed screw 2 3 6 5 2 Brake control The brakes on both w...

Page 26: ... Date of Issue 02 2008 Revision 2 3 6 5 3 Brake system layout Parking brake ON Step on both toe brake pedals to raise pressure in the brake system and with the pedals pressed pull the parking brake lever up Parking brake OFF release the parking brake lever down step on and release the toe brake pedals Note Parking brake should be used for short period parking For long period parking is better to p...

Page 27: ...Description All the wheels consist of a two part casting rim with a tire and tube The main wheels are on an axle attached to the main gear leg fastened by the nuts 2 3 6 6 2 Main undercarriage wheel layout FLIGHT DIRECTION SCREW 4x40 ÈSN 02 1781 04 NUT M16x1 5 ÈSN 02 1412 24 WASHER WHEEL WITH BRAKE SCREW 5x10 ÈSN 02 2150 01 MAIN LEG 2 3 6 6 3 Nosewheel layout NOSE WHEEL LEG WHEEL AXLE WASHER E 54 ...

Page 28: ... control arrangement which provides the crew with an excellent view and comfort It protects the crew from adverse weather conditions and allows easy access to the controls and instruments The instrument panel is located in front of the crew The flap control lever elevator trim tab lever and optional towing mechanism release lever are located on the quadrant between seats A baggage compartment is s...

Page 29: ... A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 17 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 7 2 Cockpit controls The standard cockpit control arrangement is shown in the following figure A detailed instrument panel is shown in par 2 3 8 3 Fig quadrant between the seats 1 flaps control lever 2 elevator trim tab control lever 2 1 ...

Page 30: ...f perspex The canopy is attached to the nose section of the fuselage by two pins which make it possible for the canopy to be tilted forward For easier manipulation the weight of the canopy is counterbalanced by two gas struts which allow effortless opening The canopy is equipped with a lock on the upper rear section of the frame Fig Two parts cockpit canopy 1 front tilted canopy 2 rear fixed canop...

Page 31: ...upholstery each equipped with seatbelts Adjustable rudder pedals are optional The seatbelts are attached alongside the seat and in the middle of the bulkhead behind the baggage compartment The seatbelts are provided as four point safety belts 2 3 8 2 Baggage compartment The baggage compartment is situated behind the seats Maximum baggage weight is stated on a placard located near the compartment T...

Page 32: ... N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 20 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 8 3 Instrument panel The following instrument panel is installed in the EV 97 Eurostar SL airplane S N example ...

Page 33: ...3 9 1 Flight and navigation instruments 1 Airspeed indicator 1 Altimeter 1 Compass 1 Variometer 1 Bank indicator NOTE Refer to the Manuals supplied with above listed instruments for operation 2 3 9 2 Powerplant instruments The analogous powerplant instruments are installed in the EV 97 aeroplane model 2000 version R 1 Engine RPM indicator 1 CHT indicator 1 Oil temperature indicator 1 Oil pressure ...

Page 34: ...N N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 22 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 10 Additional equipment The following optional equipment is installed in the EV 97 Eurostar SL airplane S N ...

Page 35: ...NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 23 Document No EV97SLNOEN Date of Issue 02 2008 Revision Intentionally left blank ...

Page 36: ...NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 24 Document No EV97SLNOEN Date of Issue 02 2008 Revision Intentionally left blank ...

Page 37: ...stick lateral motion is transferred by a short rod in the cockpit to a longitudinal movement of a longer rod in the wing This in turn transferrs to the angular displacement of a two armed lever attached to the wing main spar The two armed lever angular movement is transferred to the ailerons by short rods The rods have adjustable ends to adjust the aileron deflections The control stick has a termi...

Page 38: ... changing gate The flaps can then be extended to a position for takeoff or landing The flap position is locked when the lock button is released 2 3 11 5 Trim tab control system description The elevator trim tab is controlled by the control lever located in the quadrant between the seats The trim tab control lever movement is transmitted to the trim tab displacement by bowden cables Maximum trim ta...

Page 39: ...L L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 27 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 11 7 Longitudinal control system layout ...

Page 40: ... AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 28 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 11 7 1 Lateral control system layout ...

Page 41: ...ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 29 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 11 7 2 Electric aileron tab control system layout optional ...

Page 42: ...AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 30 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 11 8 Directional control system layout ...

Page 43: ...CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 31 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 11 9 Flap control system layout ...

Page 44: ... AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 32 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 11 10 Trim tab control system layout ...

Page 45: ...C CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 33 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 11 10 1 Electric elevator trim tab control system layout optional ...

Page 46: ...A AN NU UA AL L 2 34 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 11 11 Nosewheel control system layout NOSE WHEEL LEG TIGHTENING STRIP CONTROL ROD NUT M6 ÈSN 02 1413 44 NUT M6 ÈSN 02 1413 44 WASHER 6 ÈSN 31 3282 11 WASHER 6 ÈSN 31 3282 11 SCREW 6x25 ÈSN 02 1413 44 COTTER PIN 1 6x14 ÈSN 02 1781 05 COTTER PIN 1 6x14 ÈSN 02 1781 05 FRAME SYSTEM OSA S YME TRIE 1 E 2 1 E ...

Page 47: ...ata is scanned by an analog instruments or by EMS Engine Monitoring System as an option Other props are optional The ROTAX 912ULS powerplant is shown in the following figure Fig EV 97 Powerplant 2 3 12 2 Engine 2 3 12 2 1 Description The Rotax 912 S is a 4 stroke 4 cylinder horizontally opposed spark ignition engine and has one central camshaft push rods OHV Liquid cooled cylinder heads ram air co...

Page 48: ...5 4 0 bar Fuel see 2 13 Propeller and Manufacturer V 230C VZLÚ Praha Czech Republic Type two blade fixed wooden propeller Propeller diameter 1625 2 3 mm 63 98 0 008 0 01 in Propeller pitch 18 20 18 55 WARNING The Rotax 912 UL has not been certified as an aircraft engine and its failure may occur at any time The pilot is fully responsible for consequences of such a failure Fuel automotive premium g...

Page 49: ...230 C is a fixed wooden 2 blade propeller with leading edge protection The prop is attached to the propeller hub with 6 bolts A fiberglass spinner is used Refer to the manuals supplied with the prop for more information Propeller Technical Data Diameter 63 98 0 008 0 01 in 1625 2 3 mm Pitch 18 20 18 55 Weight 7 1 0 7 lbs 3 2 0 3 kg Propeller blade clearance measured from ground 12 6 1 2 in 320 30 ...

Page 50: ...ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 38 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 12 3 2 Propeller pitch adjustment Intentionally left blank ...

Page 51: ...ICE MESSAGE or CONTACT SERVICE prior the next engine start up the pilot has to identify which measured item was exceeded and eliminate the probable defect By pushing the EMS control button on the instrument panel the information about which value was exceeded is shown Signalling An actual value of each measured item except for engine hours is continuously compared to its allowed maximum limit that...

Page 52: ...50 C Evans coolant 128 C glycol coolant Cylinder Head Temp CHT R 912 S 100 hp 135 C Evans coolant 128 C glycol coolant Exhaust Gases Temp EGT 880 C 1616 F R 912 UL 80 hp 50 90 C 122 194 F 110 140 C 230 284 F 140 C 284 F Oil Temp R 912 S 100 hp 50 C 122 F 90 110 C 194 230 F 50 90 C 122 194 F 110 130 C 230 266 F 130 C 266 F Oil Pressure 0 8 bar 12 psi 2 5 bar 29 73 psi 0 8 2 bar 12 29 psi 5 7 bar 73...

Page 53: ...A AI IR R M MA AN NU UA AL L 2 41 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 12 5 Engine mount 2 3 12 5 1 Description The engine mount is welded from chrome molybdenum tubes and is attached to the firewall with 4 bolts The bed is spring mounted with four rubber silentblocks 1 2 Fig Engine mount 1 bed 2 rubber silentblock 2 3 12 5 2 Engine mount diagram ...

Page 54: ...own in the following figure Fig Rotax 912 engine cowlings 1 upper cowling 2 lower cowling with cut out for the radiator 3 cap for oil level check 2 3 12 6 2 Engine cowlings disassembly and assembly The upper cowling The disassembly and assembly are both easy just release the quick closing locks or screws The upper cowling is usually removed during engine pre flight inspection to check the engine c...

Page 55: ...e seat backrests Fuel is pulled from the fuel tank through the fuel valve located inside the cockpit on the left hand side below the instrument panel Then through the fuel filter to the engine fuel pump and on to carburetor The fuel tank is equipped with a drain pocket and drain valve The draining outlet is located under the fuselage The drain valve is located near the right flap root and accessib...

Page 56: ...CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 44 Document No EV97SLNOEN Date of Issue 02 2008 Revision 2 3 13 2 Standard fuel system layout ...

Page 57: ...aminants are visable 7 Retract the flaps WARNING Do not smoke or have open any flame during draining Fig Fuel tank draining 1 drain valve near the right hand flap root 2 draining hose outlet under the fuselage 2 3 14 Engine lubrication system scheme 2 3 14 1 Lubrication system description The Rotax 912 engine is provided with a dry sump forced lubrication system The oil pump pulls the motor oil fr...

Page 58: ...nder heads From the top of the cylinder heads the coolant passes on to the expansion tank which allows for coolant expansion The expansion tank is closed by a pressure cap with an excess pressure valve and return valve When the temperature rises the coolant creates excess pressure a relief valve opens and the coolant flows through a thin hose to the overflow bottle mounted on the firewall The engi...

Page 59: ...he outlet air hose under the aircraft The second air hose leads the outer air directly through the valve at the firewall to the mixing chamber in the cockpit floor The hot air and cold air valves are operated with a cable from the heating valve flap to a small push pull knobs located on the instrument panel Pull the knob to open the appropriate valve and bring air into the mixing chamber The flap ...

Page 60: ...tion 2 3 17 1 Description Ventilation is ensured by 2 eye ball vents located on the left and right of the tip up canopy frame Vents are connected to the NACA scoops through tip up canopy frame front flaps Defrosting of windshield and sides ensured by hot air conducted from a cold hot air mixing chamber on the firewall into the tip up canopy frame and the through a row of holes onto the glass Fig E...

Page 61: ...articular sections are guarded individually by circuit breakers Separate appliances have separate switches The dual engine ignition is a separate part of the electrical system Each ignition circuit has its own on position on the ignition box to allow ignition check and BOTH position for normal operation Piper type external power socket can be installed optionally Socket is located on the right sid...

Page 62: ...istribution to individual instruments is done through flexible plastic hoses Keep the system clear to ensure its correct function Both hose systems Dynamic and static are equipped with dirt pockets The dirt pockets are located inside the cockpit in front of the pilot s seat If water gets inside the system unscrew the covers from the dirt pockets and slightly blow into the Pitot static head Then sc...

Page 63: ...cards with supplemetal information such as a direction of handles are also supplied The placards are usually attached to the appropriate instruments and controls Limitation placards are attached to the canopy external placards are attached on the appropriate aircraft part however placards may vary slightly from plane to plane CAUTION The owner aircraft operating agency of the aircraft is responsib...

Page 64: ...NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 2 52 Document No EV97SLNOEN Date of Issue 02 2008 Revision Intentionally left blank ...

Page 65: ... CH HN NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 3 1 Document No EV97SLNOEN Date of Issue 02 2008 Revision 3 OPERATION ...

Page 66: ...e and Repair Manual EV 97 Eurostar SL Airplane Flight Manual for EV 97 Eurostar SL Engine Operator s Manual Propeller Operator s Manual Additional documents supplied with instruments or equipment The airworthiness and operational readiness of the airplane depends upon the careful adherence to the recommended procedures and regulations Climate aerodrome conditions dustiness manner of hangaring and ...

Page 67: ...ft wing 3 The person holding the wing tip lifts it to shoulder level 4 Carefully place the wing suspensions into the fuselage ones so that the wing upper suspension hook will insert into the fuselage Be carefull of the pitot static hoses on the left wing and the wires of the position lights if lights are installed 5 The person holding the wing tip lowers it down to waist level 6 Adjust the window ...

Page 68: ...1 Be sure to disconnect pitot static hoses in the cockpit if disassembling the left wing 2 Remove the screws and remove the wing fillets 3 Disconnect the position lights wire connectors if lights are installed 4 Disconnect the aileron control rod 5 First person holds the wing tip the second person holds the wing root leading edge with the third holding the wing root trailing edge 6 Disconnect the ...

Page 69: ...pted for wing folding possibility The wing folding is convenient to reduce the parking area required in a hangar and to allow transportation on a suitable trailer The wings may be folded in 15 minutes by 2 people 3 2 1 3 1 Wing suspensions scheme Fig Wing suspensions 1 disconnected aileron rod 2 upper wing suspension 3 lower wing suspension 4 rear auxiliary wing suspension 3 2 1 3 2 Tools necessar...

Page 70: ...wing tip and slightly lift the wing see FIG 6 11 Unscrew the rear pin nut and push the pin out of the hinge 12 Tap the upper and lower wing suspension pins out with a hammer and aluminous drift 13 The assistant should lift the wing tip up to eye level see FIG 7 14 The assistant with the assistance of a second person may run the wing slightly out the fuselage see FIG 7 15 The assistant holding the ...

Page 71: ...sions onto the fuselage The small hook of the wing suspension must fit in the groove of the fuselage upper main suspension 8 After insertion the assistant lowers the wing tip 9 The second person connects the flap control 10 Insert a pins into the lower and upper wing suspension with the head of the pin in the flight direction and slightly tap the pin with hammer to connect the wing fuselage suspen...

Page 72: ...CH HN NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 3 8 Document No EV97SLNOEN Date of Issue 02 2008 Revision 1 2 3 4 5 6 7 ...

Page 73: ...CH HN NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 3 9 Document No EV97SLNOEN Date of Issue 02 2008 Revision 8 9 10 11 12 ...

Page 74: ...connecting components in a safe place to avoid loosing them 3 2 2 2 HTU to fuselage assembly 3 2 2 2 1 Necessary tools a wrench to tighten M8 nuts a screwdriver to attach the tail unit fuselage fairing 3 2 2 2 2 HTU to fuselage assembly 1 Make the connecting components ready clean and lubricate HTU suspensions 2 Insert the HTU from the rear into the fuselage as far as the stabilizer will go into t...

Page 75: ...nnect the rudder control cables attach the ends of the cables together to keep the cables from sliping inside the fuselage 2 Remove the safety pin from the lower suspension bolt Remove the castle nut and washer 3 Lift and remove the rudder from suspensions 3 2 3 1 3 Assembly procedure 1 Put the rudder on the fin suspensions from above Use care not to move the spherical bearings in the rudder suspe...

Page 76: ...e cotter pin securing castle nut from the axle 5 Remove the castle nut and washer from the axle 6 Cut the safety wire securing the bolts which join together the rim halves 7 Remove the 3 bolts connecting the rims together 8 Remove outer rim from the axle 9 Remove tire 10 Replace the tire and or tube 11 Insert a new tube into a tire and pump up slightly put easy powder on the tube and or in the tir...

Page 77: ...e optional aerodynamic fiberglass wheel pants 3 2 4 2 1 Main landing gear wheel pants The main wheel pant is attached with 8 screws to the main leg from the inner side and with 1 screw from the outer side The removal and replacement is easy and straightforward Remove replace the screws to remove replace the wheel pant 3 2 4 2 2 Nosewheel pant Nose wheel pant is attached to the landing gear leg by ...

Page 78: ...e mudguard Mounting Use the following procedure to mount a mudguard on an airplane not equipped with mudguards by the manufacturer use the opposite procedure to the demounting one see above to mount a mudguard back on a main leg 1 Support the airplane to lift a main wheel on which a mudguard would be mounted on 2 Remove the cotter pin securing the castle nut on the wheel axle 3 Remove the castle n...

Page 79: ... Remove the screws from the console that holds the gas strut ball ends at the canopy frame 3 Carefully remove the canopy attachment screws Caution The front canopy hinges and the canopy should be supported 4 Remove the canopy 3 2 5 2 Canopy mounting The Mounting procedure is the reverse 3 2 6 Installation and reinstallation of instruments The installation procedure will depend on the instrument be...

Page 80: ...he airplane in a horizontal position in longitudinal direction and leveling points 5 and 7 in lateral direction Boards under the main or nosewheel may be used to level the airplane The best way to measure a leveling point height is to use a level Alternatively a running meter is sufficient for approximate measurement Measured values should be recorded in the Leveling Record see Appendices Height d...

Page 81: ...sion 3 4 Measurement of control surfaces deflections 3 4 1 Required deflections The deflection of the control surfaces are specified in the Control Surfaces Deflection Record see Appendices of this Manual and in the following Figure A protractor with deflecting hand is used by the airplane manufacturer to measure deflections The protractor is attached to a control surface with a hand clamp There a...

Page 82: ...ces Deflection Record If required adjust the aileron deflection according to 4 11 1 3 4 3 Flap deflection measurement The wing flaps can be set in 4 positions RETRACTED TAKEOFF LANDING 2 positions Measurement procedure 1 Cut a strip of aluminium sheet 2 inches 50 mm wide The strip is than attached to the flap lower surface with two bolts somewhere in the middle of the flap span where two nuts are ...

Page 83: ...levator deflection according to the par 4 11 3 If a protractor is not available the following procedure may be substituted 1 Support the airplane under the tail skid and firewall and set the airplane in a horizontal position a level set on the canopy lower frame can be used to set the airplane in horizontal position 2 Stand a suitable staff close to the elevator trailing edge and mark the neutral ...

Page 84: ...namometer to the trim tab trailing edge The trim tab deflection musn t exceed value of 5 2 mm from the original position If the trim tab deflection exceeds this value then it is neccessary to adjust trim tab cable preload by adjusting screws If a protractor is not available the following procedure may be substituted 1 Insert a stiff cardboard sheet of paper in the space between the elevator and th...

Page 85: ...railing edge up downward to find possible plays Check the part with oval hole for the control pin in the flap root rib and replace the worn out pin or the part with oval hole 0 08 in 2 mm 0 2 in 5 mm Trim tab control system Block the tab up to the elevator move the trim tab control lever to find a play in a control system Check cable tension 0 08 in 2 mm 0 2 in 5 mm Wing Fuselage attachment Move t...

Page 86: ...The empty weight of an aircraft includes all operating equipment that has a fixed location and is actually installed in the airplane It includes the weight of the painted airplane accumulator standard and optional equipment full engine coolant hydraulic fluid brake fluid oil and unusable fuel 2 9 l The aircraft is weighed without crew fuel and baggage The following weighing procedure is recommende...

Page 87: ... is possible to calculate weight and C G position according to below given formula Item Arm to the Datum Leading edge C G i Weight Wi Moment Mi in mm lbs or kg lbs in or kg mm Empty airplane Crew 19 69 500 Fuel 6 lbs USGAL 0 72 kg ltr 36 22 920 Baggage 50 00 1270 Total Weight TW Wi lbs or kg Total Moment TM Mi lbs in or kg mm C G position from Datum Leading edge mm or in Weight Total Moment Total ...

Page 88: ... a dust free environment It is necessary to tie down the aircraft when parking outside On occations when the plane must be tied down outdoors for extended periods it is advisable to cover the cockpit canopy and if possible the entire aircraft using a suitable cover The space requirements in the case of long term hangaring may be reduced by removing or folding the wings We recommend removing the ba...

Page 89: ...rts Press down on the rear of the fuselage in front of the fin to lift the front and then support under the firewall The fuselage nose may be supported under the horizontal tube of the engine mount or under the nose landing gear attachement to the fuselage To jack the rear of the fuselage grab the fuselage near the auxiliary tail skid lift it upward and then support To lift the wings push on the w...

Page 90: ...NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 3 26 Document No EV97SLNOEN Date of Issue 02 2008 Revision Intentionally left blank ...

Page 91: ...CH HN NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 4 1 Document No EV97SLNOEN Date of Issue 02 2008 Revision 4 MAINTENANCE ...

Page 92: ...tion is a visual check of the aircraft for deformations surface damage fuel and oil system leaks prop damage released locks covers and cowlings etc Any damage or failure should be repaired immediately if the airworthiness is affected or when the aircraft can not be put out of operation It is important to perform a pre flight inspection carefully to prevent problems from arising Refer to the Pilot ...

Page 93: ...rer recommends maintenance checks and periodic inspections in the following periods 1 after the first 25 2 flight hours 2 after every 50 3 flight hours 3 after every 100 5 flight hours or annual inspection Refer to the Rotax 912 Operator s Manual for engine maintenance The propeller is maintained according to its condition 4 4 2 Periodical inspections Sign off sheets The following Periodical maint...

Page 94: ...edeed White color T 50 Norm V1000 N 56582 3 2 Engine mount 3 2 1 Visually check condition attachment security of attachment bolts engine engine mounting engine mounting firewall 3 2 2 Visually check condition of rubber silentblocks replace those cracked and excessively deformed 3 3 Suction system 3 3 1 Visually check condition attachment and security of air filter at carburetor inlet clean filter ...

Page 95: ...tion leaks attachment and security replace damaged hoses 3 8 4 Check oil quantity add or change oil acc to the engine manual if needed 3 9 Exhaust system 3 9 1 Visually check exhaust system for condition cracks deformations or damage repair replace Check left front pipe clearance from radiator hose min 0 8 in 20 mm 3 9 2 Visually check condition and attachment of the muffler repair replace 3 9 3 C...

Page 96: ...ension stop for deformation cracks excessive wear replace if needed 5 4 Tire 5 4 1 Check tires for condition cuts uneven or excessive wear and slippage replace if needed 5 4 2 Check pressure inflate to required pressure 5 5 Wheel 5 5 1 Visually check for cracks permanent deformations if damaged replace 5 5 2 Check valve condition around the hole in the rim 5 5 3 Check condition of bearings wheel f...

Page 97: ...ndition of bearings wheel free rotation play 6 5 Brakes 6 5 1 Check attachment of brake system plastic hoses to the main leg 6 5 2 Visually check condition of pads steady and symmetry abrasion of pads replace pads if needed 6 5 3 Check wear of the disc 6 5 4 Check brake system for leaks add brake fluid and bleed the system if a brake pedal has soft movement 7 WING 7 1 Wing 7 1 1 Visually check con...

Page 98: ...ate per Lubricating Chart 8 FUSELAGE 8 1 Fuselage surface 8 1 1 Visually check condition no loose rivets deformations cracks or any other damage repair small damage or contact the airplane manufacturer 8 1 2 Visually check rivets near the landing gear attachment 8 1 3 Check condition and attachment of equipment antenna beacon etc 8 1 4 Check tail skid attachment 8 1 5 Visually check condition atta...

Page 99: ...turer 10 2 Visually check condition and attachment of fiberglass tips 10 3 Check rudder free movement 10 4 Check rudder suspensions 10 5 Check play move rudder upward downward 10 6 Check joints security 10 7 Lubricate per Lubricating Chart 11 COCKPIT 11 1 Instrument panel 11 1 1 Visually check condition and attachment of the instrument panel 11 1 2 Check condition and attachment of individual inst...

Page 100: ... Check stops at pedal control cables 11 5 4 Check condition and security of cables 11 5 5 Check hydraulic brake system for leaks add brake fluid if needed 11 5 6 Lubricate per Lubricating Chart 11 6 Flap and trim control Towing mechanism control 11 6 1 Check free movement of levers 11 6 2 Check opperation of flap control lever lock push button 11 6 3 Lubricate per Lubricating Chart 11 7 Complete l...

Page 101: ... RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 4 11 Document No EV97SLNOEN Date of Issue 02 2008 Revision 4 4 4 List of periodical inspections of Rotax 912 UL engine Refer to the Rotax 912 Operator s and Maintenance Manual for engine maintenance ...

Page 102: ...IR R M MA AN NU UA AL L 4 12 Document No EV97SLNOEN Date of Issue 02 2008 Revision 4 5 Fluids The fluids are fuel engine oil liquid coolant and brake fluid Filling locations can be seen in the Figure below Fuel and Brake fluid filling locations are described in 4 6 4 3 and 4 6 3 2 respectivly Fig Filling locations in engine compartment 1 oil tank 2 liquid coolant tank 2 1 ...

Page 103: ...stem amounts to 0 9 USGAL 3 5 liters Prior to oil check turn the propeller by hand ingition switched off several times to pump oil from the engine into the oil tank or leave the engine idle for 1 minute The oil level in the oil tank should be between the min and max marks and should not be below min mark 4 5 1 3 Oil filling The oil tank is located in the engine compartment and is accessible when e...

Page 104: ... that pip on the exhaust muffler using wrench 13 Disconnect the elbow from the engine and turn the exhaust pipe slightly to move it from the oil filter Replace oil filter by a new one See Maintenance Manual Line Maintenance for ROTAX Engine Type 912 Series for replacement instructions Connect the elbow to the engine and tighten the nuts slightly by fingers Set exhaust pipe clearance from the radia...

Page 105: ...t Plus produced by BASF is recommended by the engine manufacturer The engine manufacturer also recommends the use of antifreeze concentrate during cold weather operation 4 5 2 2 Coolant quantity Total coolant quantity is about 1 6 USQTS 1 5 liters 4 5 2 3 Coolant refilling The expansion tank located in the engine compartment is used for filling In addition to that an overflow bottle is attached on...

Page 106: ...e Fluid Super HD NAFTAGAS AT 2 INA UK 2 These brake fluid types may be blended as required and refilled in any mixing proportion 4 5 3 2 Brake fluid refilling Instructions Brake fluid refilling is necessary when a low brake system efficiency occurs due to a fluid leak A brake fluid is filled into reservoir located in the engine compartment on the firewall A brake fluid level must be approx 1 inch ...

Page 107: ...by means of the drain valve fill the tanks with fresh E10 fuel and let the engine run on ground long enough to deplenish residues of old E10 fuel from the fuel system The make an inspection of the fuel filter Use of and specifications of E10 fuel are listed in the Service Instruction SI 912 016 R1 and R2 released by the Rotax engine manufacturer 4 5 4 2 Fuel quantity The standard aircraft is equip...

Page 108: ...tank An advantage of fueling with this device is easy handling by 1 person Close the fuel tank filler using the lockable cap when the tank filled up Clean the aircraft surface if stained with gasoline CAUTION It is highly recommended to pour gasoline through a filter if it was not tested for water content After fueling allow 20 min for water to settle out on the bottom Drain off some fuel and look...

Page 109: ...s and to varying loads These parts will be inspected during pre flight and during periodical inspections These should be lubricated as is necessary but at least in the intervals specified below 4 6 2 Recommended lubricants 4 6 2 1 Greases Greases are mineral oils thickened with calcic sodium lithium or any other thickeners of aliphatic acids The greases do not SAE classification and their usage is...

Page 110: ...OGUL MOLYKA G foreign greases two armed aileron control levers inside the wing x MOGUL MOLYKA G foreign greases hinge joint of rods under the wing fillet x MOGUL MOLYKA G foreign greases Flaps hinges x x oil all movable joints under the quadrant cover between the seats x MOGUL MOLYKA G foreign greases All movable joints under the baggage compartment bottom cover x MOGUL MOLYKA G foreign greases Fl...

Page 111: ...2 N m kg m 42 16 4 30 52 95 5 40 74 53 7 60 104 93 10 70 125 52 12 80 M14 N m kg m 66 68 6 80 78 54 8 00 117 67 12 00 164 75 16 80 196 13 20 00 M16 N m kg m 93 16 9 50 107 87 11 50 164 75 16 80 225 55 23 00 274 58 28 00 M18 N m kg m 137 29 14 00 171 61 17 50 245 16 25 00 343 23 35 00 411 87 42 00 M20 N m kg m 176 51 18 00 225 55 23 00 313 81 32 00 441 29 45 00 539 36 55 00 M22 N m kg m 225 55 23 0...

Page 112: ...he following are the inspection and access holes Screw caps on the wings lower surface access to the aileron control rods and levers and to the pitot static installation in the left half of the wing Screw cap on the fuselage lower surface under the baggage compartment close to the fuel tank access to the fuel tank installation Screw cap on the fuselage lower surface in the middle of the rear secti...

Page 113: ...he axle 5 Take the brake disc off leave the brake on a main leg 6 Remove the cotter pins shift the pins out and remove the brake pads 7 Mount a new brake pad secure the pins with cotter pins diam 2mm length14mm part No 039 300 8 Put the brake disc on the wheel 9 Put the distance ring and the wheel on the axle adjust the distance ring between bearings 10 Set tab washers 6x2 Nom 038160 on the screws...

Page 114: ...There are two main reasons for air entering the brake system 1 Disconnected or loose hoses 2 Insufficient quantity of brake fluid Fig Brake system bleeding 1 Bleeding screw Procedure 1 Loosen the bleeding screw in the brake cylinder 2 Step repeatedly on the pedal to bleed the brake system 3 Tighten the screw 4 Repeat several times or until the pedal offers resistance against motion feels firm NOTE...

Page 115: ...n an aileron is deflected upward 4 11 2 Flap deflection adjustment Flaps deflection is determined by cut outs in a changing gate on the flap control lever inside the cockpit Use the following procedure to adjust flap deflection Remove the baggage compartment bottom cover which will allow access to a rod connecting the flap control lever and a lever welded on a tube connecting the left and right fl...

Page 116: ...r control cable in the cockpit see figure on page 2 29 4 11 5 Trim tab adjustment The following may be adjusted a The position of the trim tab control lever may be adjusted against a groove in the quadrant between the seats Loosen the bolts which clamp the ends of the trim tab control cables on the upper lower tab surface Then set the trim tab control lever in the desired position slightly tighten...

Page 117: ...cedure 1 Lift the nosewheel and neutralize wheel and rudder pedals 2 Adjust the nosewheel control cables using the adjustable cable ends located close to the control levers under the fuselage 4 12 1 Rubber shock absorber replacement Perform rubber shock absorber replacement when rubber rope is damaged or excessivelly worn down Procedure 1 Remove cotter pins from the hollow pin attaching a rubber r...

Page 118: ... Use the adjustment screw on the carburetor of the Rotax 912 engine to adjust the idle Idle engine speed is approximately 1400 r p m 4 14 Tire inflation pressure Nose wheel pressure Cheng Shin 13 x 5 00 6 160 20 kPa 23 3 psi Sava tire 14x4 160 20 kPa 23 3 psi Main wheel pressure Sava tire 14x4 180 20 kPa 26 3 psi Cheng Shin 15 x 6 00 6 120 20 kPa 17 3 psi GOOD YEAR 15 x 6 00 6 80 20 kPa 12 3 psi T...

Page 119: ...nted external surfaces twice a year by appling an automotive type polish Use only on a clean and dry surface and polish with a soft flannel rag CAUTION Never wipe a dry surface the surface may be scratched by dusts and dirt Never apply any chemical solvents Repair a damaged painted surface see par 5 6 as soon as possible to prevent corrosion 4 15 3 Interior cleaning Keep in mind the following Remo...

Page 120: ...T TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 4 30 Document No EV97SLNOEN Date of Issue 02 2008 Revision 4 15 5 Engine maintenance Refer to the engine manufacturer s instructions for engine maintenance 4 15 6 Propeller maintenance Refer to the propeller manufacturer s instructions for engine maintenance ...

Page 121: ...l temperatures occur during operation under low outside temperature then do the following Cover a portion of the radiator face using an alluminum sheet insert it between the radiator and the lower engine cowling Cover the oil cooler face or a part of face using an alluminum sheet attached with a suitable adhesive tape Cover the Reduction gear unit by means of a car engine cover Cover the oil filte...

Page 122: ...nd oil temperatures exceed 68 F 20 C Engine starting 1 Turn the propeller by hand ignition switched off 2 Open the fuel valve 3 Set throttle lever to idle 4 Open the choke 5 Master switch to ON 6 Turn the key in the switch 7 Switch on ignition switches to RUN 8 Push the starter button to start the engine 9 Adjust engine RPM after starting 10 Close the choke 11 Warm up the engine CAUTION If the cyl...

Page 123: ...NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 4 33 Document No EV97SLNOEN Date of Issue 02 2008 Revision Intentionally left blank ...

Page 124: ......

Page 125: ...C CH HN NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 5 1 Document No EV97SLNOEN Date of Issue 02 2008 Revision 5 REPAIRS ...

Page 126: ...ied out at another structural member and then back to an undamaged part of the original structure 3 The length of overlapping between a reinforcement stiffener or patch and theundamaged part of the original structure should be enough to assure a good joint The length of overlapping is very important to assure no load concentration 5 2 Damage classification Various types of damage may occur during ...

Page 127: ...h Standard Al Cu Mg 1 2 Mechanical properties Minimum Yield Point Rp 0 2 260 MPa Tensile strength Rm 400 Mpa Ductility 15 A10 3 Chemical composition Al rest Fe max 0 3 Mn 0 3 0 9 Cu 3 8 4 9 Zn max 0 3 Mg 1 2 1 8 Si max 0 3 4 Half finished products by Al plated Sheets Al thickness max 10 mm 0 4 in 5 Equivalent U S A Alclad 2024 Standards Germany DIN 1745 Russia D16AT List of Skin Sheets Thickness A...

Page 128: ...in 4 mm can be repaired by a POP rivets 3 More extensive skin damage is repaired by means of a patch A flush or surface patch may be used as shown on the following figure 1 Patch A Punctured skin 2 Frame B Cutting out and deburring the damaged spot 3 Skin C Surface patch repair D Flush patch repair Use a sheet of the same thickness as the repaired skin for the patch and frame A single row of rivet...

Page 129: ...C 356 392 F for short time 3 minutes maximum to make it easier to cut In the following table lists the pop rivets and characteristics AVEX Pop rivets supplied by AVDEL Company 1 material Al Mg 2 5 2 Shank material steel zinc chromate coating surface Rivet No Diameter Length Hole diameter Max riveting thickness Head in mm in mm in mm in mm 1691 0410 1691 0414 1691 0512 1691 0516 0 126 0 126 0 157 0...

Page 130: ...yers it is necessary to carry out surface grinding at the utmost up to the depth of contact with the stiffener do not damage It is necesary to do surface grinding with overrun of 50 mm from the damage location smoothly to the top layer It is suitable to do grinding with grain size of 160 Dry grinding equipment with suction from the grinding area is used Al2O3 fused corundum can be used as grinding...

Page 131: ...nvenient to do grinding with grinding material having grain size of 160 It is carried out by dry grinding equipment with suction from grinding area Al203 fused corundum ca be used as grinding material NOTE In case of C K stiffener K rovings tend to rise up from the surface at grinding it is difficult to grind them we recommend to use diamond grinding tool and one way grinding Dust removing Dust is...

Page 132: ... case of C K stiffener in the basic part there must not be any grinding through up to the stiffener complication see the note about preparatory grinding Finishing See para 5 6 Paint repairs 5 5 3 3 Big damage At such damage we recommend to change the part or to do this repair in a professional facility Use instructions in chapter about medium damage as recommendation for used materials 5 5 4 Struc...

Page 133: ... case of paint repairing use the same or equivalent painting system as airplane manufacturer uses By applying paints weight of airplane is increased and centre of gravity position is changed Increase in weight depends on type of coat and its thickness CAUTION Failure to meet these recommendations reduces airplane lifetime 5 6 2 1 Washing and degreasing It is possible to use both organic solvents a...

Page 134: ...eans of sponge dipped in ample amount of water or water jet Advantages different according to the type of product it is possible to highly dilute with water cheap ecological waste including dripping from the surface due to ample amount of water it is necessary to contain it can be generally eliminated after its additional dilution with water in public sewerage the least detrimental to health Disad...

Page 135: ...o final appearance before setting slight recess is not a defect do not grind Recommended bonding agents surface manufacturer name type other components drying grindable min 20 C Al alloys BASF Glasurit 839 10 base polyester BASF Glasurit 948 36 initiator 30 transitions epoxide fibreglass Al alloys BASF Glasurit 839 45 base polyester BASF Glasurit 948 36 initiator 150 Rivet heads 3M DP 190 base har...

Page 136: ... order to reach smooth surface we recommend again to carry out the paint coat by spraying see para 5 6 2 3 Top coat serves especially for creating the coat resistant to weather and external effects for aesthetic rendering of the unit Considering the higher loading by external effects we recommend to use top materials exclusively two component ones on the acrylic polyurethan or polyurethan basis al...

Page 137: ...end to carry out such repairs by a verified system Before repairing it is necessary to differentiate the type of the existing top coat single coat and two coat with the top coat For repair it is necessary to follow the used type of colour It is suitable to choose the delimited area e g connection of sheets wing edge for the scope of the place which is being repaired transition is then better blend...

Page 138: ...t is enough Actual application of primer will be carried out in the same way as for the total spray coat see 5 6 2 3 5 6 3 5 Application of top coat CAUTION For repairing it is necessary to choose the identical type single coat double coat of the repair colour as on the original surface Application of the top coat will be carried out by spraying as for the total spray coat see 5 6 2 3 with the exc...

Page 139: ...he following information is intended for the aircraft owner A test flight is mandatory in the following cases After repair or replacement of fixed surfaces wing fin stabilizer or control surfaces i e elevator aileron or flap The flight characteristics and stability can be affected when any of these parts are replaced or adjusted Therefore a test flight should be performed to check the airplane fli...

Page 140: ... Spare Parts Order form to order a replacement for a damaged or worn out part Do not hesitate to contact the airplane manufacturer phone or fax to request a required part On the Spare Part Order form additional information is necessary for systematic monitoring and analysis of our planes reliability 5 10 Recommended reading Many useful information you can find in the document Acceptable Methods Te...

Page 141: ...NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 5 17 Document No EV97SLNOEN Date of Issue 02 2008 Revision Intentionally left blank ...

Page 142: ......

Page 143: ...CH HN NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N O OP PE ER RA AT TI IN NG G M MA AI IN NT TE EN NA AN NC CE E A AN ND D R RE EP PA AI IR R M MA AN NU UA AL L 6 1 Document No EV97SLNOEN Date of Issue 02 2008 Revision 6 APPENDICES ...

Page 144: ...ces Deflection Record Weight and Balance Record Flight Test Record Spare Parts Order Airplane Failure Card Airplane Placards Airplane Wiring diagrams Service Instruction SI 18 1997 Rev 5 September 2004 For actual ROTAX information you can visit http www rotax owner com or http www kodiakbs com 4intro htm Sonnenschein A500 batteries operating instructions used type A512 16 0 G5 Cleanining polishing...

Page 145: ...en 4 Periodic insp 4 Failure consequence 1 Flight completed 2 Flight interrupted 3 Take off possible 4 Take off impossible 5 Failure description 6 Repair carried out by 1 Own means 2 Suppliers service 3 Ordering repair 7 Failure cause 8 We order We order We order part s stated in par 2 a repair of part s stated in par 2 necessary material according to the list enclosed Number of Pages Please use t...

Page 146: ......

Page 147: ...for accident CfA 3 Damage 4 Accident 5 Crash 11 Failure detected during 1 Periodical insp 4 Take off 7 Landing run 10 Accident 2 Taxying 5 Flight 8 Cross country flight 11 Othere 3 Take off run 6 Touch down 9 Pattern flight 12 General Cause of Failure 1 Constructional 4 Unskilled repair 7 Objective cause 2 Service 5 Manuf Maintenance 8 Air Personnel 3 Wear due to operation 6 Resulting 9 Not determ...

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