FK-Lightplanes FK 9 Mk IV Maintenance Manual Download

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AIRCRAFT MAINTENANCE

MANUAL

FK 9 Mk IV / Mk V ELA

Certified as Ultralight Aircraft according to
BFU 95 / LTF-UL 2003

Kennblatt Nr. 61102.1 and Nr. 61102.2

(Germany)

Type Certificate: US-SLSA

Model: FK9 Mk IV



FK9 Mk V ELA



Serial Number:

Registration :

Date of manufacture:

Manufacturer and exclusive Distributor:

FK-Lightplanes Krosno - Poland

Design Organisation and Owner of IP Rights:

B & F Technik Vertriebs GmbH Speyer

– Germany

document code: des.003

revision date: 01.of november 2013

Summary of Contents for FK 9 Mk IV

Page 1: ...1 and Nr 61102 2 Germany Type Certificate US SLSA Model FK9 Mk IV FK9 Mk V ELA Serial Number Registration Date of manufacture Manufacturer and exclusive Distributor FK Lightplanes Krosno Poland Design Organisation and Owner of IP Rights B F Technik Vertriebs GmbH Speyer Germany document code des 003 revision date 01 of november 2013 ...

Page 2: ...enance Manual carefully as it contains important safety relevant information Failure to do so may void warranty or cause serious personal injury or death Please pay attention to the following reoccurring symbols warning caution and note which you will find throughout the maintenance manual These symbols signs indicate special safety guidelines and therefore are of high importance WARNING Instructi...

Page 3: ...bbreviations and Terminology 1 4 1 5 2 Basic Empty Weight 1 4 1 5 3 Weighing 1 5 1 5 4 Required Tools 1 5 1 5 5 Parts materials required 1 5 1 5 6 Level of maintenance 1 5 1 5 7 Certification required 1 5 1 6 Tire Inflation Pressure 1 6 1 7 Approved Oils and Capacities 1 6 1 7 1 Oil 1 6 1 7 2 Fuel 1 6 1 7 3 Coolant 1 6 1 7 4 Brake Fluid 1 6 1 8 Recommended Fastener Torque Values 1 7 1 9 General Sa...

Page 4: ...nterior 3 2 3 2 9 Propeller 3 2 3 2 10 Wheels 3 2 3 3 Wing Struts Removal Installation 3 3 3 3 1 Required Tools 3 3 3 3 2 Parts required 3 3 3 3 3 Level of maintenance 3 3 3 3 4 Certification required 3 3 3 3 5 Instructions 3 3 3 4 Fuselage Interiors 3 4 3 4 1 Required Tools 3 4 3 4 2 Parts required 3 4 3 4 3 Level of maintenance 3 4 3 4 4 Certification required 3 4 3 4 5 Dismantling interiors and...

Page 5: ...5 1 5 1 4 Certification required 5 1 5 1 5 Option 1 Fuselage Tanks 5 2 5 1 6 Additional flexible Wing tanks 5 3 5 1 7 Option 2 Wing Tanks 5 4 5 1 8 Fuel Low Pressure Warning 5 6 5 1 9 Fuel Quantity Indication 5 6 5 1 10 Maintenance 5 6 5 1 11 Fuel Filter Removal and Installation 5 6 5 1 12 Electrical Fuel Pump Removal and Installation 5 7 6 PROPELLER 6 1 6 1 Inspections 6 1 6 1 1 Adjusting of angl...

Page 6: ...RUMENTS AND AVIONICS 8 1 8 1 Instrument Panel 8 1 8 2 Antennas 8 5 8 2 1 COM Antenna 8 5 8 2 2 Transponder Antenna 8 5 8 2 3 GPS Antenna 8 5 8 3 Static and Dynamic Pressure System 8 5 9 ELECTRIC 9 1 9 1 Description 9 1 9 1 1 Required Tools 9 1 9 1 2 Parts required 9 1 9 1 3 Level of maintenance 9 1 9 1 4 Certification required 9 1 10 STRUCTURAL REPAIR 10 1 10 1 Main Structure 10 1 10 1 1 Required ...

Page 7: ...required 11 1 11 0 3 Level of maintenance 11 1 11 0 4 Certification required 11 1 11 1 Preparation Procedures 11 1 11 1 1 Preparation of Metal 11 1 11 1 2 Preparation of Composites 11 1 11 1 3 Preparation of Fabric 11 1 11 2 Painting 11 2 11 2 1 Primer 11 2 11 2 2 Final Coat 11 2 12 ANNEX 12 1 12 1 Airplane Registration Card 12 1 12 2 Warranty claim report 12 2 13 FEEDBACK FORM 13 1 ...

Page 8: ...chnical service site of B F Technik Vertriebs GmbH This revision information page shall be filed behind the checklist for amendments for about 6 month in order to get at a glance all the changes that became effective during this time Index Page remove REV insert REV Remark Reason for REV all all REV 2 several editorial changes due to authorities request 0 2 Record of Revisions The fact of having i...

Page 9: ...3 3 3 Rev 2 01 11 13 3 4 Rev 2 01 11 13 3 5 Rev 2 01 11 13 3 6 Rev 2 01 11 13 3 7 Rev 2 01 11 13 3 8 Rev 2 01 11 13 3 9 Rev 2 01 11 13 3 10 Rev 2 01 11 13 3 11 Rev 2 01 11 13 3 12 Rev 2 01 11 13 3 13 Rev 2 01 11 13 4 1 Rev 2 01 11 13 4 2 Rev 2 01 11 13 4 3 Rev 2 01 11 13 5 1 Rev 2 01 11 13 5 2 Rev 2 01 11 13 5 3 Rev 2 01 11 13 5 4 Rev 2 01 11 13 5 5 Rev 2 01 11 13 5 6 Rev 2 01 11 13 5 7 Rev 2 01 1...

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Page 11: ...pment Note For weight and balance it is mandatory to list all installed equipment Standard FK9 MK IV equipment basic instruments speed indicator altimeter 5000ft compass slip indicator oil pressure and oil temperature cylinder head temperature CHT rpm indicator Junkers 3 blade propeller hydraulic disc brake 6 main wheel system with park lock fiberglass seats with two color upholstery oil inspectio...

Page 12: ...d Rescue system Rocket Exit Area Danger Rocket Exit Area safety pin rescue system Remove before flight Wheel fairings main wheels 2 0 bar Wheel fairing nose wheel 1 5 bar Towing version only Vicinity of airspeed indicator Care for tow speed Handle for cowl flap Cowl flap Handle for towing clutch TOW 1 1 2 Instrument Markings Airspeed Indicator refer to respective POH Engine Instruments refer to re...

Page 13: ...e pads M I 42176 Fuselage Seat cover FK Lightplanes 1 4 Engine specifications refer to the respective engine manual Exhaust system ROTAX The engine is delivered optionally with a Rotax steel or with a stainless steel exhaust system Note Based on past experience it is recommended to install the stainless steel system because of the durability of the product especially in regions with high humidity ...

Page 14: ...a given weight Empty weight Weight of the airplane including unusable fuel full operating fluids and full oil equipment as indicated 1 5 2 Basic Empty Weight By using the following formula the C G is computed Reference line datum for all arms is the leading edge of the wing Prior to delivery each aircraft has been weighed with the fuselage level reference line see drawing below including oil and c...

Page 15: ...eighing scales It is very important that the plane is not lifted on the scales By lifting the plane on the scales the lateral forces of the main gear spring can falsify the result Once the plane stands on the scales it must be checked if the firewall is perpendicular to the floor By inserting a plate under the front or main wheels the plane can be aligned correctly CAUTION The plane must be secure...

Page 16: ... total Fuel capacity Option 2 Wing tank 2 x wing tanks 38l 10 US gal each 76l 20 US gal total LSA optional Long range wing tanks 2 x 55l 14 5 US gal each 110l 29 US gal total WARNING The values include unusable fuel Fuel specification Refer to the original corresponding chapter in the engine operator s manual Rotax AVGAS should only be used if MOGAS is not available or in case of problems caused b...

Page 17: ... locker 1 9 General Safety Information This chapter deals with the normal procedures recommended for the safe operation of the FK 9 WARNING Ensure that the parachute system is always secured with the safety pin Never leave the plane unattended with unauthorized persons especially when the engine is running Use caution during taxi and engine run up Note that a foreign object can come into the dange...

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Page 19: ...tervals 2 1 1 Required Tools Set hexagon Allen wrench Set screwdriver Set metric ratchet wrench or set of metric combination wrench Torque wrench Oil filter wrench Side cutters Pliers Safety wire twisters 2 1 2 Parts materials required Metric screws and nuts Loctite 243 Safety wire Oil filter Gaskets Spark plugs 2 1 3 Level of maintenance Line 2 1 4 Certification required Owner LSA Repairman Inspe...

Page 20: ...heck flight controls for wear lubrication and bearings are secured X X X Check the trim for proper operation the friction must be high enough to assure the trim does not move without pilots action X X X Check fuel system for leaks contamination dirt Change the fuel filter X X X Check nose wheel damper for cracks and wear X X X Check tail wheel for cracks and wear Check nose tail wheel steering for...

Page 21: ...ecks Note An indication for an overload on the landing gear can be o Abnormal taxi behavior o Propeller cone does not fit anymore to the cowling o Unbalanced alignment from wings to ground 2 4 1 Required Tools Standard metric tools Torch light Inspection Mirrors 2 4 2 Parts materials required Only if a described part is damaged 2 4 3 Level of maintenance Line 2 4 4 Certification required Owner LSA...

Page 22: ...int from nose wheel strut to engine mount for cracks Inspect complete main gear assembly for cracks deformation and play Pos 1 Inspect main gear spring for cracks deformation and position Note Be aware that the composite main gear spring can collapse due to their characteristics long after the overload Pos 2 Check if washer plates for main gear spring is in position Pos 3 Inspect main gear spring ...

Page 23: ...fication required Owner LSA Repairman Inspection LSA Repairman Maintenance A P Note A clean surface is very important for aircraft performance Keep the whole aircraft and especially the leading edges of the wings and propeller blades as clean as possible Clean the airplane after each flight day 3 2 5 Painted Surfaces Before washing cover the pitot tube prevent water incursion Wet all painted surfa...

Page 24: ...e carpet by using the proper attachment Use a soft brush attachment to vacuum the dashboard Use the same attachment vacuuming the seats Upholstery covers and seat cushions can also be removed from the cockpit A number of upholstery cleaning agents available Use them according to the instructions If you don t have an upholstery cleaner a mild laundry detergent will work as well Mix some detergent w...

Page 25: ... be removed or closed IMPORTANT for wing assembly unfold the wing with the leading edge facing downwards turn the wing into its normal position and push it towards the fuselage close both wing bolts Install the strut with its two bolts the upper one is screwed Cover the gap between wing and fuselage with tape for better aerodynamics Secure all bolts Install the other wing in the same manner The st...

Page 26: ...leading edge facing to the ground now fold it and store it into the device 3 4 Fuselage Interiors 3 4 1 Required Tools Standard metric tools 3 4 2 Parts required None 3 4 3 Level of maintenance Annual Aircraft Inspection 3 4 4 Certification required LSA Repairman Maintenance 3 4 5 Dismantling interiors and seats Front console removal Unscrew activator handles for brakes and trim The seats can be t...

Page 27: ...which is connected to the left rudder pedal The nose wheel has a shock absorber with hydraulic damping and adjustable spring Nose wheel size is 4 00 x 4 main wheel size is 4 00 x 6 Aerodynamic wheel pants are available for the nose and main wheels Tail wheel Classic Version The taildragger version has a steerable tail wheel which is connected to the rudder cables The tail wheel support is a multi ...

Page 28: ...Structures page 6 document code des 003 3 6 Flight Controls 3 6 1 General 3 6 2 Required Tools Standard metric tools 3 6 3 Parts required None 3 6 4 Level of maintenance alteration or maintenance minor repair and Aircraft Inspection 3 6 5 Certification required A P Mechanic ...

Page 29: ...e des 003 3 6 6 Rudder Rudder and nose wheel control is served by dual rudder pedals The rudder is served by cables the nose wheel is controlled by a push pull rod connected to the left pedal The rudder is mounted to the vertical fin by two hinges and is secured by two bolts with split pins cotter pins ...

Page 30: ...Maintenance Manual FK 9 B F Technik Vertriebs GmbH Revision 2 Section 3 Structures page 8 document code des 003 3 6 7 Flaps and ailerons Note scheme as shown for Mk IV Pickup for Flap Indication Mk IV ...

Page 31: ...evision 2 Section 3 Structures page 9 document code des 003 3 6 8 Elevator dismantling of tailplane To dismantle the elevator first remove the rudder Disconnect cables and hinge bolts of the rudder so the rudder can be taken away Then dismantle elevator ...

Page 32: ...nts for jacking 1 lower engine mount where connected to the fuselage or engine mount junctions hanging up 2 main gear beam where connected to the fuselage 3 nose tail wheel where connected to the fuselage For towing forward only connect the rope to the main gear To stow the dismantled wings use storage tools with a minimum contact area of 150mm The leading edge should have no contact to the storag...

Page 33: ...urface of the horizontal stabilizer Attention when towing on wet frozen or snowed soil and weather conditions For towing we recommend to use a hand tow bar which is connected to the nose gear axel of the aircraft Push or pull with one hand on the propeller blade in close proximity to the propeller cone and with the other hand steer the plane with the tow bar A tow bar may be used to tow the aircra...

Page 34: ...cape Returning Aircraft to Service After flyable storage returning the aircraft to service is ensure by performing a thorough pre flight inspection Ensure all protective covers are removed 3 8 4 Temporary Storage Temporary storage is defined as aircraft in a non operational status for a maximum of 90 days CAUTION Do not set the parking brake as brake seizing can result Secure the aircraft with whe...

Page 35: ...ularly and clean surfaces if necessary Check fuel tanks and fuel system for moisture once a week especially when stored outside Returning Aircraft to Service After indefinite storage perform a thorough pre flight inspection before returning the aircraft to service Ensure all protective covers are removed In addition we recommend Carry out at least a 100 hour inspection Check tire pressure Check br...

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Page 37: ... manufacturer s manual 4 1 3 Level of maintenance Refer to the corresponding chapter in the engine manufacturer s manual 4 1 4 Certification required Refer to the corresponding chapter in the engine manufacturer s manual 4 2 General The engine cowling can easily be removed for maintenance and checks Oil and coolant can be checked by opening a small cap on the right upper part of the cowling Note O...

Page 38: ... page 2 document code des 003 Overview of engine installation and engine systems ROTAX Important note engine and all connected systems and parts should be clear from aircraft cowl engine mount or any fixed aircraft structure especially with engine running pictures show type Mk IV ...

Page 39: ...Maintenance Manual FK 9 B F Technik Vertriebs GmbH Revision 2 Section 4 Engine page 3 document code des 003 Systematic of waterlines connected to water pump Carburetors and throttle activators ...

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Page 41: ...other sources of ignition when working with fuel Know the next location and operation of fire extinguishers Disconnect the battery and remove or turn off ignition sources before working with fuel Any work on the fuel system should be done in a well ventilated area Note To reduce the risk of moisture condensation the tanks should be filled after the last flight of the day or before storage 5 1 Insp...

Page 42: ...el valve because its electrical fuel pump closes the fuel line as soon as the ignition is switched off One fuel drain valve is located at the lower fuselage forward of the main landing gear Fuel quantity is indicated by a gauge at the tank After refueling this indication is accurate after both tanks have leveled This can take up to 5 minutes Although the fuel cap has a water drain it is recommende...

Page 43: ...ected to the vent system 8 of the main tank Each tank has a fuel valve 19 Handling of the wing tank To fill or empty the tank the respective fuel valve 19 must be open and the pump must be switched to the UP or DOWN position Filling of the wing tank has to be done on ground with at least 20l of fuel in the main tank The wing tank is full as soon as fuel is flowing via the overflow vent 23 into the...

Page 44: ...fuel valve and a fuel quantity indication Fuel caps and vents are on top of the wings Fuel feeding to the engine is similar to option 1 Fuel must be used from one tank at a time For take off and landing the fullest tank must be used The drain valve is located underneath the wing Ensure that no fuel spills on the cockpit windows during fuelling draining because fuel can damage Lexan windows ...

Page 45: ...bs GmbH Revision 2 Section 5 Fuel System page 5 document code des 003 Fuel quantity indication 5 Fuel valve 7 Fuel System Version Wing Tanks Italy only Aircraft models for Italy also have a drain valve at the gascolator in the engine compartment ...

Page 46: ... dismantled fuselage tanks and cleaned For this drain the complete system by using the electrical fuel pump and dismantle all connections Clean the tanks using fuel or spirit alcohol Do not use water or solvents Change fuel lines filter and hardware according cycles given in maintenance tables 5 1 11 Fuel Filter Removal and Installation Before starting make sure that the tanks have been emptied or...

Page 47: ... passenger seat Replace seat pan for access Option 2 Wing Tanks Fuel Pump is located behind the dashboard next to the firewall Fold back for access Steps Open both hose clamp on the fuel pump Disconnect fuel lines from the fuel pump attention with fuel leakage Open both bolts which holds the pump and disconnect all electric cables Replace fuel pump WARNING The fuel pump has only one direction of f...

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Page 49: ...Warp Drive First release the fixing screws from propeller hub to engine flange then remove the propeller cone plate Release fixing screws of propeller blades so that it is possible to move the blades Attach the angle of attack tool in way as shown Adjust each blade to required angle of attack When fixing the screws measure proper angle of attack again this may change by tightening the screws Add p...

Page 50: ...vision 2 Section 6 Propeller page 2 document code des 003 6 1 2 Required Tools angle of attack tool 6 1 3 Parts required new lock nuts 6 1 4 Level of maintenance Line Overhaul alteration or maintenance Inspection 6 1 5 Certification required A P Mechanic ...

Page 51: ... Baggage The baggage compartment is located behind the pilots seats separated from the cabin by the backrest bulkhead The access is on the left side from the outside by a small door CAUTION Secure all items in the baggage compartment before flight 7 3 Doors The doors can be opened and locked from inside with a handle The pilots door can also be opened closed from outside Both doors have a small ve...

Page 52: ...of and aft windows are LEXAN polycarbonate type 1 0mm All windows are glued to the fuselage with SIKAFLEX 221 The roof windows are additionally secured with Alu Alu rivets LEXAN can only be cleaned and not polished The front windscreen may be Plexiglas 2 5mm glued into the airframe Note Only use Alu Alu rivets to secure LEXAN windows other type of rivets produce too much tension forces which resul...

Page 53: ...e The brake fluid reservoirs master brake cylinder is located under the pilot s seat By closing a valve at the center console when pressure has been applied the hydraulic brake can function as a parking brake CAUTION only models manufactured before November 2005 if the valve is closed park brake set the brake handle is without function In case the aircraft starts to move with park brake set open t...

Page 54: ...imately two thirds CAUTION Do not remove the cover from the master brake cylinder Fill the syringe with brake fluid and eliminate all air bubbles in the syringe Remove the protection cap from the bleeder valve and open the valve with the combination wrench 7mm till it can be unscrewed by hand Note Do not unscrew the bleeder valve too much otherwise the brake system may suck in air Connect the syri...

Page 55: ...Parts required Standard heat resistant tubes fittings and clamps 7 6 4 Level of maintenance Alteration or maintenance Annual Aircraft Inspection 100 hour inspection 7 7 Parking Parking procedures depend on local weather conditions When parking the airplane outside the hangar the airplane should be adequately secured to the ground especially in severe weather If possible head the plane into the win...

Page 56: ...eel should be secured by the optionally tow support or by wrapping the tail wheel Note To secure the airplane use sufficiently strong anchors and ropes In severe weather conditions use multiple lines During gusty or high wind conditions a periodically review of ropes and ground anchors is necessary to prevent excessive movement of airplane Do not install ground anchors direct under the tie down po...

Page 57: ...anel contains all required flight navigation and engine instruments for VFR operations This describes a standard equipment configuration for Rotax 912 engine type different options can be provided on request 8 1 Instrument Panel Standard Panel Instruments Avionics air speed indicator altimeter 5000ft compass slip indicator oil pressure oil temperature CHT rpm indicator ...

Page 58: ...ocument code des 003 Alternative Solution Instruments Avionics air speed indicator Filser ATR833 Radio three point altimeter 20 000ft min 80mm instead of original altimeter TRT800 Transponder climb indicator 80mm feet min Garmin 695 GPS compass slip indicator oil pressure oil temperature CHT rpm indicator ...

Page 59: ...3 document code des 003 Dynon Solution Instruments Avionics air speed indicator backup instrument D100 PFD altimeter 5000ft backup instrument D120 EMS climb indicator 80mm feet min Filser ATR833 Radio compass TRT800 Transponder slip indicator Garmin 695 GPS oil pressure oil temperature CHT rpm indicator ...

Page 60: ...ocument code des 003 Garmin Solution Instruments Avionics air speed indicator backup instrument duo G3X screens with PFD MFD EMS altimeter 5000ft backup instrument Garmin SL40 Radio climb indicator 80mm feet min Garmin GTX328 Transponder compass slip indicator oil pressure oil temperature CHT rpm indicator ...

Page 61: ...ressure is provided from the pitot tube on the left wing strut The pitot tube consists of two parts they are connected by a plastic line which works as bend protection The pressure is distributed by means of transparent plastic lines to the individual instruments On the back side of each instrument is an indication to which pressure it must be connected Or refer to the manufacturers installation m...

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Page 63: ... switches and fuses The electrical system is designed for a maximum load of 12A Connecting a lot of high drain components landing lights etc may result in a higher load This can lead to overheating and or an electrical smoke fire condition and must be avoided under all circumstances An actual wiring plan is available under www fk servicecenter com 9 1 1 Required Tools Standard metric tools 9 1 2 P...

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Page 65: ...r shop for composite structures Repairs on the main structure must only be performed by authorized persons or companies in accordance with type certificate holder s advice 10 2 Subsidiary Structure The subsidiary structure contains of 1 front fuselage covers cowlings glass fiber composite 2 wheel pants glass fiber composite 3 spinner 4 inside cockpit covers consoles floor 5 fabric skin 10 2 1 Requ...

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Page 67: ...ose used in car repair shops 11 1 1 Preparation of Metal Remove dust and grease For perfect adhesion of the repair area it is necessary to remove the old paint coat with sandpaper The sanded surface must be larger bigger by 2 inches from the damaged area Sand surfaces with 180 320 sandpaper and fine scuff pads Remove dust and grease 11 1 2 Preparation of Composites Remove dust and grease For perfe...

Page 68: ...color types can be received from type certificate holder 11 2 1 Primer Before applying the primer the surface should be prepared as described before The Primer should be applied with a HVLP gun to reach a corrosion protection and smooth surface After the primer has dried sand the area using 600 800 wet sandpaper with many of water till you get a smooth surface Dry the area and remove dust and grea...

Page 69: ...e latest 10 days after receipt of the airplane Non compliance with handling maintenance and checking instructions as indicated in the flight and maintenance manuals as well as the respective updates which are published in the manufacturer s website will void warranty and or guarantee claims Note No warranties and or guarantees other than defined in the actual warranty conditions are made see Gener...

Page 70: ...Maintenance Manual FK 9 B F Technik Vertriebs GmbH Revision 2 Section 12 Annex page 2 document code des 003 12 2 Warranty claim report ...

Page 71: ...Maintenance Manual FK 9 B F Technik Vertriebs GmbH Revision 2 Section 13 Feedback Form page 1 document code des 003 13 Feedback Form ...

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