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Registration mark: Category:
ULLa
Manufacturer: JIHLAVAN airplanes, s.r.o., Znojemská 826/64, 586 01 Jihlava, Czech Republic, European Union
SL200 FMM 2009-10-21
KP 2U (SKYLEADER 200)
Production number:
KP 2U (SKYLEADER 200)
OWNER – OPERATOR OF THE AIRCRAFT: Owner of the aircraft:
The change of the ownership:
Name:
Name:
Address:
Address:
Identity number:
Identity number:
Registration mark:
Registration mark:
From, To:
From, To:
The change of the ownership:
The change of the ownership:
Name:
Name:
Address:
Address:
Identity number:
Identity number:
Registration mark:
Registration mark:
From, To:
From, To:
SL200 FMM 2009-10-21
CHAPTERS: Book 1 FLIGHT MANUAL
1. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. OPERATIONAL LIMITATIONS AND PERFORMANCE. . . . . . . . . . . . . . . . . . 35 3. STANDARD PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4. OTHER PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5. EMERGENCY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Book 2 MAINTENANCE MANUAL
1. AIRCRAFT MAINTENANCE REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . 81 2. WINGS AND HORIZONTAL TAIL UNIT DISMANTLING . . . . . . . . . . . . . . . . 91 3. LANDING GEAR DISMANTLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4. CHANGING FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 5. ELECTRIC WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 6. MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
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CONTENTS: Book 1
1.
FLIGHT MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1. 1.2. 1.3. 1.4. 1.5.
Profile of the company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment of the airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amendments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.1. Amendments and supplements of the Flight Manual. . . . . . . . . . . . 1.5.2. Amendments list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6. Abbreviations and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7. Basic technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.1. Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.2. Aircraft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.3. Deflections of the control surfaces. . . . . . . . . . . . . . . . . . . . . . . . 1.7.4. Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.5. Diagram of aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8. Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8.1. Rotax 912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8.2. Rotax 914 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9. Propeller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10. Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1. Operating switches of the left control stick . . . . . . . . . . . . . . . . . . 1.10.2. Landing gear supervisory display . . . . . . . . . . . . . . . . . . . . . . . .
. 16 . 17 . 19 . 20 . 20 . 20 . 21 . 22 . 23 . 23 . 23 . 24 . 24 . 25 . 27 . 27 . 28 . 29 . 29 . 29 . 30
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1.10.3. Notices in the cockpit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.
3.
OPERATIONAL LIMITATIONS AND PERFORMANCE . . . . . . . . . . . . . . . . 35
2.1. Structural regulations . . . . . . . . . . . . . . 2.2. General. . . . . . . . . . . . . . . . . . . . . . . . 2.3. Speeds . . . . . . . . . . . . . . . . . . . . . . . . 2.4. Take-off and landing distances . . . . . . . . 2.5. Climbing . . . . . . . . . . . . . . . . . . . . . . . 2.6. Gliding . . . . . . . . . . . . . . . . . . . . . . . . 2.7. Flight range . . . . . . . . . . . . . . . . . . . . . 2.8. Ceiling . . . . . . . . . . . . . . . . . . . . . . . . 2.9. Manoeuvres approved . . . . . . . . . . . . . . 2.10. Engine limitations. . . . . . . . . . . . . . . . . 2.10.1. Rotax 912 . . . . . . . . . . . . . . . . . . . . . 2.10.2. Rotax 914 . . . . . . . . . . . . . . . . . . . . . 2.10.3. Other engines limitations . . . . . . . . . . . 2.11. Fuel capacity . . . . . . . . . . . . . . . . . . . . 2.12. Wind and air operational limitations. . . . . 2.13. Weights and C-G limits . . . . . . . . . . . . . . 2.13.1. Weight and Center of Gravity Limits charts 2.14. Load factors. . . . . . . . . . . . . . . . . . . . . 2.15. Flight envelope . . . . . . . . . . . . . . . . . . 2.16. Type of operation . . . . . . . . . . . . . . . . . 2.17. Other limitations . . . . . . . . . . . . . . . . .
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. 35 . 35 . 36 . 37 . 37 . 38 . 38 . 39 . 39 . 40 . 40 . 41 . 42 . 42 . 43 . 44 . 45 . 47 . 47 . 48 . 48
STANDARD PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.1.
Pre-flight inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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3.2. 3.3. 3.4. 3.5. 3.6. 3.7. 3.8. 3.9. 3.10. 3.11. 3.12. 3.13. 3.14. 3.15.
4.
5.
Aircraft maintenance after each flight . Procedures after cockpit entering . . . Starting the engine . . . . . . . . . . . . . Engine warm up and engine check . . . Procedures before taxiing . . . . . . . . Procedures on holding point . . . . . . . Start line procedures, take-off . . . . . . Downwind procedures . . . . . . . . . . . Base leg procedures . . . . . . . . . . . . Procedures on final approach, landing Procedures after landing . . . . . . . . . Engine shut down . . . . . . . . . . . . . . Leaving airplane. . . . . . . . . . . . . . . Check list of standard procedures . . .
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OTHER PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1.
Procedures for landing gear operation . . . . . . . . . . . . . . . . . . . . 4.1.1. Signaling check before flight . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2. Landing gear retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3. Landing gear extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2. Indicated conditions of wing flaps and LG positions . . . . . . . . . . . .
. 67 . 67 . 68 . 68 . 69
EMERGENCY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.1. 5.2. 5.3. 5.4.
Engine failure during rolling . . . . . . Engine failure after take-off . . . . . . Engine failure during flight . . . . . . . Emergency undercarriage extension.
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. 70 . 70 . 70 . 72
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5.5. 5.6. 5.7. 5.8. 5.9. 5.10. 5.11. 5.12. 5.13. 5.14. Book 2
1.
Emergency landing . . . . . . . . . . . . Belly landing . . . . . . . . . . . . . . . . Interrupted landing. . . . . . . . . . . . Fire - on ground, engine not running. Fire - on ground, engine running . . . Fire - during flight . . . . . . . . . . . . . Carburettor freezing . . . . . . . . . . . Engine and propeller vibrations. . . . Emergency parachute system usage . Check list of emergency procedures .
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. 72 . 73 . 73 . 73 . 74 . 74 . 75 . 75 . 75 . 76
MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
AIRCRAFT MAINTENANCE REGULATIONS . . . . . . . . . . . . . . . . . . . . . . 81
1.1.
Periodic maintenance . . . . . . . . . . . . . . . 1.1.1. Inspection of control surfaces clearances . . 1.1.2. Maximal allowed control clearances. . . . . . 1.2. Lubrication of the aircraft . . . . . . . . . . . . . 1.3. Accumulator maintenance . . . . . . . . . . . . 1.4. Hydraulic brakes settings and maintenance . 1.4.1. Description . . . . . . . . . . . . . . . . . . . . . 1.4.2. Operation . . . . . . . . . . . . . . . . . . . . . . 1.4.3. Refilling and deaerating . . . . . . . . . . . . . 1.4.4. Adjusting jaw clearances . . . . . . . . . . . . . 1.4.5. Brake assembly . . . . . . . . . . . . . . . . . . . 1.5. Adjusting of control cables . . . . . . . . . . . . 1.5.1. Changing cable adjusters . . . . . . . . . . . .
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. 81 . 81 . 82 . 82 . 83 . 84 . 84 . 84 . 84 . 85 . 86 . 86 . 87
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10
1.6. 1.7.
2.
3.
4. 5. 6.
The governor rectifier circuit breaker . . . . . . . . . . . . . . . . . . . . . . 88 Locking hook adjusting and checking . . . . . . . . . . . . . . . . . . . . . . 89
WINGS AND HORIZONTAL TAIL UNIT DISMANTLING . . . . . . . . . . . . . . . 91
2.1. 2.2. 2.3. 2.4.
Removal of cover strip between wing and central section . . . . . . . . Removal and replacement of inspection covers. . . . . . . . . . . . . . . Removal of seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly and assembly of outer wings . . . . . . . . . . . . . . . . . . 2.4.1. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2. Mark bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5. Disassembly and assembly of elevators . . . . . . . . . . . . . . . . . . . . 2.6. Disassembly and assembly of stabilizer . . . . . . . . . . . . . . . . . . . .
. 91 . 91 . 92 . 92 . 92 . 93 . 94 . 96 . 97
LANDING GEAR DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.1. 3.2. 3.3. 3.4. 3.5.
Removal of shock absorbers from main undercarriage . . . . . . . Disassembly and assembly of main LG shock absorber . . . . . . . Disassembly and assembly of main fixed LG shock absorber . . . Front undercarriage shock absorber removal and assembly . . . Front undercarriage shock absorber disassembly and assembly .
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. 99 . 99 100 101 102
CHANGING FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 ELECTRIC WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 MAINTENANCE PLAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
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13
200 BOOK 1 FLIGHT MANUAL
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Flight Manual SL 200
1.
Book 1
GENERAL INFORMATION
Dear Valued Customer! Kindly accept our congratulations to the purchase of the UL/S-LSA aircraft SKYLEADER, which is a pure result of our own research & development. Please remember - flying with SKYLEADER Aircraft is low-cost, safe and fun! We believe that SKYLEADER Aircraft will satisfy your needs on more than 100%. As part of our continuing commitment to responding to your needs, we continuously improve the quality of the products and services we provide to all of our customers. Team of SKYLEADER Aircraft is constantly looking for your satisfaction across a wide range of attributes such as performance, product quality, service and repair, technical support, training, delivery and most importantly, your overall satisfaction with SKYLEADER Aircraft. Our company sincerely thank all of you who became our clients. Your continued feedback is invaluable to us, and supports our endless quest in pursuing your Total Satisfaction. Let us wish You and Your new SKYLEADER Aircraft all the best!
Sincerely, Team of JIHLAVAN airplanes, s.r.o. („SKYLEADER Aircraft“) www.skyleader.aero
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1.1.
Book 1
Profile of the company The company JIHLAVAN airplanes, s.r.o. was set up in March 2005after complete takeover of all incorporeal rights and the complete technology of production of the ultra-light aircraft from its predecessor company Kappa 77 a.s.. With the usage of workers know-how the company JIHLAVAN airplanes, s.r.o., presented as SKYLEADER Aircraft, started the production of allmetal UL/S-LSA aircraft under its own trade mark SKYLEADER 150, SKYLEADER 200 and SKYLEADER 500. The primary goal of the company was start the serial production and further research & development of the aircraft.
SKYLEADER Aircraft regularly supplies the market and continues in organizational steps for the enlargement of the production. With support of the Institute of Aerospace Engineering at the Brno University of Technology, CZ is the aircraft developed and modernized all the time despite its existing top characteristics. The 3.200 m2 of modern production area in the company Jihlavan, Inc. offers developing our activities in the future. There are established trade contracts with the representatives in Italy, USA, South Africa, Taiwan, Germany, Poland, the Netherlands, France, Spain, and many other countries. Its products are presented on the international exhibitions in Friedrichshafen (Germany), Sun ´n Fun and Oshkosh (the USA), Rybnik (Poland), Blois (France), Cielo e Volo, Meeting di Primavera (Italy) etc. JIHLAVAN airplanes, s.r.o. developed the final production of WideBody model, which is now available on the market under trademark SKYLEADER 200 and SKYLEADER 500. It takes the top flying qualities and extends the comfort of crew by enlarging the cockpit on the maximum width along with the keeping of minimal operating costs and maximal safety. SL200 FMM 2009-10-21
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1.2.
Equipment of the airplane
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1.3.
Instrument panel
See separate list: Instrument panel.
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1.4. Validity:
1.5.
Book 1
Introduction The Flight Manual is valid exclusively for the plane whose number is on the first page of the manual.
Amendments 1.5.1. Amendments and supplements of the Flight Manual
All amendments and supplements of the Flight Manual should be done as follows: a) the manufacturer of UL aircraft sends an operational update with new and revised information to the owner of the Flight Manual. b) the holder of the Flight Manual is obliged: 1/ to change the original information with the revised edition, which is marked by the abbreviation „REV“ and the date of the change. 2/ to make a record of receiving the amendment into the amendment list. This list is found in art. B1-1.4.2..
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1.5.2. Amendments list
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1.6.
Abbreviations and definitions
CAS
Calibrated airspeed. It is IAS corrected by errors due to instrument and pitot port errors. CAS is equivalent to the true airspeed at zero level of international standard atmosphere. Indicated airspeed. It is the reading of the in-built airspeed indicator corrected by the instrument error. True airspeed. It is the aircraft velocity considering “undisturbed” air. Instrument flight rules. Visual flight rules. International standard atmosphere. Mean aerodynamic chord. Vertical tail unit (fin with rudder). Horizontal tail unit (stabilizer with elevator). Minimal allowed velocity in landing configuration. Stalling velocity with flaps up. Maximum velocity for flap extending and retracting. Maximum velocity with flaps fully extended. Designed maneuvering velocity. Velocity of cruising flight. Maximum velocity for landing gear extending and retracting. Maximal speed of horizontal flight. Never exceed velocity. Runway Landing gear Emergency Parachute System
IAS TAS IFR VFR ISA MAC VTU HTU VS0 VS1 VF0 VFE VA VC VL0 VH VNE RWY LG EPS
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1.7.
Book 1
Basic technical data 1.7.1. Technical description
KP 2U (SKYLEADER 200) is an ultralight, two-seater, all-metal, self-contained, low-wing aircraft with side-by-side seats. Maximal take-off weight of the airplane is 450 kg (992 lb), with Emergency Parachute System MTOW is 472,5 kg (1198 lb). Supporting surfaces are with two spars. They are composed of a rectangular centre-section and a trapezoidal outer wing with Fowler flap. The fuselage is of a semi-monocoque construction. Tail units are self-contained, all metal with a forward HTU. A three-wheeled undercarriage with a controlled front wheel is retractable or fixed.
1.7.2. Aircraft dimensions
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1.7.3. Deflections of the control surfaces
1.7.4. Fuel tanks Maximum capacity of standard fuel tanks: 2x32 l / 2x8,45 U. S. gal Maximum capacity of additional fuel tanks: 2x45 l / 2x11,9 U. S. gal Detailed information about fuel tanks are in chapter B1-2.11. SL200 FMM 2009-10-21
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1.7.5. Diagram of aircraft
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1.8.
Fluids 1.8.1. Rotax 912
For all the fluids, follow the instructions in the Rotax 912 UL/ULS manual. Operating propellants used by manufacturer:
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1.8.2. Rotax 914 For all the fluids, follow the instructions in the Rotax 914 F/UL Manual. Operating propellants used by manufacturer:
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1.9.
Book 1
Propeller
Detailed data of the propeller is stated in the Propeller Technical Manual. Type of the propeller is written in the section Equipment of the airplane at the beginning of this manual.
1.10. Instrument
1.10.1. Operating switches of the left control stick Button on the G1 head could be used for Transceiver or Intercom or stay unused.
Transceiver Intercom
G1 head
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Transceiver Trim – nose down Trim – nose up Autopilot disconnect Intercom G5 head
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1.10.2. Landing gear supervisory display
Key: 1. Control light of left gear unlocking – red 2. Control light of front gear unlocking – red 3. Control light of right gear unlocking – red 4. Control light of left gear extending – green 5. Control light of front gear extending – green 6. Control light of right gear extending – green 7. Shining lights check button
1.10.3. Notices in the cockpit
a) Limitations, restrictions, warnings Notices are placed on the instrument panel within view of the pilot.
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reg. mark .........................
Empty weight Max. take-off weight Max. take-off weight with EPS Max. total baggage weight on board Min. pilot weight Max. pilot weight Never exceed speed Min. permitted speed in landing configuration Never exceed speed with flaps extended Max. permitted speed for undercarriage extending and retracting
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............ kg / .......... lb 450 kg / 992 lb 472,5 kg / 1042 lb 30 kg / 66 lb 60 kg / 132 lb 120 kg / 265 lb VNE = 260 km/h / 140 kt VS0 = 56 km/h / 30 kt VFE = 100 km/h / 55 kt VLO = 150 km/h / 81 kt
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b) Labeling, operating and controlling
Labels on the instrument panel: - parachute system: EMERG. PARACHUTE SYSTEM PULL TO RELEASE
- controlling of the trim: TRIM
- flaps:
Control lights: BATTERY Switches: INTERCOM TRIM BEACON FUEL PUMP MASTER switch box: CIRCUIT A CIRCUIT B socket: 12 V DC/10 A circuit breaker notations Engine instruments: - RPM - Manifold pressure - Voltmeter
Controls: CHOKE HEATING - PULL TO OPEN UNDERCARRIAGE UP, DOWN COOLING L PULL ON COOLING R PULL ON
- Fuel pressure - Oil pressure - Oil temperature
- Fuel L, Fuel R - CHT (Cylinder Head Temp.) - Motohours
- EGT (Exhaust Gas Temp.) - Hobbs meter
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Labels on the panel under the instrument panel: - landing gear lever (retractable gear only!) :
- fuel cock:
Labels on tunnel between seats (from ahead):
- emergency landing gear control (retractable gear only!):
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- engine intake:
- label on the throttle lever:
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Label on canopy lock system: - inside:
- outside:
Labels on back wall of cockpit: - headphones: CO-PILOT
PILOT
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2.
OPERATIONAL LIMITATIONS AND PERFORMANCE
2.1.
Structural regulations
Book 1
The KP 2U (SKYLEADER 200) aircraft construction, materials and performance correspond with UL – 2 regulations issued by LAA ČR (Light Aircraft Association of Czech Republic).
2.2.
General
Limitations and performances stated here are valid for the version with retractable landing gear and in flight adjustable propeller. Limitations and performances for fixed landing gear and not adjustable propeller are lower. Stalling speeds ARE VALID for all aircraft versions!!!
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2.3.
Book 1
Speeds
MTOW 450 kg (992 lb) and 472,5 kg (1042 lb)
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2.4.
Take-off and landing distances
Data are valid for concrete RWY
2.5.
Climbing
Using take-off power.
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2.6.
Book 1
Gliding
Gliding velocities when engine idling.
Gliding speed with engine stopped. Flaps take-off position, undercarriage extended / fixed.
2.7.
Flight range
This data are for INFORMATION ONLY! Data are taken for 75% continuous performance.
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2.8.
Ceiling
Ceiling altitude:
2.9.
Book 1
4500m /14764 ft
Manoeuvres approved
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2.10. Engine limitations 2.10.1. Rotax 912 Specifications stated in this article are not complete. For more information, see Operator‘s Manual for all versions of ROTAX 912. Detailed data of the engine is stated in the Operator‘s Manual for ROTAX engine Type 912 Series. It is not stated in this manual!
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Book 1
2.10.2. Rotax 914 Specifications stated in this article are not complete. For more information, see Operator‘s Manual for all versions of ROTAX 914. Detailed data of the engine is stated in the Operator‘s Manual for ROTAX engine Type 914 Series. It is not stated in this manual!
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2.10.3. Other engines limitations - do not use increased power of engine during flight (allowed for take-off and in emergency cases only) - take-off is prohibited if engine is running unnaturally or if data on engine instruments is not in operating ranges
2.11. Fuel capacity Valid values for the aircraft with standard fuel tanks only:
Valid values for the aircraft equipped with additional fuel tanks:
Electromechanical fuel gauges indicate the amount of fuel. SL200 FMM 2009-10-21
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2.12. Wind and air operational limitations
For more information about temperatures see the Operator´s manual for all versions of ROTAX Type 912 or ROTAX Type 914.
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2.13. Weights and C-G limits MTOW 472,5 kg / 1042 lb
MTOW 450 kg / 992 lb
If all the limits of the variable load are respected, the C – G is situated in stated limits in all configurations.
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2.13.1. Weight and Center of Gravity Limits charts An example of how to use the Weight and Center of Gravity Limits chart:
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2.14. Load factors Max. load factor positive – flaps off + 4,0 Max. load factor negative – flaps off - 2,0 Max. load factor positive – flaps extended + 2,0
2.15. Flight envelope This is for both max. take-off weight 450 kg (992 lb) and 472,5 kg (1042 lb).
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2.16. Type of operation Only daytime flights under VFR and without known icing conditions are approved.
2.17. Other limitations - When handling the aircraft on the ground, always use the tow bar - Push the plane at the center section only - Do not push nor pull the aircraft via the propeller! - Do not push nor pull the aircraft via the wings or control surfaces - Always tie the aircraft down when it is left alone for a longer time! Use the guy eye on the rear bottom part of fuselage and main landing gear legs! - If the aircraft is placed on blocks, it is prohibited to enter the cockpit, except for training purposes or undercarriage testing and possible repairs. - Smoking is strictly prohibited in the cockpit of the aircraft! - Seat adjustment during flight is prohibited.
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Flight Manual SL 200
3.
STANDARD PROCEDURES
3.1.
Pre-flight inspection
Book 1
Take off the protective coverings. If parked out of hangar unfasten guy ropes, chock the wheels. Carry out the fuel tanks desliming. Mud traps are placed at the bottom of both fuel tanks. There are numbered checking points on the drawing. These numbers are presented behind the checking point name. When checking some parts it is necessary to open covers and casings. Inspect the airplane as follows:
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a) Cockpit before entering (1.) - Check if landing gear lever is in DOWN position * - Master switch; turn on; check the amount of fuel and other el. instruments, functional check of anticollision beacon and turn off the master - Master switch, segmental switches and magnetos – in off position! - Fuel cocks - closed - Check the instruments (integrity of protective glass, zero values and attachment to instrument panel) - Check the seat belts (attachments to the frame, integrity of belts and braces) - Check if the control systems motion is free - Check the brake function - Check throttle lever motion (outer positions, fluency of movement) - Check attachment of the seat - Canopy opening and locking have to be easy - Cleanness of canopy glass - Affix or remove loose objects
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b) Engine area (2. 3. 4.) – check the following: - Open the engine cover, check engine mounting condition and attachment of engine, engine screws and engine mounting screws, shock absorbers condition - The spiral springs condition on exhaust system and their security lock with binding wire; exhaust gas temperature sensor condition and attachment of electric cables - Electric installation cables condition - Fuel hoses tightness and whole fuel installation tightness - Carburetor attachment, check rubber packing, throttle bowdens, choke and turbo compressor servomotor - The amount of engine oil in oil tank and close the tank - The amount of cooling fluid, cooling circuit tighteness, the level in overflow tank - Bowden tip attachment and threaded joint on string clip of in-flight adjustable propeller control system, if in-flight adjustable propeller is installed - Propeller inner screws tightness and the extension flange - Propeller blades condition and propeller hub spinner attachment - Pull-rods and end stops of directional control - Engine cowling attachment (screw tightness) – close it and lock it
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c) Front landing gear (2. 3. 4.) – check the following:
Book 1
- Tyre pressure - Split pins on wheel axis, fork and shock absorber attachment - Nuts on wheel axis, tyre surface and tire slip - Folding strut, according to airspace in the lock, tightness of nuts and their security locks on attachment points and folding strut joint; free movement of roller on the joint bolt of folding strut - Control of clearance, control screws and nuts - End stops of front gear on the front landing gear leg - Condition and position of shock absorber rubber inserts - Front gear gate, condition of its surface and sufficient oiling - Foot holding and secureness of the landing gear sensors SL200 FMM 2009-10-21
Flight Manual SL 200
Book 1
d) Fuel tanks (1. 19.) – check the following: - Fuel amount and refueling - Fuel tank attachments tightness (visually on the bottom side of fuel tank, additional fuel tanks – if are installed – and interconnection between main and additional tanks) - Fuel tank filler caps seals - Free passage of fuel tank ventilation e) Wings (1. 5. 6. 7. 8. 15. 16. 17. 18. 19.) – check the following: - Leading edge and whole wing facing - Winglets riveting - Pitot tube – right wing only (free passage, condition and direction) - Nuts and split pins on the main and rear wing attachment point (after removing covering strip)
f) Ailerons (6. 7. 16. 17.) – check the following: - Ailerons, bolts clearance, free motion in whole range of flap positions - Nuts tightness on attachment, clearaces and bolt security locks - Aileron control, angled lever, pull-rod forks and joint points security locks SL200 FMM 2009-10-21
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g) Flaps (7. 8. 15. 16.) – check the following: - Flap facing, guide countershaft oiled, guide bolts tightness, control clearances - Flap control, angled lever, screws and nuts, pull-rod forks and nut security locks - Pull down flaps and check the following: - Rollers free motion (during flap movement) - Function of flap locking mechanism in fully extended position – pushing to flap trailing edge - Clearances (amount of “lost motion”) in extending direction, flap pull down to 10° (take-off position) - Clearances perpendicular to flap extending direction, together with aileron movement SL200 FMM 2009-10-21
Flight Manual SL 200
h) Main landing gear (8. 15.) – check the following: - Tire pressure (use a tire pressure gauge) - Tire surface and tire position with regard to wheel rim (according to red mark) - Nuts tightness on wheel axis, attachment points and the joint connecting folding strut and shock absorber * / Nuts on wheel axis, attachment points and shock absorber - Condition and position of rubber inserts and plates of shock absorber - Free passage of wheel between landing gear legs * - Folding strut bearing against end stop on rear spar * - Hydraulic hose and brake check – liquid emission - Position and security of landing gear sensors * i) Fuselage (1. 8. 9. 11. 12. 14. 15. 19.) – check the following: - Fuselage facing - Cable covers, belts and casing of emergency parachute system (if installed) - Bottom anticollision beacon (functioning correctly) - Attachment of fiberglass “boot” of fin - Cables and cable adjusters of directional control - VTU guiding lever, its attachment and attachment of tighteners - End stops of directional control (7th bulkhead) - Elevator clearance in carrier - HTU balance beam (6th bulkhead) and its joint - Elevator pull-rod joint - Longitudinal end stops - Angled elevator lever, carriers and its joints (7th bulkhead) - Pull-rods HTU SL200 FMM 2009-10-21
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- Doubler and its joint j) Horizontal Tail Unit (9. 10. 11. 12. 13. 14.) – check the following: - Stabilizer and elevator facing - Stabilizer attachments to the fuselage and its security locks - Elevator attachment points, positioning and security locks - Elevator clearance in carrier and in attachment points - Trim and its positioning k) Vertical Tail Unit (9. 11. 12. 14.) – check the following: - Rudder pull-rod, its joints and security lock of adjustable fork - Fin and rudder facing - Rudder attachment points and their security locks - Rudder clearance in attachment points Write the inspection results into the logbook! SL200 FMM 2009-10-21
Flight Manual SL 200
3.2.
Book 1
Aircraft maintenance after each flight
Wash the plane and the propeller with water without addition of detergents after each flight. It is recommended to use any dish washing detergent or car shampoo for washing the surface behind the exhaust for easier removal of the dirt from the exhaust gas. The canopy perspex should be washed very carefully with a soft sponge after removing the remains of insects or other matter. The remaining drops may be removed with a wet wash-leather (chamois). While washing the plane check the condition of riveted and screwed joints, check the condition of the leading and trailing edges of the aerodynamic areas of the plane. During operation on grass RWY after rainfall, when RWY is wet and muddy, it is necessary to wash the undercarriage retraction system. It is important to wash the stops on the main undercarriage and the space inside the tunnel around the front wheel retracted position sensor. Stuck and dry mud could cause no retracting during the next flight. The inside of the cockpit should be kept clean using a small vacuum cleaner. After cleaning check the levels of fuel, oil and cooling liquids. If it is necessary, fill up.
3.3. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Procedures after cockpit entering
Check security lock of emergency parachute system (if installed) Adjust seat position, check seat locking mechanism Close and lock the canopy Safety belts – fasten and tighten Control stick – free motion Check brakes function Landing gear control lever in open (down) position – check * Master – “on“ Check the landing gear display – push the test button * Instruments – check values and settings (“lock” positions of gyroscopic instruments - if installed) Balancing – function test, neutral position Flaps – free motion, retract
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3.4.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Book 1
Starting the engine
Fuel gauges – check fuel amount Transceiver – turn off Fuel cock – open fuel tank with greater quantity of fuel (If is left fuel tank filled with more than ½ of fuel capacity, it is necessary to switch fuel cock to the left fuel tank.) Fuel stop cock – open it (if installed) Throttle –set idle (for cool engine; 1/3 for warm engine) Choke – according to engine temperature Propeller pitch – set minimal angle (if it is adjustable) Hold nose wheel in straight direction Area around propeller – free Magnetos – switch on both circuits (A+B) Fuel pump – switch on Press the starter Set engine speed after start up – 2500 1/min Check oil and fuel pressure Segmental switches – switch them on (transceiver, beacon, etc.) Fuel pump – switch off, when the fuel pressure is in normal
Electric fuel pump may not be switched on with empty fuel tanks and closed fuel cock!
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Flight Manual SL 200
3.5. 1. 2. 3. 4. 5. 6.
Engine warm up and engine check
Brake the airplane (hand brake, chocks) Set control stick and pedals in neutral position Set propeller pitch to min. angle (if it is adjustable) Engine speed - 2000 rpm and let run about 2 min., then warm up engine at 2500 rpm until oil temperature reaches 50C (122°F) Stepless increase engine speed to maximum, hold about 5 sec. and than stepless reduce back to idle; repeat 2 or 3 times Check alternately both magnetos with engine speed 4000 rpm; engine speed should not descend more than 300 rpm with one magneto off Difference between both magnetos should not exceed 120 rpm.
3.6. 1. 2. 3. 4. 5. 6. 7.
Book 1
Procedures before taxiing
Unlock emergency parachute system – if it is installed Release gyroscopes (attitude indicator, turn and bank indicator, gyro compass, etc.) (if installed) Propeller pitch set to min. angle (if it is adjustable) Retract flaps Report Check brake function and range of directional control when taxiing Adjust speed of taxiing to airfield surface condition and to direction and speed of the wind
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3.7. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Book 1
Procedures on holding point
Brakes – brake on Engine speed – set idle Controls – check free motion Trim – in neutral position Flaps – adjust take off position Fuel – check quantity; open a fuel tank with sufficient quantity (If is left fuel tank filled with more than ½ of fuel capacity, it is necessary to switch fuel cock to the left fuel tank.) Fuel pump – switch on and check fuel pressure Propeller – set a minimum angle for take-off (if it is adjustable) Magnetos – check if both circles are switched on Master – check if it is switched on Engine instruments – check instrument values Engine intake - set controller to fresh air (if it is mounted in the airplane) Altimeter – set up Safety belts – have to be fasten and tighten Canopy –have to be closed and locked Traffic pattern area – clear for entry to RWY Report
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Flight Manual SL 200
3.8.
Start line procedures, take-off
1. 2. 3. 4. 5.
RWY area – clear for take-off Clock – time, report Release the brakes. Throttle – stepless set the take-off power At speed 50 km/h (27 kt) (31 mph) pull control stick and lift front wheel. The airplane will rise at 70 km/h (38 kt) (44 mph) 6. Hold in 1 m (3 ft) above the ground until reaching 90 km/h (49 kt) (56 mph) 7. Climbing at 90 – 95 km/h (49 – 51 kt) (56 – 59 mph), engine speed max. 5800 1/min 8. Flaps up in altitude 50 m (150 ft) above the ground 9. Gear up in altitude 100 m (300 ft) above the ground * 10. Engine instruments – check 11. Trim – set as you need
3.9. 1. 2. 3. 4. 5. 6. 7. 8.
Downwind procedures
Push out landing gear (airspeed less than 150 km/h / 81 kt / 93 mph) * Fuel cock – open the fuel tank with sufficient fuel quantity Fuel pump – switch on Instruments - check Brakes – check Seat belts - tighten RWY, area of 3rd and 4th turn – check Report
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3.10. Base leg procedures 1. 2. 3. 4. 5.
Hold airspeed at 100 km/h (54 kt) (62 mph), engine speed 3 500 rpm Propeller pitch – set the min. angle (if it is adjustable) Flaps – in take-off position Trim – as you need RWY, area of final turn – check if it is a clear for approach
3.11. Procedures on final approach, landing 1. 2. 3. 4. 5. 6. 7.
Hold airspeed at 100 km/h (54 kt) (62 mph); raised idle; maximal descend speed 2,7 m/s (530 fpm) Flaps – in take-off or landing position – according pilot discretion Trim – set nose up RWY – check if it is clear for landing, report At 5 m (15 ft) – set engine on idle and align at 1m (3 ft) Lose speed by stepless pulling of control stick and touch down on main landing gear * Brake as needed, hold direction with control
3.12. Procedures after landing 1. 2. 3. 4. 5.
Vacate RWY, time Engine speed - idle Balancing – neutral Flaps - up Fuel pump – switch off SL200 FMM 2009-10-21
Flight Manual SL 200
3.13. Engine shut down 1. 2. 3. 4. 5.
Cool engine at 2000 rpm Throttle – idle Transceiver, beacon, gyroscopes and other segmental switches – switch off Magnetos – off Master switch – switch off
3.14. Leaving airplane 1. 2. 3. 4. 5.
Magnetos, master switch and segmental switches – switched off - check Fuel cocks - close Emergency parachute system - lock (if installed) Canopy – close, lock Chock aeroplane or tie down, cover canopy
3.15. Check list of standard procedures Procedures after cockpit entering, before taxing. • pedals — check motion (during taxiing) • control stick — check free motion • safety belts — fasten and tighten • canopy — close and lock • head phones — put on a head • throttle leaver — idle • fuel cock — open • undercarriage leaver — down • flaps leaver — zero position • propeller leaver — minimum angle SL200 FMM 2009-10-21
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• • • • • • • • • • • • • • •
brake master switch fuel gauge instruments and gauges electric fuel pump area around propeller choke magnetos starter oil pressure fuel pressure recharge segmental switches radio trim
Holding point RWY. • pedals • control stick • trim • flaps • fuel cock • fuel quantity • electric fuel pump • propeller • magnetos • master switch • gauges
Book 1
— — — — — — — — — — — — — — —
use brake switch on check quantity check switch on check use both on use check check check switch on switch on neutral position
— — — — — — — — — — —
check motion check free motion neutral position first position open check switch on minimum angle both on on check SL200 FMM 2009-10-21
Flight Manual SL 200
• • • •
instruments safety belts canopy airfield circuit
Book 1
— — — —
check fasten and tighten close and lock check
In down-wind position. • undercarriage • fuel gauge • safety belts • electric fuel pump • brake • base-leg area
— — — — — —
open check quantity fasten and tighten switch on check check
In base-leg position. • speed • propeller • flaps • trim • RWY
— — — — —
check minimum angle first position as needed check area of final turn
In final approaching. • speed • flaps • trim • RWY
— — — —
check second position to tail check
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After landing. • RWY • trim • flaps • electric fuel pump
— — — —
vacate neutral zero position switch off
Engine shut down. • throttle leaver • radio • segmental switches • magnetos • master switch
— — — — —
idle switch off switch off switch off switch off
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4.
OTHER PROCEDURES
4.1.
Procedures for landing gear operation
Book 1
The primary landing gear control on the instrument panel controls the landing gear. Before engaging the lever, it is necessary to unlock it by drawing the locking handle to the lever, which is now free to move. The position of the undercarriage is indicated by control lights on the conventional indicator and by the mechanical indicator of the leg position on the console under the instrument panel.
4.1.1. Signaling check before flight Check if landing gear lever is in DOWN position. When switching the master switch on, look at the landing gear indicator. Only three greens are shinning for extended gear. When pushing the test button, all lights starts to shine. If any control light does not shine during the test, it is necessary for the landing gear system to be inspected by a qualified expert. A check of correct signaling - siren, can only be achieved if the airplane is on stands with the undercarriage retracted. The check of acoustic alarm can only be carried on check stand with retracted landing gear!
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4.1.2. Landing gear retraction
- Move the landing gear lever to “UP” position - Three green stops to shine - The red lights of unlocked gear starts to shine - Time necessary for retracting is about 15 sec and all control lights turning off signals the end of retracting and lock-out in “UP” position - Mechanical indicator of the leg position is retracted – only the red end is visible
4.1.3. Landing gear extension - Move the landing gear lever to “DOWN” position - The red control lights start to shine – landing gear is unlocked and moves down - When the LG is fully out the red control lights stop to shine and the green ones start to shine – LG is fully out and locked - The mechanical indicator of the leg position is extended to green strip
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4.2.
Book 1
Indicated conditions of wing flaps and LG positions
Landing gear position is indicated visually on LG control display. Warning is provided by acoustic alarm when LG is not retracted and locked in “DOWN” position together with flaps in take-off or landing position. Particular end conditions are stated in the following table:
Possible conditions on landing gear control panel: • Three green shines and mechanical indicator indicates extending - Landing gear is down - Perform standard landing • Three red or combination of red and green - Gear is really unlocked but not fully down - Use emergency lever to extend the landing gear until three green lights starts to shine or mechanical indicator indicates the LG extended - Perform standard landing • At least one red does not shine (neither the green one) but is in order - At least one locking hook is locked - Do not use emergency lever to extend landing gear - Perform belly landing - After the flight is necessary to check the landing gear system by a qualified expert.
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5.
EMERGENCY PROCEDURES
5.1.
Engine failure during rolling
1. 2. 3. 4. 5.
Throttle to idle Brake as needed Magnetos - off Fuel cock - close Master switch - off
5.2. 1. 2. 3. 4. 5. 6. 7.
Book 1
Engine failure after take-off
Airspeed 100-110 km/h (54-59 kt) (62-68 mph) Land in RWY direction or at a place ahead of you with yaw possibility Magnetos - off Fuel cock - close Master switch - off Seat belts - fasten Flaps and undercarriage* as needed
5.3.
Engine failure during flight
Insufficient height for attempt to start up the engine: 1. Airspeed 100-110 km/h (54-59kt) (62-68 mph) 2. Landing area choice (landing direction, surface, wind, gradient) SL200 FMM 2009-10-21
Flight Manual SL 200
3. 4. 5. 6. 7. 8.
Book 1
Undercarriage – according to landing area character * Magnetos - off Fuel cock - close Master switch - off Seat belts - fasten Flaps – as needed
Sufficient height for starting up the engine: 1. Airspeed 100-110 km/h (54-59 kt) (62-68 mph) 2. Landing area choice (landing direction, surface, wind, gradient) 3. Check: - Magnetos - on - Fuel cock - open, quantity check - Fuel pumps - on - Master switch – on 4. Throttle, alternatively choke – as needed 5. Starter – if it succeeds in starting up the engine, stay in reach of chosen landing area and check engine running and engine instruments!!! 6. If everything is in order, continue to the nearest airfield or make a precautionary landing on the optimal area. 7. If you fail to start up engine or if engine instruments show a defect, proceed with an emergency landing on chosen landing area. 8. Undercarriage – according to landing area character * 9. Magnetos - off 10. Fuel cock - close 11. Master switch - off 12. Seat belts – fasten 13. Flaps – as needed
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5.4.
Book 1
Emergency undercarriage extension
1. Move primary landing gear control lever to “DOWN” position (bottom position) – if not already in “DOWN” position 2. Re-circ the landing gear circuit breaker and wait 30 seconds 3. If three red lights or combination of green and red are shinning (for each wheel must shine at least one light) turn the emergency landing gear control lever until three greens are shinning or the mechanical indicator is in correct position 4. Proceed with normal landing. After the flight is necessary to check of the landing gear system by a technical staff.
5.5. 1. 2. 3.
Emergency landing
Airspeed 100-110 km/h (54-59 kt) (62-68 mph) Landing area choice (landing direction, surface, wind) Undercarriage – according to landing area character * SL200 FMM 2009-10-21
Flight Manual SL 200
If engine is not working: 4. Magnetos - off 5. Fuel cock - close 6. Master switch - off 7. Seat belts - fasten 8. Flaps – as needed
5.6.
Belly landing
1. 2.
Land with stopped engine only. Using the starter turn the propeller to a suitable position to avoid damaging the propeller blades during landing. 3. Subsequent procedures are the same as those with extended undercarriage. * Consider using flaps according to the landing area surface.
5.7. 1. 2. 3. 4. 5. 6.
Throttle – max. power Balancing – as needed When reaching 80 km/h (43 kt) (50 mph), climb up At 30 m (98 ft) set flaps to take-off position Retract flaps at safety height Repeat landing
5.8. 1. 2. 3.
Interrupted landing
Fire - on ground, engine not running
Fuel cock - close Heating - close Leave cockpit and extinguish fire (if possible)
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5.9. 1. 2. 3. 4. 5. 6. 7.
Book 1
Fire - on ground, engine running
Fuel cock - close Brakes - brake Throttle – max. power Heating - close Master switch - off Magnetos – after fuel depletion and engine stop – off Leave cockpit and extinguish fire (if it is possible)
5.10. Fire - during flight 1. 2. 3. 4. 5. 6. 7. 8.
Fuel cock - close Throttle – max. power Heating - close Master switch - off Magnetos – after fuel depletion and engine stop – off Airspeed 100-110 km/h (54-59 kt) (62-68 mph) If fire continues, make a slip; if this does not help, increase airspeed to the safe maximum in this situation. Now follow emergency landing procedures.
After extinguishing fire, do not try to start up the engine again!
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Book 1
5.11. Carburettor freezing Carburettor freezing results in power reduction and engine temperatures increase (it can lead to engine stop). 1. Airspeed 110-120 km/h (59-65 kt) (68-75 mph) 2. Throttle – idle or necessary minimum power according to flight conditions 3. Leave the area with freezing conditions 4. Pull Engine intake to preheated air, after 1-2 min gradually increase power of the engine to cruising power 5. If you fail to regenerate the engine power, land at the nearest airfield (if possible) or at any suitable place.
5.12. Engine and propeller vibrations If unnatural vibrations occur, it is necessary to: 1. Set the engine speed to minimize vibrations. 2. Proceed with a precautionary landing to the nearest airfield or other suitable terrain 3. If vibrations increase, turn off the engine and now execute emergency landing
5.13. Emergency parachute system usage 1. 2. 3. 4.
Fuel cock - close Magnetos, master switch - off Seat belts - tighten Pull the handle to release the emergency parachute system
The handle of the emergency parachute system is placed on the instrument panel. This handle must be unlocked before flight! By pulling the handle, a cartridge is activated, which gets the parachute out of the airplane and tightens hanging ropes. After opening the parachute the airplane goes down toward the ground with a pitched nose. SL200 FMM 2009-10-21
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5.14. Check list of emergency procedures Fire during flight: • fuel cock • throttle leaver • heating • master switch • speed • emergency landing
— — — — — —
close maximum angle close switch off check land
Engine failure during flight: • speed • landing area • magnetos • fuel cock • master switch • safety belts • flaps and undercarriage
— — — — — — —
check choose switch off close switch off tighten as needed
Emergency parachute system usage: • fuel cock — • magnetos — • master switch — • safety belts — • emergency leaver —
close switch off switch off tighten use
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200 BOOK 2 MAINTENANCE MANUAL
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1.
AIRCRAFT MAINTENANCE REGULATIONS
1.1.
Periodic maintenance
Book 2
Act in accordance to the Maintenance Plan, B2-6. Check the particular parts and systems of the aircraft at the stated time intervals according to its function and wear and during inspection of each part look for faults that could lead to failure. File the performed check in the Aircraft Book, Engine Book and Propeller Book.
1.1.1. Inspection of control surfaces clearances Lift the airplane on stands before measuring. Blocking of control system Deflect the directional control from the neutral position. Put the plastic tube with inner diameter Ø 20 mm (0.787 in) on the right pedal tube (on the right side of the cockpit). Align pedals to the neutral position and drag the tube on the second pedal too to block directional control. Fix a suitable lath to the side facing of the cockpit using clamps. Fix the lath to have a contact between the right control stick and the lath in the neutral position. Fix the stick to the lath using a tape or a clamp and it fixes the controls on the right side. Clearances measuring Measure the control surfaces deflection with fixed controls. It is necessary to move the rudder (or the lever) only such as allows its clearance.
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Measure control surfaces clearances on root rib position on leading edge. Fix a meter on a firm stand (a chair or a case is equal) and place the meter to be able to measure a deflection. Move control surface to one side with hand and read the value on the meter (or set a zero on the meter). Than move the rudder to the opposite side and measure its deflection. Flap clearances are measured in the same way. Extend flaps to the take-off position (10°) to measure the clearances (on both sides). Repeat it in landing position of the flaps (35°). Measure the clearances on control sticks by moving of one stick and the second is fixed. Fix the meter to the side cockpit facing or to the lath (according to type of measuring) and move the left control stick. Do measure longitudinal and transverse deflections.
1.1.2. Maximal allowed control clearances Measured when control is blocked! Control stick
transverse longitudinal
Elevator Trim (elevator fixed) Rudder (at bottom) Ailerons Flaps 10° 35°
1.2.
4 mm 3 mm 6 mm 3 mm 4 mm 2 mm 5 mm 5 mm
0.157 in 0.118 in 0.236 in 0.118 in 0.157 in 0.079 in 0.197 in 0.197 in
Lubrication of the aircraft
Lubricate the aircraft according to the Maintenance Plan - see Appendix No.: 1. It is recommended to use MOLYKOTE® lubricants (product of Dow Corning USA company), which are accessible worldwide. For more details see www.dowcorning.com.
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MOLYKOTE® products have a consistant high quality, include anti-corrosive ingredients and mainly include the ingredient MbS for “dry lubrication”. Use recommended kind of lubricants for specified areas. Cu 7439 Plus and BR2 lubricate most points. Clean all parts before each assembly. Use only the volume of lubricant that is necessary to make a thin film on lubricated surfaces. Lubricate pinned bearings disassembled with recommended grease and then assembly it again. For lubrication without disassembly, use oil with ingredient M55 plus.
1.3.
Accumulator maintenance
A non-maintenance gel accumulator 12V/18Ah (or similar) is used in the airplane. With this type of accumulator it is not necessary to check the electrolyte level. The accumulator is placed on the right side of firewall in engine compartment. Charge the battery as required. Charging is recommended once or twice a year. When charging, follow the accumulator manufacturer’s instructions. Battery is accessible after opening the engine cowling.
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1.4.
Book 2
Hydraulic brakes settings and maintenance 1.4.1. Description
Brakes are twin-disk with four working pistons hydraulically controlled within a closed circuit, placed inside the wheels of the main undercarriage. The main control piston is on the control stick.
1.4.2. Operation Pressure, which is made by pulling the lever, impacts on the working pistons inside the brake, which pushes the group of brake pads and the floating discs to the central adjusting nut. This is the principle of wheel braking. Pistons and brake pads are returned by the pressure of springs. It is possible to lock the brake lever in the operational position – parking brake.
1.4.3. Refilling and deaerating - Put the plane on control stands. Disassemble the wheel; let the brake in position. - Inject car-brake fluid into the system using filling screw. Loosen deaeration screw on the side of the brake body and the main brake piston. - Inject into the system until the fluid begins to flow from the deaeration screw without air bubbles. - Tighten deaeration screw, as the fluid in the system still has to be under pressure! Repeat procedure for second wheel. Pull the lever. If the stroke does not correspond to the data written in the next paragraph, repeat whole procedure again. SL200 FMM 2009-10-21
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1.4.4. Adjusting jaw clearances Wheel is disassembled; brake is out of the hub. Adjusting of lever’s operational range: - Turn to left (counter clockwise) by adjusting screw on the lever till beginning of screw thread. Set the operational range using the setting screw down the side of lever’s collar to leave the highest possible stroke and free lever does not interfere with the parking brake lock. There should be clearance of cca 1 mm (0.039 in). Adjusting of clearances on brake pads. - Tighten the central nut with outer toothing and concurrently press in the locking pin. If the pin is not in the mortise, loosen the nut until the pin goes into the mortise. - Loosen the nut about 5 cogs until the pin locks the nut. Total clearance between brake pads is 0,5-0,7 mm (0.02-0.028 in) and lever’s stroke has to correspond to this range (cca 60 mm (2.362 in) measured on the top of the lever). - This working range can be kept during its operation by turning the adjusting screw according to condition of the brake pads.
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- If the length of the screw thread of the adjusting screw is over 4 mm (0.157 in) more (four turns) it is necessary to make a new adjustment in the same way. - If enjambment of brake pads has reached 0,3 mm (0.012 in), replace pads.
1.4.5. Brake assembly Put brake into hub, so that the red dot on the hub is between red dots on floating discs. Put the complete wheel and spacer between the undercarriage frames to have the locking pin of the reaction fitting in mortise. Tighten castle nut and lock by the pin. Dismantle conversely.
1.5.
Adjusting of control cables
Instruments: - Meter (tapeline, ruler) - Spring ruler - Hook
Procedure: 1. Remove the cover on the left side of fuselage. 2. Grapple the spring ruler for the lefts cable in the measuring point (on drawing marked “MĚŘÍCÍ MÍSTO”). 3. Mark the hook position according to the fuselage facing in Un-tightened condition. 4. Tighten the cable by pulling the spring ruler with force 25 N (5.62 lb). 5. Mark the camber of cable.
When the ropes are tight right, the tightening force 25 N (5.62 lb) answers to cable camber 20 – 30 mm (0.787 – 1.181 in). If the tightening does not suit, it is necessary to dismount the stabilizer and make new cable adjuster. The adjustor semi product is necessary to buy from the aircraft producer. The adjusting must ensure that the rudder and the front wheel stay in neutral position. Secure both cable adjustors by a pin after adjusting again. SL200 FMM 2009-10-21
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1.5.1. Changing cable adjusters 1. 2. 3. 4. 5. 6. 7.
Disconnect front wheel driving rod from rudder pedals Fixed rudder pedals and rudder in neutral position Measure new length of a new cable adjuster on semi product Check the length of the cables with new cable adjusters Make hole in the semi product for M6 screw Undo old cable adjusters and install new one Connect front wheel driving rod to rudder pedals
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1.6.
The governor rectifier circuit breaker
The circuit breaker is instrumental for the protection of the electrical systems of the engine. The circuit breaker will cut out automatically if there is a current overload of these systems. When possible failure is rectified, pushing on the circuit breaker can reconnect the system. This circuit breaker is placed on the engine side of the firewall. More info is stated in the Installation manual of the engine!
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1.7.
Locking hook adjusting and checking
These operations are available only if the plane is lifted up on stands!! Check locking of undercarriage: - Switch on the main master. Retract undercarriage and check operation of locks. Switch off the main master. - Disassemble the covers of instrument panel. Leave the lever of undercarriage in retracted position. - Check security of ends of steel cables on lever. Clearances for cables between the end and cylinder support: - Rear hooks (on sides) without clearance. - Front hook has a clearance of 1,5-2 mm (0.059-0.079 in). - In case of any different, set clearances as above. Check unlocking of undercarriage:
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- Put suitable support under front undercarriage in place of fitting. - Main master is still switched off. - Move the undercarriage lever to the extended position. - The gap should be 2,5-3 mm (0.098-0.118 in) after the release of front undercarriage from the hook. - The same gap of 2 mm (0.079 in) is on the main undercarriage. - Remove the support under the front gear. This releases the undercarriage. - Check there is sufficient room for extending (if it is possible to extend) and switch on the main master. - Check the mechanical indicator and lights on the electronic panel (three green lights) and switch off the main master. Concurrently check positions of flaps. Control light of flap position blinks and siren beeps, if flaps are extended and undercarriage is retracted.
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2.
WINGS AND HORIZONTAL TAIL UNIT DISMANTLING
2.1.
Removal of cover strip between wing and central section
- Unhook the covering strip on the bottom part of the wing (by grasping the hook and pulling the spring) - Disengage both parts of the strip (they are held together by M4 screws (x2) and riveting nuts) - Shift both strip portions out of the wing backwards (towards the trailing edge) - Take off the strip, which is around the other wing in the same way Replace in opposite way. Remember correct position of facing sheets into the covering strip. It is recommended to lightly lubricate doubled part of the covering strip. Stated description is valid for metallic covering strips. If the covering tape is used on your aircraft, you have to check, if basic tape is still sticked on the wing and central section facings. Use tape PATTEX POWER TYPE as basic and covering tape.
2.2.
Removal and replacement of inspection covers
For the inspection covers on the bottom side of the wings and on the trailing edge close to flaps: - Insert a suitable instrument into 4 mm hole - Pull and lift cover until spring clip is freed - Move the cover round to free the other clips and pull off cover - Round covers may be moved in any direction - Rectangular covers may only be moved from side to side Replace in opposite way.
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Removal of inspection covers on the tail: - Loose the screws on the cover - Remove the cover Replace in opposite way.
2.3.
Removal of seats
- Press lever of the locking mechanism to release the seat and slide back to rear position until seat rollers reach stops - Lift up and pull forward the back of the seat about 25 mm (0.984 in) - Push backwards and slide out the front rollers from their guides and lift the seat out Replace in opposite way.
2.4.
Disassembly and assembly of outer wings 2.4.1. Disassembly
Disassembly is not allowed in dust environment. - Remove covering strips (see B2-2.1) and seats (see B2-2.3) - Remove covering metal sheets underneath out of the cockpit - Uncouple the ailerons control pull-rods from angled levers - bolt M5, nut and pin - Disengage flap control coupling - outer pivot 4 mm (0.157 in) diameter with a washer and a pin – shaft coupler stays in the central section
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- Take the split pins out of the nuts of the attachment points (x6) - On one side of the aircraft, loose the M8 nuts on all attachment points of the wing. - Unscrew the nuts on the upper and back attachment points completely. Leave the bolts in position. - If the additional fuel tanks are installed, loose a fuel hose clips on the wing side. - Grasp the wing tip as well as the wing root and take the screws out of the upper and back attachment points. Warning! Mark screws (B2-2.5.2) to not replace one another during assembly!!!! - Lower the wing tip carefully to the ground - If you are dismantling the right wing, do not forget to disconnect the hose coupling of the air pressure supply from the Pitot tube to the air speed indicator and the electric socket if installed. If additional fuel tanks are installed, disconnect and remove fuel hoses. - Unscrew the nut on the lower attachment point - Take the screw out of the lower attachment point - Lift the wing tip slowly up and at the same time slip the wing out of the last attachment point - Pull the aileron connecting strut out of the center section by moving the wing away from the rest of the airplane - Lay the wing on a suitable pad - If additional fuel tanks are installed, promptly seal fuel hoses and additional tank necks to provide against any contaminant. - Leave the hoses setted on and tighten on the main fuel tank neck in central section. Disconnect and strip the other wing in the same way.
2.4.2. Mark bolts When disassembling and assembling wings is very important not to replace bolts (wing bolts). These bolts are marked with small figures on its heads. These marking correspond to the following picture.
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2.4.3. Assembly - Lay the wing next to the fuselage into a position convenient for the following assembly (it means the left one on the left side and perpendicular to the fuselage and so on) and on a suitable pad - Lubricate cleaned shaft joint and shaft coupler of flap control using BR 2plus - Have wing bolts ready according to marking – do not replace one another!!! - Remove sealings from additional fuel tank necks and fuel hoses. - Grasp the wing at the wing root and on each the wing tip, and lift the wing root to the level of the center section height - Start inserting the pull-rod into the holes in the center section ribs by a careful movement of the wing towards the fuselage SL200 FMM 2009-10-21
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Book 2
- Put the lower wing attachment point on the center section attachment point, put a screw in and secure it with a washer and a M8 nut, then slightly tighten the nut - Put lower fuel hose on the lower neck of additional fuel tank. Set the hose clip to have a screw accessible from upper side of wing using long screwdriver. - If you are assembling the right wing, connect the air pressure supply from the pitot tube with the air speed indicator by sliding the hose endings in the hose coupling - Keep lifting the wing tip slowly. Check the lower fuel hose. While lifting, put upper fuel hose on upper neck of additional tank and connect the coupling with the flap control rod. Set the hose clip to have a screw accessible from lower side of wing. - Engage the upper and back attachment points on the wing and the center section. - Put the screws in the attachment points (shorter screw goes to the back attachment point), and secure them with a washer and a nut, then slightly tighten the M8 nuts. - If additional tanks are installed, tight the screws on hoses. - Move flap control lever to upper position in the cockpit. Connect the flap control using the bolt (4 mm (0.157 in) diameter) - Put a washer and a nut on the screw, tighten it and secure the nut with a new split pin. Drip oil + M55 plus on joint bearing of the aileron control lever. - Connect aileron control rod to aileron control lever using M5 bolt (head in flight direction), put the washer and nut, tighten and secure the nut with a new split pin - Tighten the nuts M8 on the attachment points firmly (9,5-22 Nm (7.01-16.23 lbf.ft) torque) and secure them with split pins Put on covering strip (see B2-2.1) - Install the covering metal sheets underneath out of the cockpit and install seats (see B2-2.3) Attach the other wing to the center section in the same way.
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2.5.
Book 2
Disassembly and assembly of elevators
Disassembly - Disconnect the trim connector on the right elevator - Take off the split pins on the outer attachment points of the elevator - Unscrew the nut take out the screw on one side - Extend the elevator out of stabilizer attachment point first, and then out of the fin carrier - Wrap joint bearings with scotch tape to guard against dirt - Disconnect the other elevator in the same way Assembly - Lightly lubricate inner elevator attachment by Cu 7439 plus; drip oil + M55 plus on joint bearings - Insert the front attachment points of the stabilizer to the front attachment points of the fuselage - Connect the trim cable with the connector on the right side of the elevator - Insert the inner attachment point (bolt) of the elevator to the carrier on the fuselage - Insert the screw, put the washer and the nut on, and tighten (5,5 Nm (4.06 lbf.ft)) and secure with new split pins - Carry on analogically with the second half of the elevator but remember, that there is no balancing tab SL200 FMM 2009-10-21
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2.6. Disassembly and assembly of stabilizer Disassembly - Unscrew the screws of the fiber-glass “boot” of the fin; take the fiber-glass “boot” out of the fuselage - Remove fixation to the cables; take trim control cables out - Take the split pins out of the stabilizer bolt nuts; unscrew the M6 nuts - Grasp the stabilizer and take out the bolts; lift the stabilizer until it is out of the front attachment points and than move forward until it is out of the rear attachment points and put it on a proper pad
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Assembly - Clean up attachment points and lubricate using BR-2plus - Insert the rear attachment points into attachment bolts on the fin - Insert the bolt through the spacing tube placed between the front attachment points - Put a washer on, screw the M6 nut and tighten it a bit - Tighten the nut of the stabilizer bolt (9,5 Nm (7.01 lbf.ft)) and secure with new split pin - Take the trim cable and maintain original position and fix the cables to stabilizer by the clip - Put the fiber glass “boot” and secure by M4 screws
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3.
LANDING GEAR DISMANTLING
3.1.
Removal of shock absorbers from main undercarriage
Plane must be raised on support stands. - Remove split pins, unscrew and remove M8 castle nuts from upper and lower attachment points - Original position of screws and spacing tubes must be marked and replaced accordingly - Remove upper spacing tubes from attachment points of the shock absorber and strut - Remove lower spacing tubes from attachment points of the shock absorber and gear leg. Remove the shock absorber Lubricate shock absorber on end sides by Cu 7439 before mounting. Mount conversely. - Lightly tighten up castle nuts (M8) - Secure with new split pins
3.2.
Disassembly and assembly of main LG shock absorber
Disassembly - Clean up shock absorber. - Insert long, flat-head screwdriver into hole on bottom end and hold M6 bolt firm. Unscrew nut and remove - Unscrew the M6 bolt and remove - Remove upper body of the shock absorber by lifting upwards. Rubber springs and duralumin washers will be loosened
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Assembly - Clean all parts before assembly. If Teflon assembly head washer is worn down, so that piston rod touches case, it is necessary to replace it. - Lubricate upper body chamber between teflon washers with BR 2 plus - Lubricate piston rod with BR2 plus - Hold lower body of the shock absorber in a bench vise with soft jaws. Put on rubber springs (10 pieces) and duralumin washers (9 pieces) alternately. - Insert upper body of the shock absorber - Screw M6 bolt in to have adjusted axis distance 320 ± 0,2 mm (12.5980.0079 in) - Screw bolt by self-locking M6 nut and LOCTITE 246
3.3.
Disassembly and assembly of main fixed LG shock absorber
Disassembly: - clean up shock absorber - remove self-locking nut from upper attach point of absorber (in the middle of absorber) - slide off the M8 screw and the spacing tube - unscrew two M3 screw from upper stop - expand both parts of the absorber - unscrew the M5 screw from the plastic top of the bottom part the absorber - remove plastic top and plastic bearing - remove upper stop – this will lose the rubber spring and metal fillers
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Assembly: - clean all parts before assembly from all contamination and old lubrication - if plastic parts are worn so that piston rod touches the tube, it is necessary to replace it. - set the rubber springs and metal fillers on the rod by alternating them – for one absorber use 8 rubber springs and 7 metal fillers - set the upper stop on the rod behind the last rubber spring - the slide on the plastic bearing and plastic stop - set the M5 screw to the plastic stop - slide together both parts of the absorber - set two M3 screw with washers – join upper stop with upper part of absorber (adjust properly the plastic bearing). Secure M3 screws with LOCTITE 246 - press together the absorber and set inside the hole the spacing tube and the M8 screw - use M8 self-locking nut with washer and tighten it by 23Nm moment
3.4.
Front undercarriage shock absorber removal and assembly
Disassembly - Remove split pins; unscrew castle M8 nuts and remove upper and lower M8 bolts from the ends of the shock absorber – do not interchange them! - Remove spacing tubes from ends of shock absorber - Remove shock absorber from mounts
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Mount conversely - Before mounting lubricate inner sides of mounting bracket and outside upper and lower sides of shock absorber ends with Cu 7439 plus - Lightly tighten castle nut M8 - Secure with new split pins
3.5.
Front undercarriage shock absorber disassembly and assembly
Disassembly - Remove upper and lower ends of shock absorber; rubber springs and duralumin washers will be loosened Check wear and tear of groove (not more than 0,4 mm (0.0157 in)) before mounting and surface of its opposing spacing tube. Replace if grooves on surface are deeper than 0,2 mm (0.0079 in). Check rubber stopper in upper part of chamber in piston rod.
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Assembly - Lubricate piston rod, chamber and spacing tube with BR 2 plus - Put on rubber springs and duralumin washers alternately and then upper part of the shock absorber - Shock absorber is ready for mounting into front undercarriage
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4.
Book 2
CHANGING FUEL FILTERS
Removal - Drain fuel from tanks. - Remove the left seat and covering plate - Remove covering plate on floor in front of the right seat - Remove seats and covering panels. - Loosen hose clips on filters, remove and replace with new filters – keep the direction of flow as shown on filters! Mount new filters conversely.
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5.
ELECTRIC WIRING DIAGRAM
See separate list: Electric wiring diagram.
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6.
Book 2
MAINTENANCE PLAN
See separate list: Maintenance plan.
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KP 2U (SKYLEADER 200)
NOTES:
KP 2U (SKYLEADER 200)
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