Evector EV-97 EUROSTAR SL MICROLIGHT, Maintenance Manual

Page 1: ...AR SL MICROLIGHT G MAINTENANCE MANUAL GEN EUR 04 Light Sport Aviation Tel Office 01494 524020 Wycombe Air Park Email lsa live co uk Hangar 1 Web www lightsportaviation org uk Booker Marlow Buckinghams...

Page 2: ...tails of Change Date Authorised 1 First Issue 12 05 14 2 Changes to electrical circuit diagrams Appendix 5 15 07 14 Change to trim tab deflection pages 29 and 42 15 07 14 3 Change to cockpit instrumen...

Page 3: ...on 16 2 25 Electrical System 16 2 26 Pitot Static System 16 2 27 Galaxy Balistic Rescue System GRS 6 473 SD B2 16 2 28 Stall Warner 17 3 Aircraft Assembly and Disassembly of Major Parts 17 3 1 Wing 17...

Page 4: ...r 37 12 1 Main wheel 38 12 2 Nose wheel 38 12 3 Puncture Repair all tyres 38 12 4 Tyre pressures for tyre size 14 x 4 or 400 x 6 38 13 Small Repairs 38 14 Care and Cleaning Recommendations 39 14 1 Ext...

Page 5: ...always be alert for developing problems and attentive to ensuring their timely rectification 2 Aircraft Technical Description 2 1 General The Eurostar SL airframe is a metal composite semi monocoque...

Page 6: ...gear Wheel track 5 25 ft 1 6m Wheel base 4 42 ft 1 35m Main wheel diameter 14 in 350mm Nosewheel diameter 14 in 350mm 2 4 Weight Empty weight will vary with selection of options and small manufacturi...

Page 7: ...attached to the fin by two hinges consisting of spherical joints bolted into the fin s trailing edge spar A composite fairing is fitted immediately forward of the fin blending its surface with that o...

Page 8: ...isc which is bolted onto the inner part of the rim The brakes on both wheels are controlled independently by toe brake pedals mounted on the pilot s and the co pilot s rudder pedals Fig The brake cont...

Page 9: ...ndicator ASI 2 Altimeter 3 Compass 4 Vertical Speed Indicator VSI 5 Tachometer 6 Cylinder Head Temperature CHT gauge 7 Oil temperature gauge 8 Oil pressure gauge 9 Fuel pressure gauge 10 Fuel contents...

Page 10: ...l Yaw cables attached to arms at the end of the rudder pedals torque tubes are guided along the sides of the fuselage to the rudder horn Stops in the form of swages crimped on to the cable are located...

Page 11: ...the flap end An arm on each end of the torque tube engages in slots in the flap end to deploy or retract the flaps Where the arm engages in the flap end an eccentric is provided to permit fine adjustm...

Page 12: ...BH Power Max Take off 59 6 kW 80 hp at 5800 rpm max 5 minutes Max Continuous 56 kW 75 hp at 5200 rpm Cruising 53 kW 71 hp at 4800 rpm Engine speed Max Take off 5800 rpm max 5 min Max Continuous 4800 r...

Page 13: ...UL 80 hp 50 C 122 F 90 110 C 194 230 F 50 90 C 122 194 F 110 140 C 230 284 F 140 C 284 F Oil Pressure 0 8 bar 12 psi 2 5 bar 29 73 psi 0 8 2 bar 12 29 psi 5 7 bar 73 102 psi 7 0 bar 102 psi cold engin...

Page 14: ...tion The lower cowling To remove it un screw the attachment screws connecting the cooler to the cowling face side then remove two air hoses unscrew sleeves and then un screw the attachment screws conn...

Page 15: ...pump driven from the crankshaft Coolant then passes from the top of the cylinder heads to an expansion tank mounted on top of the engine This tank allows the coolant to expand and is fitted with a pr...

Page 16: ...c and static pressures to the instruments via flexible plastic hoses Moisture and dirt collection reservoirs are installed inside the cockpit on the left sidewall in front of the pilot s seat 2 27 Gal...

Page 17: ...ngs screws Spanner to install the rear wing suspension bolts nuts For disassembly a soft metal drift or punch to remove the pins from the wing root attachments Wing Removal For each wing half proceed...

Page 18: ...2 Horizontal Tail Unit HTU 1 Remove attachment bolts from the HTU fuselage composite fairing 2 Disconnect the trim tab control cables or wire where an electric trim tab is fitted 3 Disconnect the elev...

Page 19: ...manufacturer recommends maintenance checks and periodic inspections at the following intervals 1 after the first 25 2 flight hours 2 after every 50 3 flight hours 3 after every 100 5 flight hours or...

Page 20: ...irewall Carefully check engine mount for cracks abrasion and other damage 3 2 2 Visually check condition of rubber silentblocks replace those cracked or excessively deformed 3 3 Induction System 3 3 1...

Page 21: ...ition attachment and leaks 3 8 3 Visually check hoses for condition leaks attachment and security replace damaged hoses Tighten hose clips if necessary 3 8 4 Check oil quantity add or change oil accor...

Page 22: ...rity 5 6 2 Check condition of nosewheel steering rod covers repair if necessary 5 7 Lubricate per Lubricating Chart 6 MAIN LANDING GEAR 6 1 Fiberglass legs 6 1 1 Visually check condition of fiberglass...

Page 23: ...ment of fiberglass wing tips 7 1 4 Check Vortex Generators VG s for dirt build up damage and adhesion 29 per wing 7 2 Aileron 7 2 1 Visually check condition 7 2 2 Check free movement 7 2 3 Check ailer...

Page 24: ...mation cracks scratches and damage contact the aircraft manufacturer if in doubt 9 2 Visually check condition and attachment of fiberglass tips 9 3 Check elevator for free movement 9 4 Check elevator...

Page 25: ...Hand control 11 4 1 Check hand control for free movement 11 4 2 Check all joints and bearings for wear and security 11 4 3 Check control column stops for condition 11 4 4 Check pitot static hoses for...

Page 26: ...ctivation handle and safety pin 12 2 Inspect mounting of the Galaxy Rescue System GRS 12 3 Check the fastening straps 12 4 Check for unwanted objects near the GRS unit 12 5 All parachute maintainance...

Page 27: ...lacement Remove both engine cowlings Unscrew the elbow on the left front as viewed in flight direction exhaust pipe using a 12mm spanner Loosen the pipe clamp on the exhaust muffler using a 13mm spann...

Page 28: ...Brake Pad Replacement Brake pad replacement is only necessary when a pad is worn out CAUTION Due to the possibility of brake fluid leaking it is advisable not to loosen the hose fitting during brake p...

Page 29: ...y Air can enter the system if the brake fluid reservoir is not kept topped up or a leak occurs Proceed as follows Fig Brake system bleeding 1 Bleed screw 1 Connect a short clear plastic hose to the bl...

Page 30: ...tar SL Microlight Maintenance Manual GEN EUR 04 Issue 4 30 The deflection of the control surfaces are specified in the Control Surfaces Deflection Record see Appendices of this Manual and in the follo...

Page 31: ...ecting the bell crank inside the wing Deflect the aileron upwards for access 5 7 2 Flap The flap deflection is controlled by the positions of the slots in the flap lever gate in the cockpit The relati...

Page 32: ...en cables pass through adjustable nipples immediately aft of the lever Screw these nipples in or out while maintaining tension on the inner cable to place the lever in its correct position relative to...

Page 33: ...alve 3 Fully extend the flaps 4 Put an empty container under the drainage hose on the bottom of fuselage close to the starboard flap root 5 Open the drain valve under the starboard wing fillet close t...

Page 34: ...e rudder control cables at attachment to the rudder x grease adjustable rudder pedal mechanism plunger pin and lever x x oil Trim tab trim tab hinge x x x oil control cables at inlets to the terminati...

Page 35: ...80 M14 N m kg m 66 68 6 80 78 54 8 00 117 67 12 00 164 75 16 80 196 13 20 00 M16 N m kg m 93 16 9 50 107 87 11 50 164 75 16 80 225 55 23 00 274 58 28 00 M18 N m kg m 137 29 14 00 171 61 17 50 245 16...

Page 36: ...g a weight or spring balance The trim tab deflection must not exceed 5 mm from its original position If the trim tab deflection exceeds this value then it is necessary to adjust the trim tab cable pre...

Page 37: ...yre and pump up slightly put French chalk on the tube and or in the tyre 10 Put the valve insert of the tube into the hole in the rim 11 Put the rim with the tube and tyre onto the axle and adjust the...

Page 38: ...ng is required to check the airframe alignment compared with values recorded for the new aircraft The aircraft must be on a flat level floor First set the aircraft in a horizontal position The levelli...

Page 39: ...control pin in the flap root rib and replace the worn out pin or the part with oval hole 0 08 in 2 mm 0 2 in 5 mm Trim tab control system Block the tab to the elevator move the trim tab control lever...

Page 40: ...ent that has a fixed location and is actually installed in the aircraft It includes the weight of the painted aircraft battery standard and optional equipment engine coolant hydraulic fluid brake flui...

Page 41: ...Datum Leading edge C G i Weight WI Moment Mi in mm lbs or kg lbs in or kg mm Empty aircraft Crew 19 69 500 Fuel 0 72 kg ltr 36 22 920 Baggage 50 00 1270 Total Weight TW WI lbs or kg Total Moment TM M...

Page 42: ...sure Points Measure Specified values Actual 1 1 13 Points Difference Tolerance Difference 2 3 15 1 3 0 0 08 in 3 6 17 2 4 2 mm 4 8 17 1 2 0 0 08 in 5 13 18 3 4 2 mm 6 15 18 5 6 0 0 2 in 7 7 8 5 mm 8 9...

Page 43: ...ol Rudder Starboard deflection 30 2 Port flap deflection in TAKEOFF position 15 2 Port flap deflection in LANDING 1 st position 30 3 Wing Port flap deflection in LANDING 2 nd position 50 3 Flaps Starb...

Page 44: ...tion G S N Configuration Weighing Point Scale Reading Ri lbs or kg Tare Ti lbs or kg Net Weight NWi Ri Ti lbs or kg Nose wheel RN TN 0 NWN Port wheel RL TL 0 NWL Starboard wheel RR TR 0 NWR Total Weig...

Page 45: ...hrough 1000ft IAS 63kt Engine speed max 5500 rpm Oil pressure 1 5 5 bar Oil temp max 140 C CHT max 120 C Time to climb 1000ft 1min 30sec Fuel pressure 0 15 0 4 bar Stall speed at idle IAS Landing conf...

Page 46: ...following circuits are installed as standard in the Eurostar SL Additional circuits or amendments to those shown may be installed depending on options selected Canopy Closed Indicator Regulator Recti...

Page 47: ...EV 97 Eurostar SL Microlight Maintenance Manual GEN EUR 04 Issue 4 47 Wiring Diagram Analogue Panel Wiring Diagram Electronic Panel...

Page 48: ...EV 97 Eurostar SL Microlight Maintenance Manual GEN EUR 04 Issue 4 48 Appendix 6 Additional Equipment List EV 97 Eurostar SL Microlight Serial Number...