Tecnam P92 Echo Classic Jabiru Maintenance Manual
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Tecnam P92 Echo Classic Jabiru Maintenance Manual

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Maintenance
Manual
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Issue, July 04
, 2011
Revision, 0

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  • Page 1 Maintenance Manual                 Issue, July 04 , 2011 Revision, 0...
  • Page 2 Information contained herein is based on available data at time of publication, possible variations shall be presented in servicing bulletins. This manual describes correct servicing of parts manufactured by TECNAM and, in subordinate measure, of the list of components purchased from external suppliers; for more complete information on individual components it is necessary to refer to the component’s manufacturer’s manual.
  • Page 3 P92 Classic Jabiru M a i n t e n a n c e M a n u a l INTRODUCTION LIST OF VALID PAGES Section Page Date Section Page Date July 2011 July 2011 “ “ “ “ “ “...
  • Page 4 P92 Classic Jabiru M a i n t e n a n c e M a n u a l INTRODUCTION INDEX OF SECTIONS General Sec. A Inspection and Servicing Sec. B Airframe Sec. C Powerplant Sec. D Systems Sec. E Date: Issue 3: 4 July 2011...
  • Page 5 Section A P92 Classic Jabiru M a i n t e n a n c e M a n u a l GENERAL SECTION A GENERAL TABLE OF CONTENTS 1 - DESCRIPTION AND GENERAL CHARACTERISTICS -------------------------------------------- 4 Page A-1 Date: Issue 3: 4 July 2011...
  • Page 6 Section A P92 Classic Jabiru M a i n t e n a n c e M a n u a l GENERAL TABLE I WING Wing Span 8.5 m Wing Area 11.9 m Aspect Ratio Taper ratio Chord 1.4 m Flap span 1.97 m Flap chord...
  • Page 7 Section A P92 Classic Jabiru M a i n t e n a n c e M a n u a l GENERAL Engine Manuc: JABIRU AIRCRAFT Pty Ltd Model 2200 Aero Engine Engine Type: 4 cylinder horizontally-opposed twins with overall displacement of 2200 c.c., ram-air cooled heads cylinders...
  • Page 8 Section A P92 Classic Jabiru M a i n t e n a n c e M a n u a l GENERAL Fuel  AVGAS 100LL Fuel grade:  MOGAS 95 RON 2 wings tanks integrated within the wing’s Fuel tanks: leading edge, with drainage reservoir located in engine cowling...
  • Page 9 Section A P92 Classic Jabiru M a i n t e n a n c e M a n u a l GENERAL 1 - DESCRIPTION AND GENERAL CHARACTERISTICS A-1 P92 C IGURE LASSIC HREE IEWS Page A-5 Date: Issue 3: 4 July 2011...

  • Page 10: Table Of Contents

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING SECTION B INSPECTIONS AND SERVICING TABLE OF CONTENTS GROUND HANDLING......................2 PARKING AND TIE DOWN ....................2 JACKING ..........................

  • Page 11: Ground Handling

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING 1. GROUND HANDLING Moving the aircraft on ground is accomplished by pushing on the wing struts close to wing attachments or by pulling on the propeller blades close to hub.

  • Page 12: Leveling

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING B-1 J IGURE ACKING 4. LEVELING Occasional levelling of aircraft may be necessary to insure proper wing incidence and/or dihedral or for exact CG location.

  • Page 13: Control Settings

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING 5. CONTROL SETTINGS Adjustment of control surfaces must not exceed travel limits reported in table below. Zero reference mark for stabilator is on left side of aircraft (see figure below).

  • Page 14: Aircraft Alignment

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING 7. AIRCRAFT ALIGNMENT SPINNER BACK PLATE UPPER POINT LAST RIVET ON THE LOWER SIDE OF THE REAR WING SPAR FIRST RIVET BETWEEN THE TUBULAR SPAR AND THE...

  • Page 15: Weighing And Determination Of The C.g. Vertical

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING Datum length in mm 5030  25 A -B 5030  25 A’-B 4365  25 A -C 4365 ...

  • Page 16: Table Of Weights And Determination Of C.g

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING TABLE OF WEIGHTS AND DETERMINATION OF C.G. meters Wheel weight front Distance from bob to LH wheel “...

  • Page 17: Corrosion Prevention

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING 9. CORROSION PREVENTION It is important to keep the aircraft clean and to remove any collection of corrosive agents such as oil, grease, dregs and other foreign matter.

  • Page 18: Service Bulletins

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING 10. SERVICE BULLETINS The following table must report all servicing bulletins pertaining to the aircraft’s operating life.

  • Page 19: Servicing

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING 11. SERVICING For scheduled servicing on engine Jabiru, please refer to the Jabiru documentations. The list below includes only primary engine maintenance operations.

  • Page 20: Lubrication

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING 13.Gyro instrumentation (if installed)- In case of incorrect readings of vacuum system, clean or replace central filter and, if needed, adjust vacuum valve. 14.Flap and stabilator - Check visually for condition and for absence of crack, wear etc.

  • Page 21: Lubrication Points (See Fig. B-5)

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING LUBRICATION POINTS (SEE fig. B-5) Rudder hinges Rudder control cable terminals Stabilator control rod terminals Stabilator support bearings Trim-tab hinges Tab control push-rod terminals...
  • Page 22 Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING B-5 L IGURE UBRICATION POINTS B-6 E IGURE VERY HOURS Page B-13 Date: Issue 3: 4 July 2011...
  • Page 23 Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING B-7 E IGURE VERY HOURS Page B-14 Date: Issue 3: 4 July 2011...

  • Page 24: Inspection's Point

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING 13. INSPECTION’S POINT Inspection points that are not in plain view may be accessed through specific portholes and/or removal of panels or fairings as detailed below: Portholes on wing underside - access to aileron differential bellcrank.

  • Page 25: Inspections

    AND SERVICING 14. INSPECTIONS FOREWORD TECNAM deems inspection schedule outlined below compulsory for the aircraft’s operational safety over an extended period of time. Described servicing requirements pertain to operation in non-extreme climatic conditions. For the Jabiru engine, it is compulsory to adhere to maintenance requirements as reported in the engine’s Operator’s Manual.

  • Page 26: Periodic Inspections

    Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING PERIODIC INSPECTIONS Every porthole, fairing, panel etc. shall be removed to allow for inspection. Procedures listed in SERVICING are included in the inspections. Instructions for actions following inspection are detailed in specific sections pertaining to the aircraft group or system.
  • Page 27 Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING INSPECTION ATURE OF INSPECTIONS NTERVALS Special FUEL SYSTEM  Check rigid circuit lines for integrity and wetness ...
  • Page 28 Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING ISPEZIONE ATURE OF INSPECTIONS NTERVALS Special MOVING SURFACES  Visually inspect integrity of dacron wrap-around for ailerons and stabilator;...
  • Page 29 Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING ISPEZIONE ATURE OF INSPECTIONS NTERVALS Special FUSELAGE and EMPENNAGE  Visually check general condition of wrap-around skin and rivets Inspect cabin truss for deformations and corrosion ...
  • Page 30 Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING INSPECTION ATURE OF INSPECTIONS INTERVALS Special NOSE GEAR  Inspect support truss for gear strut and attachment hinges ...
  • Page 31 Section B P92 Classic Jabiru INSPECTIONS M a i n t e n a n c e M a n u a l AND SERVICING REFERENCE MEASUREMENTS SUMMARY TIGHTENING MOMENT FOR ATTACHMENT BOLTS AS A FUNCTION OF SHANK DIAMETER BOLT Class of resistance 8.8 “UNI”...
  • Page 32 Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME SECTION C AIRFRAME TABLE OF CONTENTS 1 - INTRODUCTION ........................1 2 - WING ............................2 3 - REMOVAL AND RE-INSTALLATION OF A WINGS ............3 2.1 - F .

  • Page 33: Introduction

    Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME 1 - INTRODUCTION The airframe consists of the following main components as shown in figure C-1: 1) Wings 2) Fuselage 3) Empennage 4) Landing gear...

  • Page 34: Wing

    Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME 2 - WING Each wing is connected to the fuselage by means of two pin attachments and a single strut brace per side.

  • Page 35: Removal And Re-Installation Of A Wings

    Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME Aileron is constructed of a single light alloy spar to which are joined box type leading edge and ribs; entire structure is covered with “Dacron” synthetic cloth. Flap has the same aileron structure and is covered aluminum panels.
  • Page 36 Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME C-3 F IGURE LAP CONTROL 2.2 - Aileron control (see fig. C-4) Aileron control system uses rigid rods inside wing and steel cables inside cabin. Flight control system inside cabin includes three pairs of pulleys which transmit move- ment from the two control sticks (1) linked by a rod (2), to a small bar (3) located cabin overhead in correspondence to the main rods from the wings.
  • Page 37 Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME C-4 A IGURE ILERON CONTROL To remove aileron, disconnect one end of push-pull rod and remove pins from hinges. Reverse above procedure to reinstall aileron insuring that, with stick vertical, the aileron’s trailing edge is aligned with wing’s trailing edge.

  • Page 38: Horizontal Tail

    Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME If control stick should feel unusually hard, reduce cable tension as this may be the prima- ry cause for malfunction (ref. Section B); also check that parts of the link system posi- tioned under seats are properly greased.
  • Page 39 Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME Each half plane engage on steel tubular hub that escape to fuselage, locked in place by means of pins (7). Taking up possible tolerance make by means of two riveted grains (8). To remove each stabilator, disconnect the two halves of the tab from each other and from the control rod, remove pins (7), then remove half-planes.
  • Page 40 Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME (6) and plates (7). Actuator’s motion is transmitted to an adjustable push-pull rod (8) through a bellcrank (9). To remove stabilator’s hub disconnect electric actuator frame assembly (7), from support (6), release aft bellcrank assembly (3) then release plates (2) from brackets(6).

  • Page 41: Vertical Tail

    Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME 5 - VERTICAL TAIL The vertical tail is an all-metal light alloy structure (fig. C-8). Rudder tip is fiberglass with cut-outs for navigation and strobe light.
  • Page 42 Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME To the upper ends rudder torque tube is joined steel arm with, to the end, counterweight and rotate freely onto vertical stabilizer tip. In case tip isn’t profile two plastic fairing (one of this removable) counterweight fitting in slot.

  • Page 43: Fuselage

    Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME 6 - FUSELAGE The forward fuselage consist of a steel truss survival cell (fig. C-10) and of a light alloy semi-monocoque structure attached to the cabin’s aft section.
  • Page 44 Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME Figure C-11 Fuselage aft section Cabin access is through two doors constructed of light alloy square tubing. A fiberglass structure, external, shaped for better comfort is riveted.

  • Page 45: Landing Gear

    Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME 7 - LANDING GEAR The main landing gear (see fig. C-12) consists of two special steel leaf-spring struts (1) for elastic cushioning of landing loads.
  • Page 46 Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME C-13 H IGURE YDRAULIC BRAKE CIRCUIT Removal of single gear strut is as follows: Remove cabin seats by pushing them forward and off the railings; Raise aircraft onto supports;...

  • Page 47: Main Gear Wheel Removal (See Fig. C14)

    Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME 7.1 Main gear wheel removal (see fig. C14) Removal of a single wheel is carried out as follows: ...

  • Page 48: Removal Of Main Gear Wheel Bearing (See Fig.c15)

    Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME 7.2 Removal of main gear wheel bearing (see fig.C15) Removal of a wheel bearing (taper roller bearing) becomes necessary when eccessive re- sistance occurs during wheel motion.

  • Page 49: Nose Gear

    Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME 7.3 Nose gear The nose gear (fig. C-16) is attached to the engine mount with two hinges (1) and is equipped with a Sava 4.00-6 type tire.
  • Page 50 Section C P92 Classic Jabiru M a i n t e n a n c e M a n u a l AIRFRAME To remove nose wheel proceed as follows: Remove the fairings (5) (6) and (9) Loosen bolts (10), (11) and (13) Detach the two wheel forks (12) from each other.
  • Page 51 Section D P92 Classic Jabiru POWERPLANT and M a i n t e n a n c e M a n u a l PROPELLER SECTION D POWERPLANT and PROPELLER TABLE OF CONTENTS 1 - POWERPLANT .......................... 2 1.1 C ............................

  • Page 52: Powerplant

    Section D P92 Classic Jabiru POWERPLANT and M a i n t e n a n c e M a n u a l PROPELLER 1 - POWERPLANT 1.1 Cowling Powerplant cowling consists of two parts: fiberglass nose section and light alloy panel on top and all fiberglass bottom.

  • Page 53: Powerplant Main Features

    Section D P92 Classic Jabiru POWERPLANT and M a i n t e n a n c e M a n u a l PROPELLER 1.2 Powerplant main features The installed powerplant is a Jabiru type 2200 horizontally-opposed four-cylinder.Other features include liquid cooled cylinder heads and ram air-cooled cylinders. 1.3 Engine Manufacturer Jabiru Aircraft Pty Ltd, P.O.

  • Page 54: General Servicing Procedures

    Section D P92 Classic Jabiru POWERPLANT and M a i n t e n a n c e M a n u a l PROPELLER 2 - GENERAL SERVICING PROCEDURES 2.2 Ordinary servicing For all servicing operations refer to the Engine Manual listed in paragraph 1.4 and furnished by the engine’s manufacturer and furnished along with the present manual.

  • Page 55: Periodic Inspection

    Section D P92 Classic Jabiru POWERPLANT and M a i n t e n a n c e M a n u a l PROPELLER D-3 P IGURE ROPELLER INSTALLATION 3.3 Periodic inspection Refer to specific subsection in the Periodic Inspection Schedule of Section B. For further information refer to the “Operator’s and Servicing Manual for GT Propellers”...
  • Page 56 P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS SECTION E SYSTEMS TABLE OF CONTENTS 1 - FUEL SYSTEM .......................... 2 2 - INSTRUMENTATION ......................3 2.1 - E ......................

  • Page 57: Fuel System

    P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS 1 - FUEL SYSTEM The fuel system (see Fig. E-1) consists of two metallic fuel tanks (1) located in the wing’s leading edge after wing-fuselage union.

  • Page 58: Instrumentation

    P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS Downstream respect to the gascolator is located a fuel filter (11) built in an electric fuel pump (12) and then the mechanical (13). Mechanical pump feeds the fuel manifold (14); its left branch feeds the left carburetor.
  • Page 59 P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS  flap switch and circuit protection breakers;  throttle knobs. Individual instruments may be removed using particular care in disconnecting wiring, tubing or other linkage as the case applies.

  • Page 60: Engine Instrumentation

    P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS 2.1 - Engine instrumentation - An electric tachometer is installed; - An electric oil temperature indicator is installed. The sensor is located on the oil pump tube and is marked with “TO”...

  • Page 61: Exhaust Manifolds

    P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS For safety reasons and to ensure correct airspeed readings, it is important to check the pi- tot system for leaks adopting the following procedure: Fasten a piece of rubber hose approximately 30 centimeters long to the pitot tube, close off the opposite end of the hose and slowly roll it up until the airspeed indicator shows cruise speed.

  • Page 62: Carburetor Heat And Cabin Heat (Optional)

    P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS 5 - CARBURETOR HEAT AND CABIN HEAT (optional) Two different systems are available:  C ABIN HEAT ONLY This heat system (see Fig.

  • Page 63: Brake System

    P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS 6 - BRAKE SYSTEM The brake system (see fig. E-8) consists of a brake fluid reservoir (4), a master cylinder (3) and two disc brakes;...

  • Page 64: Replacing Brake Pads

    P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS Using a manually operated pump, add brake fluid UNIVIS J43 until level reaches bottom of reservoir, reattach line to caliper avoiding fluid spill. Repeat operations A, B, C on opposite side of aircraft.

  • Page 65: Electrical System

    P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS 7 - ELECTRICAL SYSTEM Electrical energy is supplied by a 12-volt direct-current system. Energy is sup- plied by an engine-driven generator and by a buffer battery. The 18 Ah capacity battery, is located in a distinct compartment on the right side of the tail cone.
  • Page 66 P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS Restore one by one all loads relative to the burnt fuse until circuit protection shuts down again. This new interruption will indicate faulty utility E-10 E IGURE...

  • Page 67: Emergency Parachute System (Optional)

    P92 Classic Jabiru Section E M a i n t e n a n c e M a n u a l SYSTEMS 8 - EMERGENCY PARACHUTE SYSTEM (optional) The system's main components (shown in figure E-12 below) include a capsule located inside the launch tube and set-off by pyrotechnic charges and a nylon container that hous- es the parachute rigged, in turn, to a cable attached to the cabin's metal framework.

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