Evector EV-97 EUROSTAR SL MICROLIGHT Maintenance Manual
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Evector EV-97 EUROSTAR SL MICROLIGHT Maintenance Manual

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EV-97 EUROSTAR SL
MICROLIGHT

MAINTENANCE MANUAL

Light Sport Aviation
Wycombe Air Park,
Hangar 1
Booker
Marlow
Buckinghamshire
SL6 3DP
G-
GEN/EUR/04
Tel. Office: 01494 524020
Email: lsa@live.co.uk
Web:
www.lightsportaviation.org.uk

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Summary of Contents for Evector EV-97 EUROSTAR SL MICROLIGHT

  • Page 1: Maintenance Manual

    EV-97 EUROSTAR SL MICROLIGHT 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 Buckinghamshire SL6 3DP...
  • Page 2 Changes to electrical circuit diagrams (Appendix 5) Change to trim tab deflection (pages 29 and 42) 15/07/14 Change to cockpit instruments (page 9 sect 2.12) 01/09/14 Change to weight and balance record (appendix 3 18/12/15 page 44) EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 3: Table Of Contents

    Brake fluid refilling ..................... 29 5.6.3 Brake fluid emptying ....................29 5.6.4 Brake Pad Replacement .................... 29 5.6.5 Bleeding ........................30 Control Surface Deflection Setting ................... 30 5.7.1 Aileron ........................32 EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 4 Appendix 3 - Weight & Balance Record ..................45 Appendix 4 - Flight Test Record ....................46 Appendix 5 – Electrical Circuit Diagrams ..................47 Appendix 6 - Additional Equipment List ..................48 EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 5: Introduction

    Duralumin skins. Both pop (blind) rivets and solid rivets are used for joints. All Metal parts are primary structures. All composite parts, with the exception of the undercarriage legs, are non-structural (secondary structures). Dimensions – Drawings EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 6: Basic Dimensions

    Empty weight includes 2.9 litres of unusable fuel. Centre of Gravity Empty weight CG (standard equipment) 18 ±2% Mean Aerodynamic Chord (MAC) 200 – 250mm AoD Operating CG 20-34% MAC 250 – 410mm AoD EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 7: Wing

    FOOT PEDAL NOSE WHEEL 1 7 ° CONTROL ROD COTTER PIN 4x40 ČSN 02 1781.04 NUT 765 155 WHEEL AXLE WASHER 765 478 WASHER E 54-04 21 2.10 Wheels NOSE WHEEL ASSEMBLY EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 8: Wheel Brakes

    When adjusting the rudder pedals, if the plungers are not fully engaged in one of the three holes in the plate, the pedal may rotate backwards and prevent rudder movement. See Brake Pedal Adjustment section 9.2 2.11 Tyres SAVA 14 x 4 (standard), all three wheels. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 9: Cockpit

    See additional equipment list Appendix 5 if applicable EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 10: Flap Control

    Toe Brakes - The brakes are controlled independently by hydraulic toe brake pedals mounted on the pilot’s and the co-pilot’s (optional) rudder pedals. 2.15 Flap Control EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 11: Elevator Trim

    An 80hp Rotax 912 UL engine drives a 3 blade Woodcomp 170/3/R or a Kievprop 237/1700 propeller via a 2.27:1 reduction drive gearbox. The Rotax 912UL is a 4-stroke, 4 cylinder, EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 12 (refer to engine Operator´s Manual). API classification SF or SG. (2) Propeller Woodcomp 170/3/R or Kievprop 273/1700 Type 3 Blade ground adjustable pitch, composite Propeller Pitch 28º at 350 mm radius, however see note 1. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 13: Engine Operational Limits

    Engine cowlings disassembly and assembly • The upper cowling: The disassembly and assembly are both easy by releasing the quick-closing locks (or screws). The upper cowling is usually removed during EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 14 It is highly recommended to protect the removed cowlings so as to prevent them from inadvertent damage. The cowling assembly is the reverse of disassembly. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 15: Fuel System

    Demisting/defrosting of the windshield is performed by hot air being fed from the mixing chamber on the firewall to the internal space of the canopy frame molding and then through a row of holes along the bottom edge of the tinted plastic canopy. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 16: Ventilation

    If working on or near the parachute itself, ensure that the transit safety pin is inserted. Refer to the parachute manufacturer’s maintenance manual for details of maintenance required. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 17: Aircraft Assembly And Disassembly Of Major Parts

    Take the load off the upper attachment point by lifting the root, then remove the upper wing pin, supporting the wing root at the same time. Store the wing in a safe place, taking care not to damage the VG’s. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 18: Horizontal Tail Unit (Htu)

    The pre-flight inspection is a visual check of the aircraft for deformations, surface damage, fuel and oil system leaks, prop damage, insecure locks, covers and cowlings, vortex generators (VGs) etc. Any damage or failure should be repaired immediately if airworthiness is affected. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 19: Post-Flight Inspection

    All maintenance and repair work must be recorded in the appropriate log books by reference to the above Maintenance Records. The parachute maintenance must be entered into the logbook as a separate item. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 20: Periodic Maintenance And Inspections

    Note 1: The Li-ion battery must only be charged with its dedicated, (constant current) charger. The use of a normal lead-acid battery charger (constant voltage) may result in damage to the battery and a reduction in its life. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 21 + 4.3. Propeller   4.3.1. Check prop attachment bolt torque and security.  4.3.2. Check tracking   4.3.3. Re-fit spinner EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 22  deformations – replace wheel in case of cracks  6.3.2 Check valve condition near the hole in the disc 6.3.3 Check condition of bearings, wheel free rotation,   play EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 23 Check pitotstatic system for leaks Wing Attachments    7.5.1 Remove wing root fairings. 7.5.2 Visually check condition and security of wing    attachments    Lubricate per Lubricating Chart EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 24 Check rudder hinge pins for wear and security  10.5 Check rudder end float (see Section 17)    10.6 Check security of rudder cable attachments.    10.7 Lubricate per Lubricating Chart EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 25 Lubricate per Lubricating Chart    11.6.5 Replace Cover   11.6.6 Check trim lever friction force. Force to move lever should be min 1.0 kg at lever end. Adjust friction if necessary. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 26 Check for unwanted objects near the GRS unit   12.5 All parachute maintainance must be entered into the aircraft logbook. Refer to the parachute manufacturer’s maintenance manual details maintenance required. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 27: Maintenance Procedures

    The coolant level in the small black expansion tank mounted on the engine should reach the bottom of the filler neck; the level in the overflow bottle, mounted on the firewall, should be a minimum of 25mm from the bottom. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 28: Brake System

    Bend the washer tabs to secure the screw heads. 11. Put the washer on the axle, tighten the castellated nut and secure with a split pin EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 29: Bleeding

    Continue until all the air is out of the system Control Surface Deflection Setting The neutral position of the control surfaces is used as a reference for adjustment of deflections. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 30 The deflection of the control surfaces are specified in the Control Surfaces Deflection Record (see Appendices of this Manual) and in the following Figure. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 31: Aileron

    The difference between the left and right flap deflections can also be adjusted by rotating the eccentric pin locating in the inboard flap slot. 5.7.3 Elevator Elevator stops are installed on the control stick as shown below. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 32: Rudder

    • Earth the aircraft electrically to ground prior to fueling. • No person in the cockpit during fueling! The fuel tank filler is located on the starboard side of the fuselage, close to the rear of the cockpit canopy. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 33: Fuel Emptying

    Where grease is specified use one of the following or an equivalent. CASTROL - Castrolease LM MOBIL - Mobilgrease MP SHELL - Retinax HDX2 or EPX2. Aeroshell Grease 22, 11MS or 23C EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 34: Lubricating Points

    Panel covering the control stick system in the cockpit; • Panel covering the flap & trim control levers in the cockpit; • Baggage compartment floor – access to the elevator and flap control linkage. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 35: Bolt Tightening

    After tension adjustment, the rudder movement should be checked and adjusted if necessary. Rudder deflection should be 30°±2⁰ in each direction. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 36: Rudder Pedal Adjustment

    To lift the wings, raise them using the wings lower surface at the main spar. Do not lift by the composite wing tips. Do not apply localised pressure to the skins. Puncture Repair Support the aircraft to lift the wheel with the punctured tyre. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 37: Main Wheel

    Where the skin is ruptured, or badly buckled, in any location, or where airframe structural members are damaged or deformed, it is necessary to return the aircraft to Light Sport Aviation Ltd for assessment and repair. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 38: Care And Cleaning Recommendations

    The required deflections of the control surfaces are specified in the Control Surfaces Deflection Record (see Appendix 2 to this Manual). In case of difficulty, consult with the manufacturer for the correct procedure. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 39: Permissible Tolerances (Play)

    0.12 in wheels attachment, landing then move the wheel backwards replace the bearings, if 1 mm 3 mm gear necessary and forwards; note any play in the bearings or leg attachment EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 40: Weighing The Aircraft And Centre Of Gravity Calculation

    11. Compute and record permitted crew weight for fueling and baggage - see Pilot's Operating Handbook para. 6.2. Up-date the placard "Load Limits" (make a new one) and attach it in the cockpit. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 41 100 =....[% MAC] ....C.G.range limits Empty weight C.G. range (standard equipment) 18±2% MAC or 200 – 250 mm AOD Loaded aircraft C.G. range 27±7% MAC or 250 – 410 mm AOD EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 42: Appendix 1 - Levelling Record

    ±10 mm 8-12 13-15 ±0.4 in 14-16 ±10 mm 1-13 ±0.8 in 3-15 ±20 mm 6-17 ±0.8 in 8-17 ±20 mm 13-18 ±0.4 in 15-18 ±10 mm Levelling carried out by: Date: EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 43: Appendix 2 - Control Surface Deflection Record

    Max. downward trim tab deflection (elevator 40°±5° trim tab neutral) Neutral trim tab position. 15° (elevator neutral, trim tab control lever in neutral position) Control Surfaces Deflection compliance: YES Measurements carried out by: Date: EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 44: Appendix 3 - Weight & Balance Record

    [lbs] or [kg] Nose wheel Port wheel Starboard wheel Total Weight [lbs] or [kg] TW = permitted basic empty TW=NW weight (standard equipment): max. 290.5 kg Weighing carried out by: Date: EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 45: Appendix 4 - Flight Test Record

    50 – 120 °C Oil temp. 50 - 120°C Date: Pilot’s Signature Location: Wycombe Air Park Pilot’s Name: S. Pike Transponder check 3000 feet over Stokenchurch with Farnborough satisfactory not satisfactory EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 46: Appendix 5 - Electrical Circuit Diagrams

    Canopy Closed Indicator Regulator-Rectifier Whelen Strobe and Position Lights Stall Warner Piezo Buzzer +ve 12v Supply SWITCH from 500mA Comms Fuse VANE EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...
  • Page 47 Wiring Diagram (Analogue Panel) Wiring Diagram (Electronic Panel) EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

  • Page 48: Appendix 6 - Additional Equipment List

    Appendix 6 - Additional Equipment List EV-97 Eurostar SL Microlight Serial Number ……………………………… …………………………………………................. …………………………………………................. …………………………………………................. …………………………………………................. …………………………………………................. …………………………………………................. …………………………………………................. …………………………………………................. …………………………………………................. …………………………………………................. …………………………………………................. …………………………………………................. …………………………………………................. EV-97 Eurostar SL Microlight Maintenance Manual GEN/EUR/04 Issue 4...

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